Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
  • B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
  • B65G1/00—Storing articles, individually or in orderly arrangement, in warehouses or magazines
  • B65G1/02—Storage devices
  • B65G1/04—Storage devices mechanical
  • B65G1/137—Storage devices mechanical with arrangements or automatic control means for selecting which articles are to be removed
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
  • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
  • B25J5/00—Manipulators mounted on wheels or on carriages
  • B25J5/02—Manipulators mounted on wheels or on carriages travelling along a guideway
  • B25J5/04—Manipulators mounted on wheels or on carriages travelling along a guideway wherein the guideway is also moved, e.g. travelling crane bridge type
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
  • B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
  • B65G1/00—Storing articles, individually or in orderly arrangement, in warehouses or magazines
  • B65G1/02—Storage devices
  • B65G1/04—Storage devices mechanical
  • B65G1/0457—Storage devices mechanical with suspended load carriers

Definitions

• the present disclosure generally relates generally to apparatuses and methods for automated warehousing. More particularly, the present disclosure relates to an automated warehousing system, which is suspended from the roof or ceiling of a warehouse, as opposed to a conventional floor-based system.
• the storage and retrieval system is floor based, or ground based, wherein the equipment utilized to move the product is supported by, and travels across, the floor.
• a pallet shuttle incorporates racks which are laterally movable on a designated set of linear tracks such that the racks can be laterally translated to create an aisle for a forklift or other mechanism to retrieve inventory from a designated rack.
• This system also has the advantage of being high density and permits direct access to any pallet stored on the racks.
• Other systems incorporate automated stacker cranes to replace manned forklifts and can reach storage locations up to approximately fifty (50) feet in height. This system can be utilized for heavy pallets as well as for individual boxes, totes or trays.
• the present disclosure is generally directed to an overhead warehousing system for use in a warehouse having a ceiling and a plurality of storage racks supported by the floor of a warehouse.
• the overhead warehousing system includes: a plurality of tramways affixed to the ceiling of the warehouse, each tramway being associated with at least one of the storage racks; at least one robotic module engaged upon each tramway and translatable thereon, the robotic module including a powered carrier engaging the tramway for translating the robotic module therealong, a utility head operatively mounted to the powered carrier, the utility head vertically positionable with respect to the powered carrier and angularly rotatable about a vertical axis with respect to the powered carrier, and at least one gripper head operatively mounted to the utility head and horizontally translatable from and angularly rotatable relative to the utility head, the gripper head including a plurality of gripper fingers being operable to respectively grasp and drop a parcel.
• overhead warehousing system includes: a plurality of tramways affixed to the ceiling of the warehouse, each tramway being associated with at least one of the storage racks; at least one robotic module engaged upon each tramway and translatable thereon, the robotic module including a powered carrier engaging the tramway for translating the robotic module therealong, a utility head connected to the powered carrier, the utility head vertically positionable with respect to the utility head and rotatable about a vertical axis, and at least one gripper head horizontally translatable from the utility head, the gripper head including a plurality of gripper fingers for grasping a parcel; a communication subsystem in communication with the at least one robotic module for controlling translation of the at least one robotic module on each tramway between a designated warehouse receiving location, a designated parcel retrieval location and a designated parcel drop location; and a plurality of drones each having an operatively mounted utility head and a gripper head operatively mounted to the utility head and vertically translatable from and angularly
• the overhead warehousing system includes the communication subsystem also in communication with the at least one robotic module for controlling vertical positioning of the utility head relative to the powered carrier of the robotic module and horizontal translation and angular rotation of the gripper head relative to the utility head for grasping and dropping the parcel.
• the overhead warehousing system includes the communication subsystem also in communication with each of the drones for controlling vertical translation and angular rotation of the gripper head relative to the utility head, and operation of the gripping figures to respectively grasp and drop the parcel.
• the overhead warehousing method for use in a warehouse having a ceiling and a plurality of storage racks supported by the floor of the warehouse, includes the steps of: providing a plurality of tramways and robotic modules, each of the tramways being affixed to the ceiling of the warehouse and associated with at least one of the storage racks, at least one of the robotic modules being engaged upon each of the tramways and translatable thereon, each of the robotic modules having a utility head operatively mounting a gripper head and a plurality of gripper fingers on the gripper head; translating the at least one robotic module along a respective one of the tramways between a designated parcel retrieval location and a designated parcel drop location; and horizontally translating and angularly rotating the gripper head relative to the utility head on the robotic module and operating the plurality of gripper fingers on the gripper head to respectively grasp and drop a parcel.
• the overhead warehousing method also including the step of operating a communication subsystem in communication with the at least one robotic module to control the translating of the at least one robotic module on the each tramway between the designated parcel retrieval location and the designated parcel drop location.
• the overhead warehousing method also including the step of also operating the communication subsystem in communication with the at least one robotic module for controlling vertical positioning of the utility head and the horizontal translating and angular rotating of the gripper head relative to the utility head for grasping and dropping the parcel.
• the overhead warehousing method also including the step of providing a plurality of drones each having an operatively mounted utility head and a gripper head operatively mounted to the utility head and vertically translatable from and angularly rotatable relative to the utility head, the gripper head having a plurality of gripper fingers being operable to respectively grasp and drop a parcel.
• the overhead warehousing method also including operating the communication subsystem in communication with each of the drones for plotting a trajectory and controlling flying of each drone along the trajectory between a designated docking station and a designated parcel retrieval location and a designated parcel drop location.
• the overhead warehousing method also including also operating the communication subsystem in communication with each of the drones for controlling vertical translation and angular rotation of said gripper head relative to the utility head, and operation of the gripping figures to respectively grasp and drop the parcel.
• FIG. 1 presents an isometric view of an overhead warehousing system in accordance with an exemplary implementation, wherein the system includes a plurality of robotic modules translatable upon overhead tramways;
• FIG. 2 presents an isometric view of a representative robotic module having a utility head for gripping one or more parcels
• FIG. 3 presents an isometric view of the representative robotic module wherein the utility head for gripping one or more parcels is shown rotated 90 degrees;
• FIG. 4 presents a side elevational view of a representative robotic module engaged upon a tramway and illustrates the vertical and horizontal mobility of the utility head;
• FIG. 5 presents an isometric view of the representative robotic module similar to that of FIG. 2 but now illustrated engaged upon the tramway;
• FIG. 6 presents an isometric view of a robotic module approaching a designated cell containing a parcel to be retrieved from a storage rack
• FIG. 7 presents an isometric view of the robotic module having its utility head horizontally aligned with the individual cell station for retrieval of the parcel
• FIG. 8 presents an isometric view of the robotic module having its utility head vertically aligned with the parcel to be retrieved
• FIG. 9 presents an isometric view of the robotic module, wherein a plurality of fingers of a gripper head on the utility head are shown having engaged and partially extracted the parcel from the storage rack cell;
• FIG. 10 presents an isometric view the robotic module wherein the utility head has rotated 90 degrees in preparation for translation along the tramway;
• FIG. 11 presents an isometric overhead view of the warehousing system, illustrating the robotic module placing the retrieved parcel on a conveyor;
• FIG. 12 presents a schematic diagram of an exemplary overhead warehousing system, including a computer control and communication subsystem;
• FIG. 13 presents an isometric view of alternative overhead warehousing system in accordance with an exemplary implementation, wherein a plurality of drones now
• FIG. 14 presents a top plan view of the system of FIG. 13, wherein a drone is shown flying along a trajectory calculated as the most direct route from the drone docking station to a product stored at a designated retrieval location;
• FIG. 15 presents an isometric view of the system of FIG. 13, wherein the drone is shown flying along the trajectory shown in FIG. 14;
• FIG. 16 presents an isometric view of the drone at the designated retrieval location in the process of retrieving the product
• FIG. 17 presents an isometric view of the drone at the designated retrieval location after completing retrieval of the product
• FIG. 18 presents a top plan view of the system as shown in FIG. 14, wherein now the drone is shown flying along a trajectory calculated as the most direct route from the designated retrieval location to a designated drop location;
• FIG. 19 presents an isometric view of the drone at the designated drop location in the process of dropping the product.
• FIG. 20 presents a top plan view of the system as shown in FIGS. 14 and 18, wherein now the drone is shown flying along a trajectory calculated as the most direct route from the designated drop location to the drone docking station.
• FIG. 1 an overhead warehousing system 100 is shown in FIG. 1, illustrating its various components where a warehouse 190 has a floor 192 on which are supported a plurality of storage racks 106. Each storage rack 106 is divided into a plurality of individual cells 108. Although the various figures herein illustrate storage racks 106 as having cells 108 separated one from the other by physical walls, those practiced in the art will readily recognize that each cell 108 can be readily identified by unique physical coordinates without the need for physical walls separating one cell 108 from an adjacent cell 108.
• tramways 102 are positioned above the storage racks 106 which are supported on floor 192 of the warehouse 190.
• Tramways 102, on which robotic modules 110 translate as shown in FIG. 1 and in the various figures throughout, are shown as rails.
• the tramways 102 can alternatively be comprised of an overhead rail, a cable, or other suitable track permitting the translation of robotic modules 110 thereon.
• the tramways 102 are affixed to or suspended from a ceiling (not shown for the sake of clarity) of the warehouse 190.
• the warehousing system 100 permits use of storage space up to the ceiling normally unavailable with floor-based warehousing systems, and thus increases product throughput without the financial investment for expensive floor space or additional warehousing.
• the overhead warehousing system 100 as described herein can be combined with a traditional floor-based system to create a hybrid warehousing system.
• the addition of the overhead warehousing system 100 to an existing floor-based system thereby further optimizes use of available warehouse space.
• big-box retail stores typically use the upper levels of storage racks for bulk inventory storage and access them with floor-based mechanical systems such as forklifts.
• the overhead system 100 permits establishments to utilize the overhead system 100 for bulk storage in the upper rack areas, while continuing to use floor-based systems such as worker-driven forklifts to transport inventory to display areas at the lower consumer accessible areas.
• Each tramway 102 is positioned proximate to a storage rack 106 and has at least one robotic module 110 engaged thereon and can preferably accommodate a plurality of robotic modules 110.
• the robotic module 110 includes a powered carrier 112 having at least one tramway guide 114 for receiving a single track of the tramway 102 for translation therealong.
• the powered carrier 112 includes positioning motors (not shown) and two spaced-apart tramway guides 114 each for receiving a correspondingly one of dual spaced-apart tracks of the tramway 102, with the positioning motors engaging the tracks of the tramway 102 for translation of the robotic module 110 therealong in accordance with arrow "E" (FIG. 5).
• the dual spaced-apart tracks of the tramway 102 provide stability for the robotic module 110.
• the powered carrier 112 can receive power via the dual tracks of the tramway 102, flexible wiring (not shown), or batteries (not shown), for example.
• provisions for power transfer to the robotic module and positioning motors therein can be provided by different modalities known in the art. If the robotic module 110 is battery operated, the overhead warehousing system 100 would also include provisions for taking the robotic module 110 off-line at a charging station (not shown).
• the system 100 may include a plurality of charging stations, and the selection of a charging station for a particular robotic module 110 requiring charging would be determined by the position of the robotic module 110, available power, and available workload.
• the tramway 102 can include indexing points 136 at regular intervals therealong and the powered carrier 112 of each robotic module 110 can include a positioning encoder for sensing the individual indexing points 136 to accurately position itself on the tramway 102.
• the communications for placement is generated by the communication subsystem 160 (FIG.
• Each robotic module 110 has a unique identifier for individualized communication. Additionally, power for the various functions of the robotic module 110 can be transferred using mechanical connections and interfaces along the tramway 102.
• the powered carrier 112 also includes a vertical control 116 extending downwardly therefrom along a vertical axis 150 (FIG. 2).
• the vertical control 116 is vertically extendable in a powered manner along the axis 150, bi-directionally in accordance with arrow "D" (FIG. 3). Further, the powered control of the vertical control 116 also facilitates the rotation of the vertical control 116 about the vertical axis 150 in accordance with arrow "A" (FIG. 2).
• the robotic module 110 also includes a selectively-interchangeable utility head 118 being detachably attached to the vertical control 116 utilizing a common mounting interface 119.
• the common mounting interface 119 permits the attachment of different devices including, but not limited to, a parcel carrier 120 for rectangular objects, a gripper for cylindrical objects, a gripper for custom-shaped objects, a camera, scanner, a weighing scale, a label or, a vacuum cleaner, a scrub brush, etc.
• the various figures herein representatively illustrate the attachment of a rectangular parcel carrier 120 attached to the vertical control 116 via the common mounting interface 119.
• the rectangular parcel carrier 120 incorporates a gripper control 121which includes the communications interface, motors and actuators (not shown) for the carriage, placement, and retrieval of a rectangular parcel 199 (FIGS. 6- 10).
• a horizontal control actuator 122 is positioned at each of opposing ends of the gripper control 121.
• the geometric configuration of the gripper control 121 can be modified to accommodate multiple horizontal control actuators 122 and gripper heads 124.
• Each horizontal control actuator 122 has a respective gripper head 124 attached to an end of the actuator 122 and facilitates angular rotation of the respective gripper head 124, in accordance with the directional arrows "B" (FIG.
• Each gripper head 124 includes a plurality of gripper fingers 126 which are selectively positionable by a powered mechanism (not shown) in the gripper head 124.
• the gripper fingers 126 can be extended to an open position to receive a parcel 199 therein and then retracted in accordance with directional arrows "F" (FIG. 5) to frictionally grasp the parcel 199 for movement within the warehouse 190.
• the parcel carrier 120 operably affixed to the powered carrier 112 can be used to pick parcels 199 for distribution or for placing parcels 199 into a designated cell location for future retrieval.
• the parcel carrier 120 can be used for stocking shelves or for retrieving parcels from shelves, and for removing or placing parcels on conveyors, sorters, boxes, pallets, crates, etc.
• a station (not shown) is also provided for placing different utility heads 118 onto the vertical control actuator 116 utilizing the common mounting interface 119.
• This permits the use of a common powered carrier 112 to selectively attach or detach a specific utility head 118 such as parcel carrier 120, specialized grippers for various geometric shapes, cameras, scanners, scales, labelers, and cleaning apparatuses.
• the overhead warehousing system 100 can include a communication subsystem 160.
• the communication subsystem 160 includes a central processing unit (CPU) 161 which executes an instruction set stored on a memory module 162 for conducting the warehousing protocol.
• the memory module 162 further includes a database of locations of individual cells 108, of which cells 108 are unoccupied, and which cells are occupied by specified parcels 199.
• the CPU 161 may also be connected to a user input device 166, such as a keyboard, and to a display 164 to facilitate interactive control by a user.
• the CPU 161 is also connected to a communication transmitter which can be communicatively connected to the various robotic modules 110 via a hardwired
• the robotic module 110 can have an antenna 130 for receiving the wireless signal transmission 174 or, alternatively, can receive the control signals from hardware 172 via the tramway 102.
• FIGS. 6-12 during operation, when a designated parcel
• a user designates a particular parcel 199 to be retrieved by interfacing with the communication subsystem 160 utilizing the user input device 166 and display 164.
• the user queries the communication subsystem 164 the location of the desired parcel 199.
• the CPU 161 executes the warehousing instruction set stored on memory module 162 and identifies, via the database thereon, the individual cell 109 in which the parcel 199 is located.
• the CPU 161 then transmits to the transmitter 168 a retrieval order, including the cell 109 location, to the robotic module 110 servicing the designated cell 109.
• the powered carrier 112 of the robotic module 110 receives the retrieve signal, via the antenna 130 or the hardwire connection 172, and translates along the tramway 102 (FIG. 6).
• the robotic module 110 stops in front of the designated cell 109 in which the parcel 199 to be retrieved is located (FIG. 7).
• the vertical control actuator 116 is then extended to position the parcel carrier 120 substantially in a horizontal alignment with the parcel 199.
• the gripper head 124 expands the gripper fingers 126 to enable capture of the parcel 199 therein, and the horizontal control actuator 122 is extended toward the parcel 199 until the gripper fingers 126 engage the parcel 199.
• the gripper fingers 126 are then retracted to frictionally secure the parcel 199 within the grasp of the plurality of gripper fingers 126 (FIG. 8).
• the horizontal control actuator 122 is retracted to extract the parcel 199 from the designated cell 109 of the storage rack 106. (FIG. 9).
• the parcel carrier can then be rotated 90 degrees about the vertical axis 150 to align the parcel carrier in preparation for translation of the robotic module 110 along the tramway 102 (FIG. 10).
• the robotic module 110 then translates along the tramway 102 to its designated destination, such as conveyor 104.
• the vertical control actuator 116, the horizontal control actuator 122, and the gripper fingers 126 as controlled by the gripper head 124, are then manipulated to place the parcel 199 on the conveyor 104 (FIG. 11).
• the robotic module 110 is then free to be re- tasked by the communication subsystem 160 for the placement or retrieval of a new parcel.
• FIGS. 13-20 an exemplary implementation of an alternative overhead warehousing system 200 is shown which incorporates a plurality of drones 202 that now perform a portion of the operations previously performed by the overhead tramways 102 and the robotic modules 110 .
• the overhead tramways 102 and robotic modules 110 of the system 100 are still employed in the alternative system 200 but are not shown in FIGS. 13-20 for purposes of clarity.
• the drones 202 are shown located at a designated charging/docking station 204.
• a drone 202 would be selected and assigned by the communications subsystem 160 to retrieve a parcel 199 from a designated retrieval cell location 109.
• each cell, or bin, 108, 109 can be readily identified by unique physical coordinates.
• the subsystem 160 plots a retrieval trajectory 206 (that does not interfere with other drones and is the most direct route) for the selected drone 202 to fly from the designated docking station 204 to the designated retrieval cell location 109.
• the cell is opened using the robotic module 110 (or other electro-mechanical mechanism) controlled by the communication subsystem 160 in the manner as described earlier.
• FIGS. 14-15 show the selected drone 202 flying along the retrieval trajectory 206 from the drone docking station 204 to a designated retrieval cell location 109 in one of the racks 106 where the parcel 199 to be retrieved located.
• FIGS. 16-17 show the drone 202 at the designated retrieval location in the process of completing retrieval of the parcel 199.
• the drone 202 has a utility head 218 (including a gripper control 221 with a gripper actuator 222) operatively mounted to the drone and a gripper head 224 mounted to the utility head (via the gripper actuator) and having a plurality of gripper fingers 226 being selectively positionable relative to the gripper head 224.
• the gripper fingers 226 are extendible to an open position to receive the parcel 199 therein and then retractible to frictionally grasp the parcel 199, similar to the operations performed by the robotic module 110 as described earlier.
• the gripper head 224 thus grasps the parcel and the drone 202 starts flying away from the retrieval cell location 109.
• the bin/shelf is closed by operations performed by the robotic module 110.
• the communication subsystem 160 also plotted a delivery trajectory 212 from the designated retrieval cell location to a designated drop location 214 and a return trajectory 216 from the designated drop location 214 to the drone docking station 204.
• FIGS. 18-19 show the drone 202 flying along along the delivery trajectory 212 calculated as the most direct route from the designated retrieval location to a designated drop location.
• the drone 202 Upon the drone 202 reaching the designated drop location, it drops the parcel at the designated drop location 214. Then, as seen in FIG. 20, the drone 202 flies along the return trajectory 216 and lands at its charging/docking station 204 where it awaits further instructions.
• One of the drones may be selected and assigned to stock a parcel at a designated receiving bin location.
• the same process is carried out as described above but the drone instead picks up a parcel from a designated warehouse receiving location.
• the designated receiving bin location where the drone is to bring the parcel is opened in advance of the drone's arrival using an appropriate robotic module.
• the communication subsystem 160 plots the various trajectories (not to interfere with other drones and along most direct route) the drone is to follow respectively: a first trajectory to the designated warehouse receiving location, then a second trajectory to designated receiving bin location, and then a third trajectory back to the charging/docking station.
• the drone After flying along the first trajectory and picking up the parcel at the designated warehouse receiving location, the drone flies along the second trajectory to, and deposits the parcel at, a known empty position in the bin/shelf at the designated receiving bin location. After the deposit, the bin/shelf is closed by the appropriate robotic module (or other electro-mechanical mechanism). The drone then returns along the third trajectory to the docking station to await further instructions or is redirected to pick another parcel for retrieval from the warehousing storage area.

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• Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• Robotics (AREA)
• Warehouses Or Storage Devices (AREA)

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• 2016
  • 2016-03-22 US US15/076,995 patent/US9617075B2/en not_active Expired - Fee Related
  • 2016-03-23 WO PCT/US2016/023728 patent/WO2016154279A1/en not_active Ceased
  • 2016-03-23 CN CN201680018068.XA patent/CN107428466B/zh not_active Expired - Fee Related
  • 2016-03-23 EP EP16769587.3A patent/EP3274275A4/en not_active Withdrawn
  • 2016-03-23 JP JP2017548377A patent/JP2018509357A/ja active Pending
• 2017
  • 2017-09-24 IL IL254656A patent/IL254656B/en active IP Right Grant

Patent Citations (7)

Non-Patent Citations (1)

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