Warehouse shuttle devices, and systems and methods incorporating the same

A system for moving pallets can include a rectangular grid, pallets, a shuttle device, a motive assembly, and one or more processors. The pallets can be arranged upon a matrix of cells of the rectangular grid. The one or more processors can be communicatively coupled to the shuttle device and the motive assembly. The one or more processors can execute machine readable instructions to activate a vertical actuator to urge the pallet engagement member of the shuttle device into engagement with a shuttle engagement member of a selected pallet of the pallets. The motive assembly can be actuated to slide the selected pallet along the rectangular grid, while the pallet engagement member of the shuttle device and the shuttle engagement member of the selected pallet are engaged.

BACKGROUND

The present specification generally relates to systems and methods for moving pallets and, more specifically, to systems and methods for moving pallets throughout a warehouse.

Traditional warehouse facilities generally include a plurality of racks for storing goods. The racks can be separated by roads or aisles that provide access to the racks for loading or unloading goods from the racks. For example, a pair of racks can be separated by a road. The roads can be designed to accommodate forklift traffic. Accordingly, the road and the portion of the warehouse above the road cannot be utilized for storage. Moreover, the forklifts are frequently manually operated. Human operators can be prone to mistakes in material handling. In addition, manual operation can provide a direct payroll cost that can increase the cost to operate a warehouse.

Accordingly, a need exists for alternative systems and methods for moving pallets to provide for efficient storage and retrieval of goods within a warehouse.

SUMMARY

In one embodiment, a system for moving pallets can include a rectangular grid, pallets, a shuttle device, a motive assembly, and one or more processors. The rectangular grid can include lateral rails oriented along an x-axis and orthogonal rails oriented along a y-axis. The lateral rails and the orthogonal rails can intersect to demarcate a matrix of cells. The pallets can be arranged upon the matrix of cells of the rectangular grid. Each of the pallets can include an underside that faces the rectangular grid and a shuttle engagement member located on the underside. The shuttle device can be suspended beneath the pallets and the rectangular grid. The shuttle device can include a vertical actuator that urges a pallet engagement member vertically. The motive assembly can be suspended beneath the pallets and the rectangular grid. The motive assembly can move the shuttle device. The one or more processors can be communicatively coupled to the shuttle device and the motive assembly. The one or more processors can execute machine readable instructions to activate the vertical actuator to urge the pallet engagement member of the shuttle device into engagement with the shuttle engagement member of a selected pallet of the pallets. The motive assembly can be actuated to slide the selected pallet along the rectangular grid, while the pallet engagement member of the shuttle device and the shuttle engagement member of the selected pallet are engaged.

In another embodiment, a method for moving pallets can include engaging a shuttle engagement member disposed on an underside of a pallet with pallet engagement members of a shuttle device. The pallet can be in sliding engagement with a rectangular grid that demarcates a matrix of cells. The underside of the pallet can face the rectangular grid. The shuttle device can be moved beneath the rectangular grid and along a direction of motion. The pallet can be slid along rectangular grid, while the shuttle engagement member of the pallet is engaged with the pallet engagement members of the shuttle device. A leading set of pallet engagement members and a trailing set of pallet engagement members can be identified from the pallet engagement members, automatically with one or more processors, based at least in part upon the direction of motion.

In yet another embodiment, a warehouse can include one or more processors and multiple floors. Each of the floors of the warehouse can include a rectangular grid, pallets, a shuttle device, and a motive assembly. The rectangular grid can include lateral rails oriented along an x-axis and orthogonal rails oriented along a y-axis. The lateral rails and the orthogonal rails can intersect to demarcate a matrix of cells. The pallets can be arranged upon the matrix of cells of the rectangular grid. Each of the pallets can include an underside that faces the rectangular grid and a shuttle engagement member located on the underside. The shuttle device can be suspended beneath the pallets and the rectangular grid. The shuttle device can include a vertical actuator that urges a pallet engagement member vertically. The motive assembly can be suspended beneath the pallets and the rectangular grid. The motive assembly can direct or move the shuttle device. The one or more processors can be communicatively coupled to the shuttle device and the motive assembly. The one or more processors can execute machine readable instructions to activate the vertical actuator to urge the pallet engagement member of the shuttle device into engagement with the shuttle engagement member of a selected pallet of the pallets. The motive assembly can be actuated to slide the selected pallet along the rectangular grid, while the pallet engagement member of the shuttle device and the shuttle engagement member of the selected pallet are engaged.

According to any of the systems, methods or warehouses provided herein, the rectangular grid can include pallet tracks that constrain the pallets in sliding engagement with the rectangular grid. Alternatively or additionally, the pallet tracks can include a first lateral track and a second lateral track located on one of the lateral rails. The first lateral track and the second lateral track can demarcate different cells of the matrix of cells. Alternatively or additionally, the pallet tracks can include a first orthogonal track and a second orthogonal track located on one of the orthogonal rails. The first orthogonal track and the second orthogonal track can demarcate different cells of the matrix of cells. Alternatively or additionally, each of the pallets can include a sliding member located on the underside of the pallet. The sliding member of each of the pallets can be constrained by one of the pallet tracks. Alternatively or additionally, the sliding member can include a ball bearing.

According to any of the systems, methods or warehouses provided herein, the matrix of cells can include an unoccupied cell that is unobstructed by the pallets. The selected pallet can be positioned in a cell of the matrix of cells that is adjacent to the unoccupied cell, before the pallet engagement member of the shuttle device and the shuttle engagement member of the selected pallet are engaged. The selected pallet can slide towards the unoccupied cell, while the pallet engagement member of the shuttle device and the shuttle engagement member of the selected pallet are engaged.

According to any of the systems, methods or warehouses provided herein, the motive assembly can include a lateral dimension actuator that moves the shuttle device along the x-axis and an orthogonal dimension actuator that moves the shuttle device along the y-axis. Alternatively or additionally, the lateral dimension actuator, the orthogonal dimension actuator, or both can include a linear bearing.

According to any of the systems, methods or warehouses provided herein, the vertical actuator can be a hydraulic actuator.

According to any of the systems, methods or warehouses provided herein, the rectangular grid can be provided as a floor of a warehouse.

According to any of the systems, methods or warehouses provided herein, the shuttle engagement member can include latching features that are each arranged at a corner of a rectangular pattern.

According to any of the systems, methods or warehouses provided herein, the underside of each of the pallets can be rectangular and can include an identification device that is positioned centrally.

According to any of the systems, methods or warehouses provided herein, the pallets can include a flat-bed shelf, a box-style shelf, a cabinet-style shelf, or a combination thereof.

According to any of the systems, methods or warehouses provided herein, the rectangular grid can include an intersecting rail that is orthogonal to the direction of motion. The leading set of pallet engagement members can be disengaged from the shuttle engagement member as the pallet slides over the intersecting rail and while the shuttle engagement member of the pallet is engaged with the trailing set of pallet engagement members.

According to any of the systems, methods or warehouses provided herein, the rectangular grid can include an intersecting rail that is orthogonal to the direction of motion. The trailing set of pallet engagement members can be disengaged from the shuttle engagement member as the pallet slides over the intersecting rail and while the shuttle engagement member of the pallet is engaged with the leading set of pallet engagement members.

According to any of the systems, methods or warehouses provided herein, an identification device located on the underside of the pallet can be detected with an optical sensor of the shuttle device.

According to any of the systems, methods or warehouses provided herein, a distance sensor of the shuttle device and the motive assembly can be communicatively coupled to the one or more processors. A mapped location of a selected cell of the matrix of cells can be provided. The shuttle device can be moved, automatically by the one or more processors, to the mapped location with the motive assembly. A detected position of the shuttle device can be detected with the distance sensor. The mapped location and the detected position can be compared, automatically with the one or more processors.

DETAILED DESCRIPTION

The embodiments described herein generally relates to a system and method for selectively accessing pallets arranged upon a rectangular grid. The rectangular grid can comprise a plurality of lateral rails and a plurality of orthogonal rails. The rails can intersect one another to demarcate a matrix of cells that are formed by the rectangular grid. Various embodiments of the system and the operation of the system will be described in more detail herein.

Referring collectively toFIGS. 1 and 2, an embodiment of a system10for moving pallets20to provide for efficient storage and retrieval of goods. For example, the embodiments of the system10provided herein can be utilized to improve the usage of the storage volume within a facility such as, for example, a warehouse. The system10can comprise a rectangular grid100that organizes and constrains the motion of the pallets20. In some embodiments, the rectangular grid100can form a pallet interface102configured to contact the pallets20.

The rectangular grid100can comprise lateral rails104oriented along an x-axis, i.e., the lateral rails104can extend along a span and can be substantially aligned with the x-axis. The rectangular grid100can further comprise orthogonal rails106oriented along a y-axis. In some embodiments, the lateral rails104and the orthogonal rails106can be coupled to one another in order to provide structure for rectangular grid100. In some embodiments, the lateral rails104, the orthogonal rails106, or both can be formed from relatively rigid material such as, for example, metal (e.g., steel), wood, or the like. Moreover, the lateral rails104, the orthogonal rails106, or both can be shaped such that the rectangular grid100is substantially planar and is configured to resist bending or twisting when subjected to loads. Accordingly, the lateral rails104, the orthogonal rails106, or both can be formed as beams such as, but not limited to, an I-beam.

The lateral rails104and the orthogonal rails106can intersect to demarcate a matrix of cells108. In some embodiments, the lateral rails104and the orthogonal rails106can intersect at a substantially orthogonal angle. Thus, each of the lateral rails104can be separated by a length span110. Likewise, each of the orthogonal rails106can be separated by a width span112. The lateral rails104can extend across the width span112and the orthogonal rails106can extend across the length span110. Accordingly, the lateral rails104and the orthogonal rails106can cooperate to demarcate the matrix of cells108. As used herein, the term “matrix” can mean an array of similarly dimensioned rectangular objects that are repeated along a first dimension and a second dimension. For example, the rectangular grid100can define a substantially x-y plane that it divided into a plurality of substantially rectangular cells to form the matrix of cells108.

Accordingly, the matrix of cells108can comprise a first dimension of n cells arranged along the x-axis to form a row and a second dimension of m cells arranged along the y-axis to form a column. Thus, the n-by-m matrix can comprise n columns and m rows of cells. For clarity, and not by way of limitation, the matrix of cells108is depicted inFIGS. 1 and 2as a 4-by-3 matrix, where n=4 and m=3 (i.e., a matrix having 4 columns and 3 rows). It is noted that the matrix of cells108can be formed into an n-by-m matrix of any suitable n dimension and/or m dimension without departing from the embodiments described herein. It is furthermore noted that the lateral rails104should be suitable to support the combined weight of the pallets20and goods supported by the pallets20across the width span112without obstructing the motion of a shuttle device200. Likewise, the orthogonal rails106should be suitable to support the combined weight of the pallets20and goods support by the pallets20across the length span110without obstructing the motion of the shuttle device200.

Referring collectively toFIGS. 2, 3 and 4, the rectangular grid100can comprise pallet tracks114that are configured to constrain the motion of the pallets20. Specifically, the pallet tracks114can be configured to constrain the pallets20in sliding engagement with the rectangular grid100. In some embodiments, the pallet tracks114can run along substantially entire span of each of the lateral rails104and the orthogonal rails104. Accordingly, the pallet tracks114can provide a path for each of the pallets20to travel to a desired cell of the matrix of cells108. In some embodiments, each of the pallet tracks114can be formed as a linear groove that is recessed within a substantially planar surface of the pallet interface102.

Referring collectively toFIGS. 2 and 3, the pallet tracks114can comprise a first lateral track116and a second lateral track118located on one of the lateral rails104. In some embodiments, the first lateral track116and the second lateral track118can demarcate different cells of the matrix of cells108. Specifically, the first lateral track116can be offset from the second lateral track118with respect to the y-axis such that the pallets20constrained by the first lateral track116occupy different cells than the pallets20constrained by the second lateral track118. In some embodiments, the first lateral track116and the second lateral track118can be substantially parallel. Thus, each width span112of the lateral rails104can be configured to constrain two pallets20contemporaneously. Additionally, the pallet tracks114can comprise a first orthogonal track120and a second orthogonal track122located on one of the orthogonal rails106. In some embodiments, the first orthogonal track120and the second orthogonal track122can demarcate different cells of the matrix of cells108. In some embodiments, the first orthogonal track120can be offset from the second orthogonal track122with respect to the x-axis. Alternatively or additionally, the first orthogonal track120and the second orthogonal track122can be substantially parallel. Thus, each length span110of the orthogonal rails106can be configured to constrain two pallets20contemporaneously.

In some embodiments, the pallet tracks114can comprise one or more intersection region125that is configured to allow pallets20to change between rows or columns of the matrix of cells108. For example, the first lateral track116and the second lateral track118can intersect the first orthogonal track120. Additionally, the first lateral track116and the second lateral track118can intersect the second orthogonal track122. Likewise, each of the first orthogonal track120and the second orthogonal track122can intersect the first lateral track116and the second lateral track118. Accordingly, the first lateral track116, the second lateral track118, the first orthogonal track120and the second orthogonal track122can cooperate to form the intersection region125, which can comprise a substantially rectangular region of grooves. located on one of the orthogonal rails106. In some embodiments, the intersection region can be formed at each portion of the rectangular grid100adjacent to four corners of cells of the matrix of cells108. Accordingly, the intersection regions125of the pallet tracks114can be utilized by pallets20to move from a current cell location in the matrix of cells108to any adjacent cell that is not occupied by a pallet20by moving in the positive x-direction, the negative x-direction, the positive y-direction, the negative y-direction, or combinations thereof with respect to the current cell location.

Referring collectively toFIGS. 1, 2, and 5, the system10can comprise pallets20for storing and moving goods throughout the matrix of cells108. Each of the pallets20can comprise a topside22which can be configured to support goods. In some embodiments, the topside22can comprise a surface that faces upwards, i.e., the topside22can be defined by a normal vector that is substantially aligned with the z-axis. Each of the pallets20can comprise an underside24that faces the rectangular grid100and is configured to interface with the rectangular grid100and the shuttle device200. The underside24of the pallet20can be located on an opposite side of the pallet20compared to the topside22. Accordingly, the topside22can be defined by a normal vector that is substantially aligned with the positive z-direction and the underside24can be defined by a normal vector that is substantially aligned with the negative z-direction. Each pallet20can be substantially rectangular. Accordingly, the pallet20can be defined by a width dimension40substantially along the x-axis, and a length dimension42substantially along the y-axis. It is noted that the pallet20can have any desired width dimension40and any desired length dimension42provided that the pallet20is correspondingly shaped to the cells of the matrix of cells108.

Referring collectively toFIGS. 2, 4 and 5, the underside24of the pallet20can configured for sliding engagement with the rectangular grid100. The sliding engagement can be provided by constraining each sliding member26within one of the pallet tracks114. In some embodiments, each of the pallets20can comprise a sliding member26located on the underside24of the pallet20. The sliding member26can be any device suitable to reduce the friction between the pallet20and the rectangular grid100such as, but not limited to, a roller bearing. In some embodiments, the underside24of each pallet20can comprise a plurality of sliding members26. For example, the underside24of each pallet can comprise four of the sliding members26. The sliding members26can be arranged in a substantially rectangular pattern that is substantially similar to the cell demarcated by the pallet tracks114. Alternatively or additionally, each sliding member26can be positioned adjacent to a corner at the underside24of the pallet20. Accordingly, the sliding members26can be in sliding engagement with the pallet tracks114, while the pallet20occupies a cell.

As is noted above, the underside24of the pallet20can be configured to interface with the shuttle device200. In some embodiments, the pallet20can comprise a shuttle engagement member28located on the underside24of the pallet20. The shuttle engagement member28can comprise one or more latching features30that are configured to selectively engage with the shuttle device200. The latching feature30can be configured to promote contemporaneous motion between the pallet20and the shuttle device200in the x-direction, the y-direction, or combinations thereof. Alternatively or additionally, the latching feature30can be configured to release the shuttle device200along the z-direction. In some embodiments, the latching feature30can be formed as an orifice that is bored into the underside24of the pallet20substantially along the z-direction. It is noted that, while the latching features30are depicted inFIG. 5as being substantially circular, the latching feature30can be formed into any shape suitable to promote selective engagement with the shuttle device200.

According to the embodiments described herein, the shuttle engagement member28can comprise four of the latching features30arranged at corners of a substantially rectangular pattern. In some embodiments, the latching features30can be separated by a length span32substantially along the y-axis. The length span32can be greater than a lateral rail span124of the lateral rails104. Alternatively or additionally, the latching features30can be separated by a width span34substantially along the x-axis. The length span32can be greater than an orthogonal rail span126of the orthogonal rails106. In some embodiments, length span32and the lateral span34can be substantially equal. Alternatively or additionally, the length span32, the lateral span34, or both can be shorter than the shortest length of the width dimension40or the length dimension42. For example, the length span32, the lateral span34, or both can be less than about 50% of the shortest length such as, but not limited to, about one third of the shortest length. Applicants have discovered that controlling the length span32, the lateral span34, or both can improve stability during movement of the pallet20.

Referring again toFIG. 5, each of the pallets20can be configured for unique identification. For example, each pallet20can comprise an identification device36that is encoded to uniquely identify the pallet20, i.e., each pallet20can be individually addressed. The identification device36can be any machine decodable object such as, for example, a printed barcode, a radio frequency identification (RFID) tag, or the like. In some embodiments, the identification device36can be located on the underside24of the pallet20. Alternatively or additionally, the identification device36can be positioned substantially centrally with respect to the width dimension40and the length dimension42. In some embodiments, the identification device36can be positioned substantially centrally with respect to the shuttle engagement member28to facilitate improved accuracy in the positioning of the shuttle device200(FIG. 2).

Referring again toFIGS. 1 and 2, one or more of the pallets20can comprise a topside22that forms a substantially planar surface, i.e., a flat-bed shelf. Referring toFIG. 6, in some embodiments, the pallet20can comprise one or more wall38that at least partially encloses a volume bounded by the topside22of the pallet20, i.e., a box-style shelf. Referring toFIG. 7, in further embodiments, the pallet20can comprise a cabinet44that completely encloses a volume, i.e., a cabinet-style shelf. Alternatively or additionally, the cabinet44can be provided with one or more drawers, doors, or combinations thereof that provide access to the interior volume of the cabinet44. According to the embodiments described herein, the pallets20can be provided as any combination that comprises one or more of a flat-bed shelf, a box-style shelf, and a cabinet-style shelf.

Referring collectively toFIGS. 1, 2, 8A and 8B, the system10can comprise a shuttle device200that is configured to selectively access and engage the pallets20arranged upon the rectangular grid100. In some embodiments, the shuttle device200can comprise one or more vertical actuators202. Each vertical actuator202can be operable to urge a pallet engagement member204vertically, i.e., motion substantially aligned with the z-axis. For example, the vertical actuator202can comprise a hydraulic pump and valves and be configured to hydraulically urge the pallet engagement member204vertically, i.e., the pallet engagement member204can comprise a piston in fluidic communication with the hydraulic pump. Alternatively or additionally, the vertical actuator202can comprise any servomechanism suitable for providing a controlled amount of force to urge the pallet engagement member204. As used herein, the term “servomechanism” can mean any actuator that can be controlled with a signal such as, for example, a mechanical actuator, a hydraulic actuator, a pneumatic actuator, an electrical actuator, or combinations thereof. Furthermore, the term “signal” can mean a waveform (e.g., electrical, optical, magnetic, or electromagnetic), such as DC, AC, sinusoidal-wave, triangular-wave, square-wave, and the like, capable of traveling through a medium.

Referring collectively toFIGS. 5, 8A, and 8B, the shuttle device200can comprise four of the vertical actuators202and four of the pallet engagement members204. The pallet engagement members204can be provided upon an upper face206of the shuttle device200in an arrangement that corresponds to the shuttle engagement member28. Specifically, each of the pallet engagement members208can be provided at a corner of a substantially rectangular pattern upon the upper face206of the shuttle device200. The pallet engagement members204can be separated by the length span32substantially along the y-axis. Alternatively or additionally, the pallet engagement members204can be separated by the width span34substantially along the x-axis. Accordingly, when the shuttle device200and the pallet20are aligned, each of the pallet engagement members204can be aligned with one of the latching features30of the shuttle engagement member28. It is noted that, while the pallet engagement members204are depicted inFIG. 8Aas being substantially cylindrically shaped, the pallet engagement members204can be provided in any shape that corresponds to the latching features30.

In some embodiments, the shuttle device200can comprise an identification sensor208configured to detect the identification device36of the pallets20. The identification sensor208generally comprises a non-contact or wireless sensor configured to detect the identification device36such as, for example, an optical sensor, a bar code reader, an RFID detector, or the like. It is noted that the term “sensor,” as used herein, can mean a device that measures a physical quantity and converts it into a signal, which is correlated to the measured value of the physical quantity. Additionally, it should be understood that the term “optical” can refer to various wavelengths of the electromagnetic spectrum such as, but not limited to, wavelengths in the ultraviolet (UV), infrared (IR), and visible portions of the electromagnetic spectrum. In order to improve detection accuracy, the identification sensor208can be located on the upper face206of the shuttle device200in a position that corresponds to the location of the identification device36, when the pallet engagement members204engage the latching features30of the pallet20. For example, the identification sensor208can be substantially centered with respect to the pallet engagement members204.

According to the embodiments described herein, the shuttle device200can comprise one or more distance sensors210that are configured to detect the position of the shuttle device200. For example, the one or more distance sensors210can be configured to detect the position of the shuttle device200with respect to the x-axis. Alternatively or additionally, the one or more distance sensors210can be configured to detect the position of the shuttle device200with respect to the y-axis. The one or more distance sensors210can comprise any device capable of detecting position or length such as, for example, a laser distance sensor, a linear encoder, or the like.

Referring collectively toFIGS. 1, 2, and 9, the shuttle device200can be configured to travel beneath the rectangular grid100. In some embodiments, the shuttle device200can be configured for motion along the x-axis, the y-axis, or a combination thereof. Specifically, the shuttle device200can be operably connected to a motive assembly220for motion along the x-axis, the y-axis, or a combination thereof. The motive assembly220can comprise structural components that are configured to constrain the motion of the shuttle device220. For example, the motive assembly220can comprise a lateral dimension actuator222that moves the shuttle device200along the x-axis and an orthogonal dimension actuator224that moves the shuttle device200along the y-axis.

In some embodiments, the lateral dimension actuator222, the orthogonal dimension actuator224, or both can comprise a linear bearing. Specifically, the lateral dimension actuator222can comprise outer rails226and the orthogonal dimension actuator224can comprise inner rails228. The outer rails226of the lateral dimension actuator222can be in sliding engagement with inner rails228of the orthogonal dimension actuator224. Optionally, the outer rails226can extend substantially along the x-axis and the inner rails228can extend substantially along the y-axis. Alternatively, the outer rails226can extend substantially along the y-axis and the inner rails228can extend substantially along the x-axis. It is noted that providing the inner rails228along the longest dimension of the matrix of cells108can improve the operation of the system10. In some embodiments, each of the outer rails226can be substantially parallel with respect to one another. Additionally, each of the inner rails228can be substantially parallel with respect to one another and can extend between the outer rails226. During operation of the lateral dimension actuator222, the outer rails226can be held substantially stationary as the inner rails228slide throughout rows of the matrix of cells108. Accordingly, the lateral dimension actuator222can comprise a lateral servomechanism230that provides a force that urges the inner rails228into motion with respect to the outer rails226. The lateral servomechanism230can be positioned upon the inner rails228, the outer rails226, or a combination thereof.

In some embodiments, the inner rails228of the orthogonal dimension actuator224can be in sliding engagement with the shuttle device200. Specifically, the shuttle device200can comprise a plurality of roller bearings232that roll along the profile of the inner rails228to provide the sliding engagement. In some embodiments, the profile of each inner rail228can be formed by an I-beam. Roller bearings232can be provided at each side of the shuttle device200and confined within the profile of the inner rails228. Alternatively or additionally, the upper face206of the shuttle device200can extend beyond the inner rails228. Such an oversized upper face206can reduce the profile of the shuttle device200and provide additional stability. The orthogonal dimension actuator224can comprise an orthogonal servomechanism234that provides a force that urges the shuttle device200into motion with respect to the inner rails228. The orthogonal servomechanism234can be positioned upon the shuttle device200, the inner rails228, or a combination thereof. Accordingly, the orthogonal servomechanism234can urge the shuttle device200along the rows of the matrix of cells108. It is noted that, while the motive assembly220is depicted inFIGS. 1, 2, and 9as comprising a particular type of linear bearing, the embodiments described herein are not so limited. It is contemplated that the motive assembly220can comprise any motion system suitable to urge the shuttle device200along the x-axis, the y-axis, or combinations thereof.

Referring collectively toFIGS. 1 and 2, the system10can comprise a controller50configured to direct the shuttle device200and the motive assembly220according to software modules and prioritization rules. Specifically, the controller50can be communicatively coupled to the shuttle device200and the motive assembly220. The controller50can comprise one or more processors52for executing machine readable instructions and memory54for storing the machine readable instructions. The one or more processors52can be communicatively coupled to the memory54. The one or more processors52comprise an integrated circuit, a microchip, a computer, or any other computing device capable of executing machine readable instructions. The memory54can comprise RAM, ROM, a flash memory, a hard drive, or any device capable of storing machine readable instructions.

In the embodiments described herein, the one or more processors52, the memory54, or both can be integral with the shuttle device200, the motive assembly220, or both. However, it is noted that the one or more processors52, the memory54, or both can be separate components communicatively coupled with one another without departing from the scope of the present disclosure. As used herein, the phrase “communicatively coupled” can mean that components are capable of exchanging data signals with one another such as, for example, electrical signals via conductive medium, electromagnetic signals via air, optical signals via optical waveguides, and the like.

Thus, embodiments of the present disclosure can comprise logic or an algorithm written in any programming language of any generation (e.g., 1GL, 2GL, 3GL, 4GL, or 5GL) such as, e.g., machine language that may be directly executed by the processor, or assembly language, object-oriented programming (OOP), scripting languages, microcode, etc., that may be compiled or assembled into machine readable instructions and stored on a machine readable medium. Alternatively, the logic or algorithm may be written in a hardware description language (HDL), such as implemented via either a field-programmable gate array (FPGA) configuration or an application-specific integrated circuit (ASIC), and their equivalents.

Referring still toFIGS. 1 and 2, the system10can comprise a plurality of pallets20arranged upon the matrix of cells108formed by the rectangular grid100. The shuttle device200and the motive assembly220can be suspended below the rectangular grid100such that the rectangular grid100is positioned between the pallets20and the shuttle device200. In some embodiments, the outer rails226of the motive assembly220can be fixed beneath the rectangular grid100and can span the extent of the rectangular grid100. The motive assembly220can be operatively coupled to the shuttle device200and configured to align the shuttle device beneath any of the pallets20or cells of the matrix of cells108.

As is noted above, the controller50can direct the operation of the shuttle device200to selectively position the pallets20throughout the matrix of cells108. Specifically, the one or more processors52can execute machine readable instructions to automatically perform the processes described herein. The machine readable instructions can comprise address information associated with each cell of the matrix of cells108. For example, each cell can be associated with coordinates that correspond to the position of the cell. In some embodiments, the coordinates can be indicative of the position of the center of the cell with respect to the x-axis and the y-axis. In embodiments with multiple levels, the coordinates can further be indicative of position with respect to the z-axis. Likewise, each pallet20can be associated with coordinates indicative of the position of the pallet. During operation, each pallet20can be mapped or associated with a cell of the matrix of cells108. Accordingly, the controller50can track the position of each pallet20and identify any unoccupied cell128of the matrix of cells108that is unobstructed by the pallets20.

Referring collectively toFIGS. 1, 2 and 10, a method300for moving pallets20throughout the matrix of cells108is provided. Initially, a targeted pallet46of the pallets20can be determined automatically by the one or more processors52. For example, the targeted pallet46can be associated with a desired good that has been marked for retrieval. Accordingly, each pallet20can be associated with a good within the memory54such that the targeted pallet46can be determined by identifying the desired good. Upon determining the position of the targeted pallet46, the one or more processors52can automatically determine the position of the unoccupied cell128with respect to an exit position130and the targeted pallet46. It is noted that, while the exit position130is depicted inFIGS. 1 and 10as being a row, the exit position130can be any portion of the matrix of cells108where the pallet20can be accessed such as, for example, a column or a cell. It is furthermore noted that, while the methods described herein comprise a number of enumerated processes, the processes can be performed in any order or omitted without departing from the scope of the present disclosure.

If it is determined that the unoccupied cell128is further from the exit position130than the targeted pallet46, the method300can proceed to process302. At process302, the column132that corresponds to unoccupied cell128can be identified. Each pallet20in the column132can be moved by the shuttle device200towards the unoccupied cell128. Specifically, starting the pallet20nearest the unoccupied cell128, the pallets20can be moved until the unoccupied cell128is positioned in a row134, which is one row nearer to the exit position130than the targeted pallet46. The method300can then proceed to process304.

At process304, each pallet20located in the row134between the unoccupied cell128and the targeted pallet46can be moved by the shuttle device200into the unoccupied cell128. Specifically, starting with the pallet20nearest the unoccupied cell128, the pallets20can be moved away from the targeted pallet46and into the unoccupied cell128. The pallets20can be moved until the unoccupied cell128is positioned in the cell adjacent to the targeted pallet46, i.e., the unoccupied cell128can be positioned in the same column136as the targeted pallet46. The method300can then proceed to process306.

Referring still toFIGS. 1, 2 and 10, at process306, the target pallet46can be moved towards the exit position130and into the unoccupied cell128. The one or more processors52can determine the position of the target pallet46with respect to the exit position130. If the target pallet46is not at the exit position130, the method300can then proceed to process308. If the target pallet46is at the exit position130, the method300can then proceed to process310.

At process308, each pallet20located adjacent to the targeted pallet46can be moved by the shuttle device200in a half circle movement. Specifically, pallets20adjacent and in the same column136or the adjacent column138of the targeted pallet46can be moved into the unoccupied cell128. Specifically, starting with the pallet20nearest the unoccupied cell128, the pallets20can be moved until the unoccupied cell128is positioned between the targeted pallet46and the exit position130, i.e., the unoccupied cell128can be positioned in the same column136as the targeted pallet46. The method300can then proceed to process306.

At process310, the targeted pallet46can be positioned within the exit position130. Accordingly, the goods stored upon the targeted pallet46can be access by an access device that is configured to load or unload goods from the targeted pallet46. Exemplary access devices include, but are not limited to, an elevator, an industrial lift, a conveyor, a picker, a fork truck, or the like.

In some embodiments, the unoccupied cell128can be closer to the exit position130than the targeted pallet46when the method300is initiated. In such instances, instead of process302, the method300can proceed to process312. At process312, the row140that corresponds to unoccupied cell128can be identified. Each pallet20in the row140between the column136and the unoccupied cell128can be moved by the shuttle device200towards the unoccupied cell128. Specifically, starting with the pallet20nearest the unoccupied cell128, the pallets20can be moved until the unoccupied cell128is positioned in the column136. The method300can then proceed to process314.

At process314, each pallet20located in the column136between the unoccupied cell128and the targeted pallet46can be moved by the shuttle device200towards the unoccupied cell128. Specifically, starting with the pallet20nearest the unoccupied cell128, the pallets20can be moved away from the targeted pallet46and into the unoccupied cell128. The pallets20can be moved until the unoccupied cell128is positioned in the cell adjacent to the targeted pallet46. The method300can then proceed to process306.

Referring collectively toFIGS. 2, 5, 8A, 8B, and 11, a method400for moving pallets20to an adjacent cell is provided. The method400can comprise process402for initializing the shuttle device200. At process402, the shuttle device200can be prepared to access any selected one of the pallets20. Generally, the pallet20that is selected can be located in a cell of the matrix of cells108that is adjacent to the unoccupied cell128, before the pallet engagement member204of the shuttle device200and the shuttle engagement member28of the pallet20become engaged. Prior to moving the shuttle device200, the shuttle engagement members204can be moved to the lowered position (FIG. 8A). Specifically, the one or more processors52can automatically actuate the vertical actuators202to ensure that the shuttle engagement members204are lowered. The method400can then proceed to process404.

At process404, the position of the unoccupied cell128can be verified by the one or more processors52. As is noted above, the position of the unoccupied cell128can be provided to the one or more processors52. For example, the position can be mapped by coordinates associated with the unoccupied cell128. The shuttle device200can be directed towards the position of the unoccupied cell128. Specifically, the one or more processors52can direct the motive assembly220to actuate in order to cause the shuttle device200to move to the position of the unoccupied cell128. In some embodiments, the distance sensor210can detect a detected position of the shuttle device with respect to the coordinate system. Accordingly, the distance sensor210can be utilized to provide feedback, i.e., the one or more processors52can compare the mapped position of the unoccupied cell128to the detected position observed by the distance sensor210. Once the shuttle device200is appropriately positioned, the identification sensor208can be utilized to verify that the unoccupied cell128is unobstructed by the pallets20. The method400can then proceed to process406.

At process406, the position of the pallet20that is selected for movement can be verified by the one or more processors52. Specifically, the one or more processors52can automatically move the shuttle device200to the mapped location of the pallet20with the motive assembly220. In some embodiments, the one or more processors52can direct the motive assembly220to mapped locations based on a feed forward control, i.e., the one or more processors52can be configured to determine the location of the shuttle device200based only upon a known position of the shuttle device200and subsequent inputs provided to the motive assembly220. Optionally, the distance sensor210can detect the position of the shuttle device200. Accordingly, the one or more processors52can compare the detected position to the mapped location of the pallet20or feed forward location of the shuttle device200for feedback control. Once the shuttle device200is positioned within detection range of the pallet20, the method400can then proceed to process408.

At process408, the one or more processors52can automatically align the shuttle device200and the pallet20. Specifically, the identification sensor208can detect the identification device36of the pallet20. The identification sensor208can communicate data indicative of the identification device36of the pallet20. The data can be decoded by the one or more processors52to determine the relative position of the pallet20and the shuttle device200. Accordingly, the one or more processors52can actuate the motive assembly220to provide alignment suitable for engagement. For example, the center of each of the pallet20and the shuttle device200can be aligned. The method400can then proceed to process410.

Referring collectively toFIGS. 5, 8A, 8B, and 11, at process410, the one or more processors52can cause the shuttle device200to engage the pallet20. Specifically, the one or more processors52can cause the vertical actuators202to actuate to transition the pallet engagement members204from a lowered position (FIG. 8A) to a raised position (FIG. 8B). As the pallet engagement members204are transitioned, the pallet engagement members204can engage the shuttle engagement member28disposed on the underside24of the pallet20. Specifically, each pallet engagement members204can interlock with a corresponding latching feature30of the shuttle engagement member28. Since the pallet20is in sliding engagement with the rectangular grid100, movement of the pallets20can be provided without lifting the pallet20from the rectangular grid100. Accordingly, the pallet engagement members204can be configured to engage the shuttle engagement member28without providing a force that urges the pallet20and the rectangular grid100apart. The method400can then proceed to process412.

Referring collectively toFIGS. 2, 5, 8A, 8B, and 11, at process412, the pallet20can be moved towards the unoccupied cell128, while the shuttle device200avoids the rectangular grid100. For example, the shuttle device200can cause the pallet20to slide towards the unoccupied cell128, while the pallet engagement members204of the shuttle device200and the shuttle engagement member28of the pallet20are engaged. Movement of the shuttle device200and the pallet20can be provided along a direction of motion. The one or more processors52can determine or be provided with the direction of motion. Accordingly, the one or more processors52can identify a leading set236of the pallet engagement members204and a trailing set238of the pallet engagement members204based at least in part upon the direction of motion. Specifically, the leading set236of the pallet engagement members204can be the pallet engagement members204nearest to intersection with the rectangular grid100along the direction of motion. The trailing set238of the pallet engagement members204can be the pallet engagement members204that are furthest from the rectangular grid100along the direction of motion. For example, should the direction of motion be in the positive y-direction, the leading set236and the trailing set238of the pallet engagement members204can be identified as depicted inFIGS. 8A and 8B. It should be understood that the leading set236and the trailing set238of the pallet engagement members204are dependent upon and change with the direction of motion.

The direction of motion and the current position of the shuttle device200can be utilized to identify an intersecting rail from the lateral rails104and orthogonal rails of the rectangular grid100. The intersecting rail can be defined as the nearest rail of the rectangular grid100to the shuttle device200along the direction of motion. Generally, the intersecting rail can be orthogonal to the direction of motion. As the shuttle device200and the pallet20to slide towards the unoccupied cell128, the intersecting rail can be traversed by sequentially actuating the pallet engagement members204. Specifically, the leading set236of the pallet engagement members204can be disengaged from the shuttle engagement member28as the leading set236of the pallet engagement members204approached the intersecting rail. The pallet20can slide over the intersecting rail and the shuttle device200can travel under the intersecting rail, while the shuttle engagement member28of the pallet20is engaged with the trailing set238of the pallet engagement members204and the shuttle engagement member28of the pallet20is disengaged with the leading set236of the pallet engagement members204.

The pallet20can continue to slide over the intersecting rail and the shuttle device200can continue to travel under the intersecting rail. When the leading set236of the pallet engagement members204are clear of the intersecting rail and prior to the trailing set238of the pallet engagement members204contacting the intersecting rail, the leading set236of the pallet engagement members204can re-engage the shuttle engagement member28of the pallet20and the trailing set238of the pallet engagement members204can disengage the shuttle engagement member28of the pallet20. The pallet20can slide over the intersecting rail and the shuttle device200can travel under the intersecting rail, while the trailing set238of the pallet engagement members204are disengaged from the shuttle engagement member28and the leading set236of the pallet engagement members204are engaged with the shuttle engagement member28of the pallet20. The pallet20can continue to slide over the intersecting rail and the shuttle device200can continue to travel under the intersecting rail. When the trailing set238of the pallet engagement members204are clear of the intersecting rail, the trailing set238of the pallet engagement members204can re-engage the shuttle engagement member28of the pallet20. Accordingly, both the leading set236and the trailing set238of the pallet engagement members204can be engaged with the shuttle engagement member28of the pallet20after the pallet engagement members204are clear of the intersecting rail. The method400can then proceed to process414.

At process414, the pallet20can be delivered to the unoccupied cell128. Specifically, the shuttle device200can continue to slide the pallet20until the pallet20is positioned upon the unoccupied cell128. In some embodiments, the distance sensor210can detect a detected position shuttle device200, which can be utilized to verify that the pallet20has been properly delivered. Once the pallet20is delivered, both the leading set236and the trailing set238of the pallet engagement members204can be disengaged from the shuttle engagement member28of the pallet20, i.e., placed in the lowered position (FIG. 8A). It is noted that the method400can be utilized to move the pallets to an adjacent cell in any direction such as, for example, the positive x-direction, the negative x-direction, the positive y-direction, or the negative y-direction. It is furthermore noted that each movement of the pallet20described above with respect to method300can comprise one or more process described herein with respect to the method400.

Referring again toFIGS. 1 and 2, the machine readable instructions stored in the memory54can comprise a storage algorithm that arranges the pallets20according to the goods associated with the pallets20. The storage algorithm can comprise restrictions that are automatically enforced by the one or more processors52. The restrictions can restrict the pallets20that can be stored adjacently according to the associated goods. For example, the storage rules may prevent household items from being stored adjacent to food items. Alternatively or additionally, the storage algorithm can track demand history for goods within a database stored in memory54. The storage algorithm can place pallets20with respect to the exit position130based upon the demand for the associated good, i.e., goods with higher demand can be stored closer to the exit location130than goods with less demand. Alternatively or additionally, the storage algorithm can arrange pallets according to groups. Specifically, the associated goods can be grouped according to goods that are frequently retrieved at the same time, i.e., sub components of an assembly may frequently be retrieved contemporaneously (e.g., components need to build an engine). In some embodiments, the storage algorithm can be configured to run offline, i.e., within a defined time frame that corresponds to an idle period. Accordingly, the arrangement of the pallets20can be performed without conflicting with picking requests or storage requests.

Referring collectively toFIGS. 1, 2 and 12, the system10can be provided within a warehouse60for increasing the storage utilization of the warehouse60. In some embodiments, the warehouse60can comprise multiple floors or levels, which can each be provided above one another along the z-axis. Each floor of the warehouse60can comprise or be formed from the system10. For example, each floor of the warehouse60can comprise a plurality of pallets20provided upon the rectangular grid100. In some embodiments, the exit position130of the floors can be provided as a row of the rectangular grid100along the x-axis. The warehouse60can comprise a row retrieval device62such as, for example, an elevator or industrial lift. The row retrieval device62can be configured to move pallets20from the exit position130throughout the various floors of the warehouse60. Alternatively or additionally, the exit position140of the floors can be provided as a column of the rectangular grid100along the y-axis. The warehouse60can comprise a column retrieval device64configured to move pallets20from the exit position140throughout the various floors of the warehouse60.

It should now be understood, the embodiments described herein can be utilized within a warehouse facility to decrease the amount of wasted storage volume. For example, a typical warehouse may waste about 40% of the storage space due to the space consumed by roads between storage racks. In embodiments of the present disclosure utilizing a column exit and a column retrieval device, the amount of storage space waste can be reduced to about 21%. Moreover, in embodiments of the present disclosure utilizing a row exit and row retrieval device, the amount of storage space waste can be reduced to about 1%. Accordingly, the storage capability of the warehouses according to the embodiments described herein can be relatively large compared to a typical warehouse. Furthermore, the automated systems provided herein improve accuracy by reducing human interaction, e.g., human errors are decreased and instances of expired goods due to human error are reduced. Additionally, goods can be retrieved with greater speed due to the use of the offline organization techniques provided herein.

It is noted that directional references such as, for example, x-direction, y-direction, z-direction, x-axis, y-axis, z-axis, x-z plane and the like have been provided for clarity and without limitation. Specifically, it is noted such directional references are made with respect to the coordinate system depicted inFIGS. 1-10 and 12. Thus, the directions may be reversed or oriented in any direction by making corresponding changes to the provided coordinate system and the associated structure to extend the examples described herein.