System and Method for Autonomous Shelving Units INVENTORS

David Wayne Russell, (USA) Winter Garden, Florida USA CROSS-REFERENCE TO RELATED APPLICATIONS US 62/275,598 1/6/2016

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable

REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM

LISTING COMPACT DISK APPENDIX

Not Applicable

FIELD

[0001] This invention relates generally to the field of storage shelving and more specifically to a method and system for automatically reconfigurable shelving systems.

BACKGROUND

[0002] Packages often require temporary storage in preparation for shipping to their ultimate destination or in transport hubs where they are sorted to different routing and transport systems. This is a predominantly manual operation and is prone to error, requiring the packages to be rescanned as they are placed on or taken off the shelves to ensure they are routed correctly. Additional spacing for aisles between the shelves must be maintained to allow personnel and vehicles to traverse the shelves resulting in greater storage inefficiency. [0003] This storage step occurs at the end of order fulfillment lines or point of sale package drop-off locations, during intermediate transport stops, and before final delivery. In addition, shelving units are often static, resulting in significant inefficiencies when storing boxes of random size. A solution is needed that allows shelving units to autonomously reconfigure to maximize storage efficiency and to assist autonomous box transport vehicles to access all storage with increased efficiency and lower costs.

BRIEF DESCRIPTION OF THE INVENTION

[0004] In order to accomplish the goal of a totally automated package delivery system, not only must the "last mile" delivery service be automated but the entire delivery chain from the moment the customer puts down a box at the dispatch office or the package fulfillment department completes an order. Several segments of this process such as conveyor belts and automated sorting systems have already been proposed and implemented, but significant manual labor is still expended loading and unloading from trucks or shipping containers and moving packages to and from shelving for temporary storage.

[0005] In order to enable efficient loading and unloading with Autonomous Box Transport Vehicles (ABTs or Boxtrolls) and to store packages in a reachable manner both in a warehouse and trucking/container environment, the shelving system must be automatically adjustable and synchronized to the needs of the full order processing and distribution system.

[0006] Once this is accomplished loading and unloading as well as moving boxes in and out of storage is possible in a completely automated system. The primary components of such a system are first, a lift mechanism that can transport boxes up and down a vertical column, and second a shelving unit that can attach and detach from the lift mechanism at arbitrary points determined by the shelving system.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007] The detailed description is described with reference to the accompanying figures. In the figures, the left-most digit(s) of a reference number identifies the figure in which the reference number first appears. The use of the same reference numbers in different figures indicates similar or identical components or features. [0008] The novel features believed characteristic of the illustrative embodiments are set forth in the appended claims. The illustrative embodiments, however, as well as a preferred mode of use, further objectives, and features thereof will best be understood by reference to the following detailed description of illustrative embodiments of the present disclosure when read in conjunction with the accompanying drawings, wherein:

[0009] FIG. 1 depicts a perspective view of one embodiment of an ASU.

[0010] FIG. 2 depicts a view of the below floor level embodiment of an ASU.

DETAILED DESCRIPTION OF THE INVENTION

[0011] The following detailed description illustrates embodiments of the invention by way of example and not by way of limitation. The description clearly enables one skilled in the art to make and use the disclosure, describes several embodiments, adaptations, variations,

alternatives, and use of the disclosure, including what is currently believed to be the best mode of carrying out the disclosure. The disclosure is described as applied to an exemplary embodiment namely, systems and methods of autonomous shelving units. However, it is contemplated that this disclosure has general application to vehicle management systems in industrial, commercial, military, and residential applications.

[0012] As used herein, an element or step recited in the singular and preceded with the word "a" or "an" should be understood as not excluding plural elements or steps, unless such exclusion is explicitly recited. Furthermore, references to "one embodiment" of the present invention are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features.

[0013] In one embodiment a chain drive and sprocket system could be implemented to achieve vertical transport. In other embodiments a belt drive could be utilized or a pneumatic or hydraulic lift mechanism used to position the shelf while a secondary mechanism attaches or detaches it from the static support structure.

[0014] In this embodiment a fixed number of detached shelving units are stored at the bottom of the stack. The number of shelving units allocated to the ASU could be predetermined by a calculation of the average number of boxes of a given size expected to be placed within a given unit. Since the shelving units are not attached to the lift mechanism before deployment, the ABTs could also be used to manage distribution of shelving units between multiple ASUs on an as-needed basis.

[0015] To begin operation, one of the shelving units from the stack is attached to the lift mechanism and raised to floor height. The system may be built into floor recesses, hung from ceiling structures, or the floor or a ramp may be used to define the floor access above the structural flooring.

[0016] An ABT or in some cases a human operator places the box on the shelving unit. The height of the box may be known to the distribution system or determined by some form of internal or external sensor. Once the box has been placed and the ABT has cleared, the lift mechanism raises the shelving unit to a height that represents the maximum height of the box expected to be placed into the ASU plus the additional clearance for the ABT. While engaged in this lift, the next shelving unit is attached to the lift mechanism and also raised to floor height as long as the calculated height of the entire stack is less than the defined maximum height. If adding another shelving unit would exceed the maximum height of the ASU, the current shelving unit is left at floor level and no more boxes are added to this ASU.

[0017] Because the lowest shelving unit is always the maximum height of the box plus ABT clearance, the ASUs can be implemented in arrays without aisles significantly increasing storage efficiency in both warehouse and shipping container or truck environments. While piling boxes into a truck such that there is no unused space is the maximum efficiency that can be achieved per truck, the overall efficiency and cost of manually loading and unloading the truck drives the overall system efficiency down. If multiple sizes of ASUs are deployed within the truck or container, very little space is wasted but ABTs can load and unload in a fully autonomous manner.

[0018] The load process of an ASU array begins at the back, the front shelving units simply adjusted to be floor level shelving units. The ABTs simply pass through the ASUs at the front of the array filling the stacks at the back and progressing forward until the final ASU shelf is filled. To unload, the opposite approach is used unloading the forward ASUs until at least one space at floor level is available for the ABT to pass through the array to the next. With intelligent loading by the distribution system, this technique also provides for prioritization of the packages as well as sorting by destination distance and time considerations.

[0019] In a similar manner the array of ASUs can all be configured as floor space to simplify human operator access to the array for maintenance and inspection.

[0020] The array of ASUs is controlled in either a cooperative or fully autonomous manner. In a cooperative operation the lift controller of each stack communicates with the overall distribution management system such that the location and shipping information of each box is known and the ASU is directed to make a shelving unit of a given size (height) available at a certain time. The ABTs are similarly cooperatively controlled to deliver and pick up the package from a particular shelving unit at a particular window of time. This allows for highly efficient time and space management of the facility.

[0021] In a fully autonomous control system, each ASU would have its own sensor array so that the controller could detect when a box was delivered and automatically reconfigure for the next one, and detect when a box was removed and automatically reconfigure to present the next box for pickup. This would be easily accomplished in a First In Last Out (FILO) configuration but with cooperative assistance from ABTs boxes could also be shuffled within the array to adapt to any configuration.

[0022] In another embodiment the shelving units may be suspended from one axis rather than fixed at all four corners. This would allow a two-stack Ferris Wheel configuration where the boxes can be cycled all of the way around the ASU stack rather than just up and down a single lift column. This provides a simpler random access mechanism at the cost of some size efficiency, as might be used at a dedicated automated kiosk where random access to the boxes would be the primary requirement.

[0023] FIG. 1 depicts one embodiment of an autonomous shelving unit (ASU) 100. In this embodiment two chain lift mechanisms 110 120 comprised of looped chains at all 4 corners provide the ability to move a shelving unit higher or lower in the stack. Static shelving systems are often limited by stability and safe human reach to a total height significantly lower than the actual height of the building resulting in significant inefficiency. In one embodiment a framework is set up to support the shelving column. [0024] In another embodiment the entire column is suspended and supported from the roof. This makes it more stable overall, in case of an earthquake, for example, but requires more roof support and as such may not be suitable for all buildings. In general, however, because the packages move up and down the column not the warehouse workers, the column may be much higher than would normally be considered safe for workers.

[0025] To increase efficiency for random box sizes, the columns may have different X and Y dimensions (Z being height above floor). For example, sizing of the columns could be 12" x 12" for Small, 24" x 24" for Medium, and 36" x 36" for Large packages. If all of the boxes in a given facility were the same size - in a manufacturing environment with only one product, for example, one size of ASU would be sufficient. If random sized packages are expected, then the greater the number of different ASU sizes, the greater the overall efficiency can be. With size distinctions weight distinctions could also be taken into account, although the two do not directly correlate small columns could be built to different standards than large columns. In other embodiments from 1 to N different column XY sizes and aspect ratios could be constructed without altering the intent of the invention.

[0026] Each shelving unit consists of a platform 130 fit to ride within the chain columns and a chain attachment mechanism 140 which allows the platform to be affixed to one given link in the chain assembly at any given point for all four corners. As the shelving unit is not expected to ride over the sprockets, the chain is essentially always vertical with respect to the latching mechanism simplifying its design. A mechanical assembly such as but not limited to a solenoid, rotational solenoid, screw base, linear actuator, stepper motor or other device is used to cycle the four corner attachment mechanism between active and inactive, or between attached and detached.

[0027] As this mechanical actuator may be electrically driven and it would be expensive to power each moving shelf, the system is designed with an electrical coupling, either inductive or contact, at the lowest level. This is the only area where the setting of the attachment pins has to be changed. In another embodiment the coupling units could be dispersed at discrete distances on the lift mechanism itself, simplifying the shelving units. [0028] In theory, one or more boxes 150 can be placed on each shelf as space allows as long as there is sufficient space between packages for the ABT grasping mechanism. It is not necessary to stack the boxes vertically as the shelving will adjust to the minimum height of the boxes in the column. If automated box transports are used, they may be partially guided by guide tiles 160 in the flooring. If so, the same guide pattern could be replicated in the shelving. The autonomous systems are able to deal with the small discontinuities between the shelves and the flooring.

[0029] In FIG. 2 one embodiment of the subfloor section 200 of the column is depicted. In one embodiment the motor unit and transmission 210 to keep all four columns moving equally is installed in the bottom of the column below floor height. There would be sufficient room below the floor level to house all of the shelf panels in a stack that would just reach floor level at the top shelf. In this configuration all of the shelf panels 220 are disengaged from the chain drive.

[0030] Adjustable structural columns below the shelf stack 230 serve two purposes, first they are set to give the proper floor-level height to the stack when all shelves are down and second, they may be conductive and provide power to the stack. Electrical contacts at the bottom of the shelf go through to the top, contacting the bottom of the next shelf so that the entire stack is energized.

[0031] In one embodiment for each shelf to be individually told to activate and deactivate they would have some addressing method and perhaps a microprocessor control with a control line in one of the four columns. This would provide full control of each shelf in the stack. In another embodiment a simple electrical circuit between the other two columns allows the shelf unit to detect if it is now the one on the top of the stack. If there is another shelf unit on top, the electrical conductivity and/or current of the two connectors would be different than if no shelf was attached. This simple analog circuit is sufficient to activate the attachment pins on only the top shelf. Note that the top shelf is only at the floor level when all stacks are detached. Once the top shelf is used, the top shelf of the stack is no longer at floor level, and would need to be attached to the chain and then moved up to floor level. This can be coordinated with the move of the previous floor panel up the stack.

[0032] Having the shelf stack, machinery 210, and control system 240 below floor level may present structural problems either in cutting the below floor depression or in raising the floor level. In another embodiment all of these elements are flipped to the top of the stack, but this could make maintenance more complex if designed for maximum height.

[0033] In operation, the system starts out in its detached formation, all shelves at or below floor level. The ASU works in conjunction with an overall planning system and may also work with some combination of humans and autonomous box transport vehicles. It is the job of the planning unit to orchestrate all of the movement of autonomous vehicles over space and time to achieve maximum efficiency. In one embodiment the control system of the stack manages its own stack independent of other stacks. In another embodiment the central control system controls all stacks.

[0034] In order to use space more efficiently, the stacks may be implemented in horizontal and vertical arrays, without space between the stacks. This is particularly useful in container or truck stack arrays. When the first stack in rank is deleted of all boxes, it now presents an open access route to the next rank of boxes, providing significantly more storage at the cost of less random access capability.

[0035] In the case where one package from within the array needs to be accessed, the front ranks need only raise their lowest box high enough to provide the ABT a route through to the box stack in question. In the case where a box other than the lowest in the stack must be accessed, a shuffle operation can be performed to move other boxes to other shelves in order to access the one required.

[0036] Once the first box is deposited on the floor level shelf and the ABT has exited the platform, the top (floor level) shelf is instructed to latch its position on the chain, and this chain location is reset to zero the height. As the chain is continuous, where the chain was previously is immaterial. The stack is then directed to raise the shelf to the height required for access by the ABT, and when the chain is at that height minus the current shelf distance below the floor, the next shelf is directed to latch to the chain, and as the chain reaches the proper height this shelf is now at floor level.

[0037] When the next box is deposited, the chain is directed to descend until the height between shelf N and shelf N+l is the height of box N+l . This will require that shelf N+l detach as it reaches the top of the shelf stack, and then re-attaches when the chain has completed its decent. The system then raises boxes N and N+l to a height where room between N+l and N+2 is sufficient for ABT access and shelf N+2 is at floor height. This process can then be repeated for any number of shelves with each shelf spaced just the amount required for each box height. Because the control system is orchestrating which box is accessed and the trackpath or pre- calculated trajectory data for each ABT, the ABT arrives just in time for cycling the shelf either for depositing or removing boxes, and the control system can programmatically optimize which boxes are accessed at a given time for maximum efficiency. Removing the boxes from a stack is basically a reversal of the deposit process.

[0038] While the foregoing written description of the invention enables one of ordinary skill to make and use what is considered presently to be the best mode thereof, those of ordinary skill will understand and appreciate the existence of variations, combinations, and equivalents of the specific embodiment, method, and examples herein. The invention should therefore not be limited by the above described embodiment, method, and examples, but by all embodiments and methods within the scope and spirit of the invention. Further, different illustrative embodiments may provide different benefits as compared to other illustrative embodiments. The embodiment or embodiments selected are chosen and described in order to best explain the principles of the embodiments, the practical application, and to enable others of ordinary skill in the art to understand the disclosure for various embodiments with various modifications as are suited to the particular use contemplated.

[0039] The flowcharts and block diagrams described herein illustrate the architecture, functionality, and operation of possible implementations of systems, methods, and computer program products according to various illustrative embodiments. In this regard, each block in the flowcharts or block diagrams may represent a module, segment, or portion of code, which comprises one or more executable instructions for implementing the specified logical function or functions. It should also be noted that, in some alternative implementations, the functions noted in a block may occur out of the order noted in the figures. For example, the functions of two blocks shown in succession may be executed substantially concurrently, or the functions of the blocks may sometimes be executed in the reverse order, depending upon the functionality involved.