System comprising a multilevel warehouse racking system comprising tote transfer zones, materials handling vehicles, and transporters, and methods of use thereof

Goods storage and retrieval systems and materials handling vehicles are provided. The goods storage and retrieval system includes a multilevel warehouse racking system; a materials handling vehicle comprising a mast assembly, a picking attachment, and vehicle-based cart engagement hardware; a mobile storage cart; and a transporter comprising transporter-based engagement hardware. The transporter-based engagement hardware enables the transporter to engage, transport, and disengage the mobile storage cart. The vehicle-based cart engagement hardware is coupled to the mast assembly to (i) engage and disengage the mobile storage cart and (ii) transport the mobile storage cart to multiple levels of the multilevel warehouse racking system. The mast assembly and the picking attachment are configured to access multiple levels of the multilevel warehouse racking system. The picking attachment is configured to transfer totes between the multilevel warehouse racking system and the mobile storage cart.

BACKGROUND

The present disclosure relates to a goods storage and retrieval system in a warehouse environment. The system functionally integrates a multilevel warehouse racking system, one or more materials handling vehicles, one or more mobile storage carts, and one or more transporters. For the purposes of defining and describing the concepts and scope of the present disclosure, it is noted that a “warehouse” encompasses any indoor or outdoor industrial facility in which materials handling vehicles transport goods including, but not limited to, indoor or outdoor industrial facilities that are intended primarily for the storage of goods, such as those where multi-level racks are arranged in aisles, and manufacturing facilities where goods are transported about the facility by materials handling vehicles for use in one or more manufacturing processes.

BRIEF SUMMARY

According to the subject matter of the present disclosure, goods-to-man warehousing systems are provided to increase the adaptability, utility, and efficiency of partially and fully autonomous materials handling vehicles and transporters in the warehouse environment.

In accordance with one embodiment of the present disclosure, a goods storage and retrieval system is provided. The goods storage and retrieval system comprises a multilevel warehouse racking system comprising a tote transfer zone, a materials handling vehicle comprising a mast assembly and a picking attachment, a target tote, and a transporter comprising transporter-based engagement hardware. The transporter-based engagement hardware enables the transporter to engage, transport, and disengage the target tote at the tote transfer zone independent of movement of the materials handling vehicle within the goods storage and retrieval system. The picking attachment is coupled to the mast assembly for movement along a lifting dimension of the mast assembly to (i) engage and disengage the target tote at the tote transfer zone and at multiple levels of the multilevel warehouse racking system independent of movement of the transporter within the goods storage and retrieval system and (ii) transport the target tote to multiple levels of the multilevel warehouse racking system independent of movement of the transporter within the goods storage and retrieval system. The mast assembly and the picking attachment are configured to access multiple levels of the multilevel warehouse racking system.

In accordance with another embodiment of the present disclosure, a method of operating a goods storage and retrieval system is provided. The method comprises providing the goods storage and retrieval system comprising a multilevel warehouse racking system, a materials handling vehicle disposed on an inventory transit surface, a tote transfer zone, a target tote, and a transporter comprising transporter-based engagement hardware. The materials handling vehicle comprises a traction control unit, a braking system, and a steering assembly, each operatively coupled to one or more of the vehicle wheels. The materials handling vehicle further comprises a mast assembly, a fork carriage assembly movably coupled to the mast assembly, a mast assembly control unit, a carriage control unit, a picking attachment comprising an X-Y-Z-Ψ positioner secured to the fork carriage assembly, a navigation subsystem, and one or more vehicular controllers in communication with the traction control unit, the braking system, the steering assembly, the mast assembly control unit, the carriage control unit, the picking attachment, and the navigation subsystem. The method comprises navigating the materials handling vehicle along the inventory transit surface to the target tote through use of the navigation subsystem and the one or more vehicular controllers independent of movement of the transporter within the goods storage and retrieval system. The method comprises engaging or disengaging the target tote with the picking attachment secured to the fork carriage assembly through use of the X-Y-Z-Ψ positioner at the tote transfer zone and at multiple levels of the multilevel warehouse racking system independent of movement of the transporter within the goods storage and retrieval system. The method further comprises placing with the picking attachment the target tote on the tote transfer zone or on a level of the multilevel warehouse racking system and engaging the target tote with the transporter through use of the transporter-based engagement hardware comprising a transporter lifting surface.

DETAILED DESCRIPTION

Referring initially toFIG. 1I, a goods storage and retrieval system100comprises a multilevel warehouse racking system200, a materials handling vehicle300, a mobile storage cart400, and a transporter500, disposed on an inventory transit surface110. The materials handling vehicle300comprises vehicle-based cart engagement hardware316(FIG. 5), a mast assembly302, and a picking attachment320(FIG. 5). The multilevel warehouse racking system200comprises a tote transfer zone219. As shown inFIGS. 1C and 1D, the transporter500comprises transporter-based engagement hardware540that enables the transporter500to engage, transport, and disengage the mobile storage cart400by raising a lifting surface520of the transporter500to contact the mobile storage cart400. Referring back toFIG. 1I, the transporter500may engage, transport, and disengage the mobile storage cart400at a variety of locations along an inventory transit surface110of the goods storage and retrieval system100independent of movement of the materials handling vehicle300within the goods storage and retrieval system100. Referring toFIGS. 1I, 1E, and 1F, the transporter-based engagement hardware540further enables the transporter500to engage, transport, and disengage a target tote214at the tote transfer zone219by raising a lifting surface520of the transporter500to contact the target tote214independent of movement of the materials handling vehicle300within the goods storage and retrieval system100.

Referring toFIGS. 1I and 5, the vehicle-based cart engagement hardware316is coupled to the mast assembly302for movement along a lifting dimension (along the Z′-axis as shown inFIG. 1I) of the mast assembly302to (i) engage and disengage the mobile storage cart400at a variety of locations along the inventory transit surface110independent of movement of the transporter500within the goods storage and retrieval system100and (ii) transport the mobile storage cart400to multiple levels of the multilevel warehouse racking system200independent of movement of the transporter500within the goods storage and retrieval system100. The picking attachment320is coupled to the mast assembly302for movement along a lifting dimension of the mast assembly302to (i) engage and disengage the target tote at the tote transfer zone219, the mobile storage cart400, and at multiple, vertically spaced, levels of the multilevel warehouse racking system200independent of movement of the transporter500within the goods storage and retrieval system100and (ii) transport the target tote to the tote transfer zone219, the mobile storage cart400, and to multiple levels of the multilevel warehouse racking system200independent of movement of the transporter500within the goods storage and retrieval system100.

The mast assembly302and the picking attachment320are configured to access multiple levels of the multilevel warehouse racking system200. The picking attachment320of the materials handling vehicle300is configured to transfer totes between the multilevel warehouse racking system200and the mobile storage cart400at multiple levels of the multilevel warehouse racking system200when the mobile storage cart400is engaged by the materials handling vehicle300. Additionally or alternatively, the picking attachment320of the materials handling vehicle300may be configured to transfer totes between multiple levels of the multilevel warehouse racking system200and the transporter500. Additionally or alternatively, the picking attachment320of the materials handling vehicle300may be configured to transfer totes between the transporter500and the mobile storage cart400when the mobile storage cart400is engaged by the materials handling vehicle300. As described in more detail below, the goods storage and retrieval system100may further comprise a cart home position410, one or more mobile storage cart transfer nodes420, one or more goods receiving stations610, and one or more warehouse management computing hubs.

Referring still toFIGS. 1I and 5, the materials handling vehicle300may further comprise a vehicle body301, a plurality of wheels306supporting the vehicle body301, a traction control unit372, a braking system371, and a steering assembly373, each operatively coupled to one or more of the vehicle wheels306. The materials handling vehicle300may further comprise a mast assembly302, a fork carriage assembly310movably coupled to the mast assembly302, a mast assembly control unit374, a carriage control unit375, the picking attachment320secured to the fork carriage assembly310, a cart engagement subsystem350, and a navigation subsystem360.

Referring toFIGS. 5 and 12, the materials handling vehicle300may comprise one or more vehicular controllers in communication with the traction control unit372, the braking system371, the steering assembly373, the mast assembly control unit374, the carriage control unit375, the picking attachment320, the cart engagement subsystem350, and the navigation subsystem360. The vehicular controller(s) may comprise a picking controller376, a braking controller377, a traction controller378, a steering controller379, a mast controller380, or one or more integrated controllers, to control operational functions of the picking attachment320, the braking system371, traction control unit372, the steering assembly373, or the mast assembly control unit374. The vehicular controller(s) will be described in further detail later in the application.

While the mast assembly302is depicted inFIG. 1Ias extending to the height of the racks210, it is understood and within the scope of this disclosure that the mast assembly302may extend to different heights with respect to the racks210. For example, the mast assembly302may be a multi-stage mast, with or without a free-lift feature. The aforementioned materials handling vehicles may include lift trucks available from Crown Equipment Corporation such as, for example, SP Series Order Pickers such as the Crown SP 3500/4500 Series Order Picker or TSP Series Order Pickers such as the Crown TSP 6500/7000 Series Order Picker.

Referring now toFIG. 5, the vehicle body301of the materials handling vehicle300may be described as comprising a fork side303and a power unit side304, with the fork carriage assembly310positioned at the fork side303of the vehicle body301and being movably coupled to the mast assembly302. The materials handling vehicle300may also comprise an operator compartment307that may also be movably coupled to the mast assembly302. This operator compartment307may be positioned between the fork carriage assembly310and the power unit side304of the vehicle body301. In embodiments, the materials handling vehicle300does not include the operator compartment307.

Referring again toFIG. 1I, a variety of technologies may be provided to facilitate partial or fully autonomous navigation of the materials handling vehicle300, including conventional, or yet-to-be developed technology. For example, and not by way of limitation, radio frequency identification (RFID) tags may be embedded in the inventory transit surface110, or secured to various warehouse objects, to help facilitate partially or fully autonomous navigation. Wire guidance systems, which are well documented in the art, may also be employed to help facilitate partially or fully autonomous navigation. In one contemplated embodiment, RFID tags embedded in the inventory transit surface110may be used in conjunction with a wire guidance system. In which case, it may be advantageous to embed the RFID tags230at vehicle stop locations, pick-place locations, tote transfer zones, transfer node locations, or other significant navigational markers along a racking system aisle, as shown inFIG. 1I. Partially or fully autonomous navigation may also be implemented, by way of non-limiting examples, through laser-based navigation, time of flight cameras, environmental based location, overhead feature-based localization, illumination-invariant feature detection, map partitioning, pre-positioned object-based localization, and/or transversal edge detection based localization. The vehicle stop locations may be recorded in a navigation map in the navigation subsystem360(FIG. 12) of the materials handling vehicle300such that physical RFID tags230are not needed for the materials handling vehicle300to position itself correctly at a vehicle stop location.

Referring toFIG. 1I, the mobile storage carts400may be presented as a multilevel storage cart400with individual container bays430that are configured to accommodate at least one tote213which can carry a plurality of different types of goods. In this embodiment, the mobile storage carts400are structurally configured to stand on an inventory transit surface110while permitting transporter travel there beneath. Specifically, the mobile storage cart400comprises a transporter access opening510that is sized and configured to permit the transporter500to enter and exit through one or more of a plurality of transporter access openings510along the inventory transit surface110. Furthermore, the mobile storage cart400comprises at least two vertically-oriented fork slots450(shown inFIG. 5).

Referring toFIGS. 1A-1G and 1I, the transporter500comprises transporter-based engagement hardware540that enables the transporter500to transport mobile storage carts400from one or more mobile storage cart transfer nodes420to one or more goods receiving stations610of the goods-to-man warehousing system600. For example, the transporter500may feature a lifting surface520(shown inFIG. 1A) and be structurally configured to lift a mobile storage cart400off of the inventory transit surface110upon which the mobile storage cart400is supported by elevating the transporter lifting surface from a traveling height (as shown inFIGS. 1B and 1G) to a cart contacting height (as shown inFIG. 1C) and then to a transporting height (as shown inFIGS. 1D and 1F). Referring back toFIG. 1I, each of the mobile storage carts400may be structurally configured to permit the transporter500to enter and exit a lifting zone530beneath the mobile storage cart400in at least two orthogonal directions, with the lifting surface of the transporter500at the traveling height.

Similarly, the transporter500may feature a lifting surface520and be structurally configured to lift the target tote214, as shown inFIGS. 1E-1F. Referring toFIGS. 1I, 1E-1G, 7A, and7B, the target tote214has a tote width of t and comprises a pair of protruding rims214A positioned on opposite sides of the target tote214. These protruding rims214A define a target tote rimmed width r. Totes may be a variety of different sizes, varying from smaller than the lifting surface520of the transporter500to larger than the lifting surface520of the transporter500. In some embodiments, the bottom of the tote214may be approximately the same size as the lifting surface520of the transporter500. In some embodiments, the length and width of the tote214may be approximately equal. In other embodiments, the length of the tote214may be greater than the width of the tote214. In embodiments, the width and height of the tote214may be approximately equal. In other embodiments, the height of the tote214may be less than the width of the tote214. In other embodiments, the height of the tote214may be greater than the width of the tote214. The tote transfer zone219comprises a plurality of tote suspension tracks219A defined by a track spacing b. For the totes214to rest securely on tote suspension tracks219A of the tote transfer zone219, t<b<r. The tote transfer zone219is elevated above an inventory transit surface110of the goods storage and retrieval system100such that the totes214stored therein are accessible by the transporter500. The tote transfer zone219may form a bottom level of the multilevel warehouse racking system200. In some embodiments, as shown inFIG. 1H, the multilevel warehouse racking system200comprises a first rack and a second rack arranged on opposite sides of a racking system aisle. The first and second racks define end points of the racking system aisle and the tote transfer zone219extends past the end points of the racking system aisle. In an alternative embodiment, the tote transfer zone219does not extend past the end points of the racking system aisle and is instead inset within the rack of the multilevel warehouse racking system200. When the tote transfer zone219is inset within the rack210of the multilevel warehouse racking system200, the tote transfer zone219may form a bottom level of the multilevel warehouse racking system200.

In embodiments, the transporter500may be structurally configured such that the lifting surface520lifts the target tote214relative to a tote supporting surface (in some embodiments, this may include the tote suspension tracks219A) of the tote transfer zone219. The lifting surface520of the transporter500may lift the target tote214by elevating the transporter lifting surface520from the traveling height to a rack height (shown inFIG. 1E) and then to the transporting height (shown inFIG. 1F). The lifting surface520of the transporter500may be structurally configured to lower the target tote214onto a tote supporting surface (such as the tote suspension tracks219A) of the tote transfer zone219by lowering the transporter lifting surface520from the transporting height (shown inFIG. 1F) to the rack height (shown inFIG. 1E), such that the protruding rims214A of the target tote214rest on the tote suspension tracks219A.

The multilevel warehouse racking system200may comprise a plurality of racking system aisles220between the racks210.FIG. 1Iillustrates an embodiment of a rack210of the multilevel warehouse racking system200having a plurality of shelves240having at least a portion configured to support a rack module211configured to store one or more totes213. In embodiments, the rack module211may be similar to or the same as the rack modules disclosed in U.S. Patent Application Publication 2017/0334644. The transporter500may be further configured to transport the mobile storage cart400within, into, and out of the racking system aisles220. Further, the mobile storage carts400may be structurally configured for a transporter500to travel there beneath by, for example, ensuring that a bottom surface of a lowest storage level of each of the mobile storage carts400has a height exceeding the traveling height of the transporter lifting surface of the transporter500. As shown inFIGS. 1C and 1D, the lifting surface520of the transporter500may lift the mobile storage cart400by elevating the transporter lifting surface520from the traveling height to an engagement height (shown inFIG. 1C) and then to the transporting height (shown inFIG. 1D). Referring again toFIG. 1I, in embodiments, the travel path130beneath the multilevel warehouse racking system200for the transporter500is a travel path extending along the inventory transit surface110, in a storage plane defined by the distributed array of racks210, which follow the shape of the distributed array of racks210.

Referring now toFIGS. 5, 6, and 12, as stated previously, the materials handling vehicle300further includes a picking attachment320. The picking attachment320may be added as a vehicle retrofit such that the picking attachment320and materials handling vehicle300collectively define dual axis vertical displacement. More specifically, as a non-limiting example, the mast assembly302and the mast assembly control unit374may be configured to move the fork carriage assembly310along a vertical axis Z′, and the picking attachment320, which comprises the X-Y-Z-Ψ positioner322, may be secured to the fork carriage assembly310. The vehicular controller(s) of the materials handling vehicle300executes vehicle functions to use the X-Y-Z-Ψ positioner322of the picking attachment320to engage and disengage a target tote214positioned in the multilevel warehouse racking system200with the picking attachment320. The mast assembly302, mast assembly control unit374, and the picking attachment320are collectively configured such that movement of the X-Y-Z-Ψ positioner322along the Z-axis328by the picking attachment320is independent of movement of the fork carriage assembly310along the vertical axis Z′ by the mast assembly302and mast assembly control unit374. It is noted that “independent” movement means that the X-Y-Z-Ψ positioner322can effectuate vertical displacement without relying on movement of the fork carriage assembly310along the vertical axis Z′.

In embodiments, the mast assembly302, mast assembly control unit374, and the picking attachment320are collectively configured such that movement of the X-Y-Z-Ψ positioner322along the Z-axis328by the picking attachment320is supplemented by movement of the fork carriage assembly310along the vertical axis Z′ by the mast assembly302and mast assembly control unit374. “Supplemental” movement contemplates that, since the picking attachment320is secured to the fork carriage assembly310, movement of the X-Y-Z-Ψ positioner322along the Z-axis328by the picking attachment320can also result from movement of the fork carriage assembly310(for example, with respect to the mast assembly302) along the vertical axis Z′.

Referring toFIGS. 6-9, the X-Y-Z-Ψ positioner322may comprise a slide-out334that is configured to extend and retract to engage the target tote214. The slide-out334, which may be a telescoping assembly, is provided with hardware that selectively engages the target tote214to push and pull the target tote214into, and out of, a warehouse shelf240(shown inFIG. 1I), a container bay430of the mobile storage cart400(shown inFIG. 1I), or the transporter lifting surface520(shown inFIG. 1E), in a sliding motion. The slide-out334may be configured to slide within slots336defined in a pair of inner side walls338of the picking attachment320. In embodiments, the slide-out334may include slide rails, ball bearing extension slides, or both. In embodiments, and not by way of limitation, the hardware that selectively engages the target tote214may be pivoting engagement fingers that pivot into and out of a sliding path of a target tote214for tote engagement. In embodiments, and not by way of limitation, the hardware that selectively engages the target tote214may be a mechanism configured to grip the target tote214such as, for example, at least one of a claw, a gripper, one or more vacuum cups, electromagnetic coils, an articulating arm, and the like.

Referring toFIG. 5, as stated previously, the materials handling vehicle300includes vehicle-based cart engagement hardware316. The vehicle-based cart engagement hardware316may comprise a mobile storage cart support platform312defined by one or more vertically-oriented cart lifting forks314, in which the major faces of the respective cart lifting forks314lie in a vertical plane. The mobile storage cart400may include vertically-oriented fork slots450that are structurally configured to receive the vertically-oriented cart lifting forks314.

Furthermore, referring toFIGS. 2-5 and 10, the vehicle-based cart engagement hardware316may comprise anti-rock cart engagement hardware340configured to engage a top end401of the mobile storage cart400. The vehicular controller(s) may be in communication with the vehicle-based cart engagement hardware316and may execute vehicle functions to use the vehicle-based cart engagement hardware316to engage a mobile storage cart400with the one or more cart lifting forks314and the anti-rock cart engagement hardware340of the fork carriage assembly310.

The anti-rock cart engagement hardware340may comprise a pair of support arms342configured to engage a top end401of the mobile storage cart400. The anti-rock cart engagement hardware340may comprise lateral anti-rock hardware wherein each support arm342comprises a hook subtending extension348, and the mobile storage cart400comprises a pair of extension passages408structurally configured to permit the hook subtending extensions348to pass at least partially through the pair of extension passages408. The anti-rock cart engagement hardware340may comprise front-rear anti-rock hardware wherein each support arm342comprises an anti-rock hook344defining a notch345, the anti-rock hook344extends downwardly at a distal portion346of the support arm342to define an engagement gap between the hook subtending extension348and a terminal portion of the anti-rock hook344. The mobile storage cart400may comprise hook engaging features structurally configured to engage the anti-rock hooks344of the pair of support arms342. The pair of extension passages408are structurally configured to permit the hook subtending extensions348to pass at least partially through the pair of extension passages408to permit the anti-rock hooks344of the pair of support arms342to engage the hook engaging features of the mobile storage cart400while the pair of support arms342engage a top end401of the mobile storage cart400. The extension passage408spacing is approximately equal to the spacing of the pair of support arms342, and the extension passages408are large enough to permit the support arms342to pass therethrough.

Each support arm342may include an anti-rock hook344defining a notch345, and a hook subtending extension348. The anti-rock hook344may extend downwardly at a distal portion346of the support arm342to define an engagement gap between the hook subtending extension348and a terminal portion of the anti-rock hook344. The hook engaging features may be structurally configured to engage the anti-rock hooks344of the pair of support arms342. Furthermore, the mobile storage cart400may comprise a pair of extension passages408structurally configured to permit the hook subtending extensions348to pass at least partially through the pair of extension passages408to permit the anti-rock hooks344of the pair of support arms342to engage the hook engaging features of the mobile storage cart400. In some embodiments, the hook engaging features may include vertical prongs406.

Referring still toFIGS. 2-5 and 10, the anti-rock cart engagement hardware340may comprise a pair of support arm engagement features402disposed at and extending from a top end401of a mobile storage cart400which is supported by the cart lifting forks314. Each support arm engagement feature402may include a horizontal lip404and a vertical prong406. The horizontal lip404is configured to be supported on the hook subtending extension348of the support arm342, and the vertical prong406is configured to be received and supported by the notch345in the anti-rock hook344. In embodiments, the anti-rock cart engagement hardware340is configured to engage the mobile storage cart400. In another embodiment, the anti-rock cart engagement hardware340is configured to engage the mobile storage cart400supported by the cart lifting forks314. By way of example and not as a limitation, the anti-rock cart engagement hardware340is configured to engage the mobile storage cart400supported by the cart lifting forks314at a cart contact point that is vertically displaced from the mobile storage cart support platform312by a distance approximating a height of the mobile storage cart400. In another embodiment, the anti-rock cart engagement hardware340may be configured to engage the mobile storage cart400supported by the cart lifting forks314at a pair of cart contact points that are vertically displaced from the mobile storage cart support platform312by a distance approximating a height of the mobile storage cart400.

It should be understood that different suitable variations of these mobile storage carts to be engaged with the cart lifting forks314are within the scope of this disclosure. For example, the mobile storage cart400may also include a wired grid, plexiglass, or mesh insert along the sides of shelving of the mobile storage cart400not configured to face the materials handling vehicle300when engaged.

Referring toFIGS. 1I, 5, 5A, 5B, 6, and 12, as previously stated, the materials handling vehicle300includes a cart engagement subsystem350(shown inFIG. 12). The cart engagement subsystem350is characterized by a storage cart engagement field of view352(shown inFIGS. 5A and 5B). The storage cart engagement field of view352may be defined by a vision system354(shown inFIG. 6) within the cart engagement subsystem350. Referring toFIGS. 1I, 5, 5A and 12, the vehicular controller(s) of the materials handling vehicle300execute vehicle functions to: (i) use the navigation subsystem360to navigate the materials handling vehicle300along the inventory transit surface110to a localized engagement position where a cart home position410(as shown inFIG. 1I) is within the storage cart engagement field of view352(as shown inFIG. 5A), and (ii) use the cart engagement subsystem350to engage the mobile storage cart400in the cart home position410with the fork carriage assembly310.

Referring toFIGS. 1I, 5, 5A, 5B, 6, and 12, the cart engagement subsystem350may be operatively coupled to at least one of the traction control unit372, the braking system371, the steering assembly373, the mast assembly control unit374, the carriage control unit375, cart engagement sensors355, and the picking attachment320to facilitate cart engagement. The cart engagement subsystem350may be coupled to these components directly, or indirectly, through the vehicular controller(s). The cart engagement subsystem350may be further characterized by a close approach field of view358(shown inFIGS. 5A and 5B) that is more restricted than the cart engagement field of view352(also shown inFIGS. 5A and 5B). The cart engagement subsystem350may transition from an initial approach mode in the cart engagement field of view352to a close approach mode in the close approach field of view358as the cart home position410moves into the close approach field of view358(shown inFIG. 5A).

For example, the materials handling vehicle300navigates to the location of the mobile storage cart400using the navigation subsystem360and positions the materials handling vehicle300in the localized engagement position. From there, the cart engagement subsystem350uses cart engagement sensors355(shown inFIG. 5B) to identify the mobile storage cart400in the initial approach mode. The cart engagement sensors355may be positioned within a hollow body portion of a monofork carriage assembly of a materials handling vehicle900(as will be subsequently described), as shown inFIGS. 5A and 5B. In alternative embodiments, the cart engagement sensors355may be positioned on the fork side303of the materials handling vehicle300(as shown inFIG. 5C). The cart engagement sensors355may include lasers, proximity sensors, cameras, or combinations thereof. The cart engagement sensors355may be capable of detecting the presence of a mobile storage cart400without any physical contact. In embodiments, the cart engagement sensors355may detect the mobile storage cart400by emitting an electromagnetic field and detecting changes in the electromagnetic field. Similarly, the cart engagement sensors355may detect the mobile storage cart400by emitting a beam of electromagnetic radiation (such as an infrared laser beam) and detecting changes in the return beam. Similar cameras and imaging equipment are disclosed in U.S. Pat. Nos. 9,990,535 B2 and 9,087,384 B2.

The cart engagement subsystem350uses the cart engagement sensors355to make course adjustments to align the cart lifting forks314to the vertically oriented fork slots450of the mobile storage cart400in the initial approach mode. Once the cart engagement field of view352no longer detects the mobile storage cart400, the cart engagement subsystem350transitions from the initial approach mode to the close approach mode and makes fine adjustments to the alignment of the cart lifting forks314and the vertically oriented fork slots450. The cart engagement subsystem350remains in the close approach mode until the cart engagement sensors355indicate the mobile storage cart400is coupled to the materials handling vehicle300.

When the materials handling vehicle300sets down a mobile storage cart400the cart engagement subsystem350starts in a reverse equivalent of the close approach mode and makes fine adjustments to maintain the alignment of the cart lifting forks314and the vertically oriented fork slots450of the mobile storage cart400as the materials handling vehicle300backs away from the mobile storage cart400. The cart engagement subsystem350then transitions to a reverse equivalent of the initial approach mode and the mobile storage cart400moves out of the close approach field of view358. This mode can be maintained until the mobile storage cart400moves out of the engagement field of view352(or out of some other predetermined distance, e.g. from 1 meter to 3 meters) at which point the cart engagement subsystem350may halt and allow the navigation subsystem360to control navigation. It is contemplated that this localized engagement position is recorded for future cart engagement by the materials handling vehicle300.

Referring toFIGS. 1I and 12, the navigation subsystem360may comprise one or more environmental sensors and an environmental database. In embodiments, the environmental sensors are configured to capture data indicative of a position of the materials handling vehicle300relative to the multilevel warehouse racking system200, the inventory transit surface110, or both. Further, the environmental database may comprise stored data indicative of the multilevel warehouse racking system200, the inventory transit surface110, or both. The navigation subsystem360may be configured to enable at least partially automated navigation of the materials handling vehicle300along the inventory transit surface110utilizing the captured data and the stored data. For example, and not by way of limitation, it is contemplated that the navigation subsystem360may utilize a stored warehouse map and captured images of ceiling lights or sky lights to enable navigation, as is disclosed in U.S. Pat. No. 9,174,830 issued on Nov. 3, 2015, (CRNZ 0053 PA), U.S. Pat. No. 9,340,399 issued on May 17, 2016 (docket no. CRNZ 0053 NA), and other similar patents and patent publications. Additional suitable environmental sensors include, but are not limited to, inertial sensors, lasers, antennae for reading RFID tags, buried wires, WiFi signals, or radio signals, global positioning system (GPS) sensors, global navigation satellite system (GNSS) sensors, or combinations thereof.

In embodiments, a warehouse map is stored in a memory that is communicatively coupled to the vehicular controller(s). The vehicular controller(s) of the materials handling vehicle300may execute vehicle functions to use the navigation subsystem360to determine a localized position of the materials handling vehicle300with respect to the inventory transit surface110of a warehouse based on a position of the materials handling vehicle300in the warehouse in comparison with the warehouse map. The vehicular controller(s) of the materials handling vehicle300may further execute vehicle functions to use the navigation subsystem360to track navigation of the materials handling vehicle300along the inventory transit surface110based on the localized position, navigate the materials handling vehicle300along the inventory transit surface110in at least a partially automated manner, or both.

The navigation subsystem360may be operatively coupled to at least one of the traction control unit372, the braking system371, the steering assembly373, the mast assembly control unit374, the carriage control unit375, and the picking attachment320to facilitate cart engagement. Further, the navigation subsystem360may be coupled to these components directly, or indirectly, through the vehicular controller(s).

As stated previously, the materials handling vehicle comprises a picking attachment. Referring further toFIG. 5, the picking attachment320may comprise an X-Y-Z-Ψ positioner322and the vehicular controller(s) of the materials handling vehicle300may execute vehicle functions to use the X-Y-Z-Ψ positioner322of the picking attachment320to engage and disengage a target tote214positioned in the multilevel warehouse racking system200with the picking attachment320.

As illustrated inFIG. 6, the X-Y-Z-Ψ positioner322may comprise an X-positioner323configured to move the picking attachment320in a first degree of freedom along a first lateral axis324in a lateral plane, a Y-positioner325configured to move the picking attachment320in a second degree of freedom along a second lateral axis326perpendicular to the first lateral axis324in the lateral plane, a Z-positioner327configured to move the picking attachment320in a third degree of freedom along a Z-axis328perpendicular to the first lateral axis324and the second lateral axis326, and a rotational Ψ-positioner329configured to rotate the picking attachment320in a fourth degree of freedom about the Z-axis328. The X-positioner323may comprise rails330configured to permit movement of the picking attachment320along the first lateral axis324. The Y-positioner325may comprise rails331configured to permit movement of the picking attachment320along the second lateral axis326. The Z-positioner327may comprise a vertical displacement mechanism configured to slidably engage with a post332of the fork carriage assembly310for vertical displacement with respect to the fork carriage assembly310. The rotational Ψ-positioner329may comprise a shaft333configured to permit rotation of the picking attachment320about the Z-axis328. Such “rails” may include mechanical engagement components such as one or more tracks fixed on an upright support, each including an engagement mechanism configured to engage with a corresponding engagement mechanism of a respective positioner for a sliding engagement. For example, an engagement mechanism of a rail may be one of a notch or a protrusion configured to slidably engage with the notch, and the corresponding engagement mechanism may be the other of the notch or the protrusion. As a non-limiting example, the tracks may be bars made of metal such as stainless steel or a suitable material understood to be within the scope of this disclosure.

The materials handling vehicle300may further comprise a picking attachment subsystem321, which is illustrated schematically inFIG. 12, in communication with the vehicular controller(s) of the materials handling vehicle300. As is illustrated inFIG. 6, the picking attachment subsystem321comprises the picking attachment320(including the X-Y-Z-Ψ positioner322) and a time-of-flight (TOF) system356. The picking attachment subsystem321is configured to use the TOF system356to generate a target TOF depth map of a target tote214(shown inFIG. 6). In embodiments, the target tote214may be positioned in a shelf unit217of a rack bay218of the rack module211(as shown inFIG. 7). Additionally or alternatively, the target tote214may be positioned in the tote transfer zone219(as shown inFIGS. 1I, 1G, and 1H). In embodiments, the target tote214may be positioned on the transporter (not shown). Referring toFIGS. 6-8, the vehicular controller(s) of the materials handling vehicle300may execute vehicle functions to use the X-Y-Z-Ψ positioner322of the picking attachment subsystem321to engage the target tote214with the picking attachment320based on the target TOF depth map. For example, the picking attachment320engages the target tote214or a target pallet with the aid of a TOF depth map, which is particularly useful for rotational (Ψ) positioning about the Z axis. Rotational adjustments may compensate for target tote214rotation or rotational error in the materials handling vehicle300. The navigation subsystem360may be configured to position the materials handling vehicle300such that the target tote214is within a tote engagement field of view351of the TOF system356.

Referring toFIGS. 1I, 6-8, and 12, the vision system354may also be part of the navigation subsystem360, and the multilevel warehouse racking system may comprise a target fiducial216associated with the target tote214. The navigation subsystem360may be configured to position the materials handling vehicle300such that the target fiducial216is within a field of view of the vision system354to visualize the target fiducial216for identification purposes. The navigation subsystem360may further be configured to utilize the target fiducial216to position the materials handling vehicle300such that the target tote214is within the tote engagement field of view351of the TOF system356. In embodiments, the vision system354may be configured to read the target fiducial216to identify the target tote214and verify that the correct target tote214is within the field of view of the vision system354. For example, it is contemplated that suitable target fiducials216may include markings or tags on the multilevel warehouse racking system200, or distinctive elements of the multilevel warehouse racking system200itself. The target fiducial216may be a barcode or any other two-dimensional visual machine-readable data representation. An example is depicted inFIG. 7with respect to a target fiducial216disposed on a rack module211such as a shelf unit217. Rack modules within the scope of this disclosure may have different numbers of slots to position items such as totes within, and a fiducial such as the target fiducial216attached to each rack module211may be configured to identify the number of slots per respective module. Once a position of the target fiducial216is recorded as an X-Y-Z position on the warehouse map, a position of the totes (including, for example, the target tote214) within the shelf unit217will be known as well. An entire rack module including or empty of one or more totes may be picked as described herein from a storage location such as the shelf unit217or a target tote214may be individually picked as described herein. A target tote214to be picked may not include a target fiducial216but may be stored in a storage location such as a shelf unit217that includes the target fiducial216to guide the materials handling vehicle300to the localized position of the shelf unit217to engage the target tote214as described herein. Alternatively, both the rack module211, such as the shelf unit217, and the target tote214may include target fiducials216to guide engagement of the target tote214with the picking attachment320as described herein.

With reference toFIGS. 7, 8, 9 and 12, a picking scheme as described herein may include travel to a tote location215of a target tote214within a rack module211to engage the target tote214. In other embodiments, the target tote214may be positioned in the tote transfer zone or positioned on the transporter as previously described. Another picking scheme may include travel to a rack module211within a rack bay218of the multilevel warehouse racking system200and visualization of a target fiducial216of the rack module211to pick, based on, for example, known coordinates of the target fiducial216, the entire rack module211or a target tote214from within the rack module211. Further, a picking scheme may include dual target fiducial visualization and include travel to a rack module211within a rack bay218of the multilevel warehouse racking system200, visualization of a target fiducial216of the rack module211, movement to a location of a target tote214within the visualized rack module211based on information received from visualization of that rack module211, visualization of the target tote214within the rack module211, and engagement of the target tote214by the picking attachment320as described herein. Thus, the navigation subsystem360may be configured to position the materials handling vehicle300such that the target fiducial216of a shelf unit217of the rack module211is within a field of view of the vision system354. The navigation subsystem360may additionally be configured to utilize the target fiducial216to position the materials handling vehicle300such that the shelf unit217is within a rack module field of view of the TOF system356. The navigation subsystem360may further be configured to utilize a target fiducial216of the target tote214within the rack module211field of view to position the materials handling vehicle300such that the target tote214is within the tote engagement field of view351of the TOF system356.

As illustrated inFIGS. 7 and 8, the target tote214may be stored within a rack module211such as on a shelf unit217of the multilevel warehouse racking system200. InFIG. 7, the picking attachment320of the materials handling vehicle300ofFIG. 5is in a position in which a slide-out334of the picking attachment320is in an extended position to either retrieve the target tote214from or store the target tote214on the shelf unit217. InFIG. 8, the materials handling vehicle300ofFIG. 5is in a position in which the slide-out334has positioned the target tote214in the picking attachment320in a secured position. InFIG. 9, the materials handling vehicle300ofFIG. 5is in a position in which the picking attachment320is in rotational alignment, through a rotation as described in greater detail below, with a shelf of the engaged mobile storage cart400, and the slide-out334is in an extended position to either retrieve the target tote214from or store the target tote214on the shelf of the engaged mobile storage cart400.

Referring toFIG. 1I, the picking scheme as described in reference to a target tote214positioned within the shelf unit217as shown inFIGS. 7, 8, 9 and 12may be similarly applied to a target tote214positioned in the tote transfer zone219or positioned on the lifting surface of the transporter500. In such embodiments, the picking attachment320may (i) transfer the target tote214between multiple levels of the multilevel warehouse racking system200and the transporter500, (ii) transfer the target tote214between multiple levels of the multilevel warehouse racking system200and the tote transfer zone219, (iii) transfer the target tote214between the tote transfer zone219and the transporter500, and (iv) transfer the target tote214between the transporter500and the mobile storage cart400when the mobile storage cart400is engaged by the materials handling vehicle300.

Referring now toFIGS. 5, 12, and 13, in embodiments, a hand-held drive unit370is secured to the vehicle body301and comprises a user interface388and an operational command generator389that is responsive to the user interface388. In alternative embodiments, the hand-held drive unit370may be remote from and not secured to the vehicle body301.

The operational command generator389may comprise any suitable combination of conventional, or yet-to-be developed, circuitry and software that enables the hand-held drive unit370to send operational commands generated in response to user input at the user interface388to the vehicular controller(s) to control operational functions of the traction control unit372, the braking system371, the steering assembly373, the mast assembly302through the mast assembly control unit374, the picking attachment320, or combinations thereof. The hand-held drive unit370may be secured to the vehicle body301so as to be accessible for removal from the vehicle body301from the power unit side304of the vehicle body301by an operator sharing (such as positioned on) the inventory transit surface with the wheels306supporting the vehicle body301.

The vehicle body301may also comprise a pair of lateral sides305extending between the fork side303and power unit side304of the vehicle body301, with the lateral sides305defining a vehicle width w1. In narrow aisle environments, where when the materials handling vehicle300is positioned in a warehouse aisle characterized by an aisle width w2, where w2−w1<W inches where W is in a range of from about 2 inches to about 4 inches (and w2>w1), the hand-held drive unit370is secured to the vehicle body301so as to be accessible for removal by the operator sharing the inventory transit surface110with the materials handling vehicle300. The equation above is an example equation for a maximum gap value, and values set forth are not contemplated to a limitation. As a non-limiting example, the hand-held drive unit370may be secured to a surface of the power unit side304of the vehicle body301and may be configured to permit an operator to fully control the materials handling vehicle300positioned in a first aisle without a need for the operator to travel down an empty, adjoining aisle next to the first aisle to get to the operator compartment307on the fork side303of the materials handling vehicle300. In other words, a retrofitted materials handling vehicle300may require manual intervention on the part of an operator and, if the operator is located in the first aisle on the power unit side304opposite from the operator compartment307and unable to fit between the vehicle body301and the first aisle, the hand-held drive unit370provides a way for the operator to manually intervene without the need to get to the operator compartment307. It is contemplated that all of the functionality of the hand-held drive unit370described herein is duplicated with user controls in the operator compartment307such that the operator may control the materials handling vehicle300as if the operator were within the operator compartment307without actually being in the operator compartment307.

As previously referenced, the vehicular controller(s) may comprise a picking controller376, a braking controller377, a traction controller378, a steering controller379, a mast controller380, or one or more integrated controllers, to control operational functions of the picking attachment320, the braking system371, traction control unit372, the steering assembly373, or the mast assembly control unit374. Where the vehicular controller(s) comprises a traction controller378configured to control operational functions of the traction control unit372, the user interface388of the hand-held drive unit370may comprise traction control operators384. The traction controller378may be responsive to operational commands generated with the traction control operators384of the hand-held drive unit370. For example, it is contemplated that the traction control operators384, and other types of control operators described herein, can be implemented in a variety of ways, such as via virtual buttons provided on a touch screen display390, physical inputs391located on the hand-held drive unit370(such as buttons, joysticks, etc.), any of which may be dedicated or customizable. It is contemplated, for example, that the physical inputs391may be customized using configurable menu options, scrolling interfaces, or other on-screen options provided at the touch screen display390. It is also contemplated that the body of the hand-held drive unit370could be used as a control operator if the unit were to be provided with one or more motion sensors, such as a gyroscope, accelerometer, etc., to detect movement and/or rotation of the hand-held drive unit370. In further contemplated embodiments, gesture tracking, gaze tracking, voice control, and other types of indirect control operators may be used.

The vehicular controller(s) may also comprise a braking controller377configured to control operational functions of the braking system371. The user interface388of the hand-held drive unit370may comprise braking control operators383. The braking controller377may be responsive to operational commands generated with the braking control operators383of the hand-held drive unit370.

Similarly, the vehicular controller(s) may comprise a steering controller379configured to control operational functions of the steering assembly373. In which case, the user interface388of the hand-held drive unit370would comprise steering control operators385, and the steering controller379would be responsive to operational commands generated with the steering control operators385.

The vehicular controller(s) may also comprise a mast controller380configured to control operational functions of the mast assembly control unit374that is configured to control the mast assembly302. In which case, the user interface388of the hand-held drive unit370would comprise mast assembly control operators386, and the mast controller380would be responsive to operational commands generated with the mast assembly control operators386.

The vehicular controller(s) may additionally comprise a picking controller376configured to control operational functions of the picking attachment320. In which case, the user interface388of the hand-held drive unit370would comprise picking attachment control operators382, and the picking controller376would be responsive to operational commands generated with the picking attachment control operators382.

The vehicular controller(s) may additionally comprise a carriage controller381configured to control operational functions of the carriage control unit375, which is configured to control the fork carriage assembly310. In which case, the user interface388of the hand-held drive unit370would comprise carriage control operators387, and the carriage controller381would be responsive to operational commands generated with the carriage control operators387.

The materials handling vehicle300may further comprise a camera308coupled to the fork carriage assembly310, with the camera308being configured to send image data representing objects within a field of view of the camera308to the hand-held drive unit370. The hand-held drive unit370may comprise a touch screen display390or other type of display for displaying image data representing objects within the field of view of the camera308. In this manner, a ground-based operator can use the image data as an aide to using the hand-held drive unit370to control various functions of the materials handling vehicle300. This is particularly advantageous where the field of view of the camera308extends beyond the field of view of an operator sharing an inventory transit surface110with the materials handling vehicle300. In some embodiments, the hand-held drive unit370may be configured to allow an operator to view images of the picking attachment320and send operational commands to the picking controller376through picking attachment control operators382of the hand-held drive unit370to control operational functions of the picking attachment320.

It is also contemplated that the hand-held drive unit370may be configured to control the field of view of the camera308. For example, the field of view of the camera308may be controlled by changing the position or orientation of the camera308, by controlling the zoom of the camera optics, by controlling an aiming direction of the camera optics, or combinations thereof. In various embodiments, the hand-held drive unit370is configured to control focusing optics of the camera308. In other embodiments, the camera308may be coupled to the fork carriage assembly310by a camera positioner309, and the hand-held drive unit370may be configured to control the operational functions of the camera positioner309.

It is also contemplated that the camera308may be coupled to the fork carriage assembly310either internally or externally. An internally-coupled camera could reside at least partially within the fork carriage assembly310, such as with a pinhole camera. An externally-coupled camera may be attached to the fork carriage assembly310by any suitable means, such as with coupling mechanisms (screws, bolts, etc.), attachment mechanisms (camera base-mounts, brackets, etc.), adhesives, or combinations thereof.

In many cases, it will be advantageous to ensure that the hand-held drive unit370is secured to a surface of the vehicle body301that is not located within a path of vertical movement of the fork carriage assembly310. In this manner, by ensuring that the hand-held drive unit370is accessible from the power unit side304, and not the fork side303of the materials handling vehicle300, the operator will not be required to walk under the fork carriage assembly310to access the hand-held drive unit370. In some embodiments, it may be sufficient to merely ensure that the hand-held drive unit370is secured to a surface of the vehicle body301that is not located at the fork side303of the vehicle body301. In other embodiments, it may be advantageous to ensure that the hand-held drive unit370is held within a drive unit case392, and the drive unit case392is secured to the vehicle body301. For example, referring toFIG. 5, the materials handling vehicle300includes the drive unit case392housing the hand-held drive unit370at the power unit side304of the materials handling vehicle300.

It is contemplated that the hand-held drive unit370described above may be secured to the materials handling vehicle300, or may be present at a location remote from the materials handling vehicle300. Further, the functionality of the hand-held drive unit370may be presented more broadly in the form of a remote controller that is communicatively coupled to the materials handling vehicle300through, for example, a wireless communication link. The remote controller may or may not be a hand-held and may or may not be secured to the materials handling vehicle300. The remote controller may comprise a video link to display image data from the camera308. Contemplated remote controllers may, for example, be presented as a desktop computer, a laptop computer, a smartphone, a tablet, a wearable computing device, or some combination thereof. It is also contemplated that the remote controller, whether hand-held or not, may be utilized in a dual mode operation where user control is facilitated from two separate remote controllers. For example, and not by way of limitation, in one type of dual mode operation, a user is able to control vehicular operations through a remote controller at a remote location, such as through a laptop computer, while also permitting the same or another user to sign in through a secured webpage or a software application loaded on a smartphone, or other hand-held device, to control such vehicular operations. Regardless of the mode of operation, it is contemplated that the remote controller may be utilized by an operator at a location that is remote from the materials handling vehicle300, or by an operator sharing the inventory transit surface110with the materials handling vehicle300.

InFIG. 1I, the goods receiving station610comprises a goods selection terminal620that is outfitted for removal of totes from the mobile storage carts400or from the transporters500. In an alternative embodiment, the goods-to-man warehousing system600further comprises an intermediate transfer station630that is positioned along a mobile storage cart travel path extending from the mobile storage cart transfer node420to the goods receiving station610. The mobile storage carts400may be positioned at the intermediate transfer station630and may be transferred from the goods receiving station610at the intermediate transfer station630to the goods selection terminal620by the transporter500.

Referring now toFIGS. 1A and 1B, the goods selection terminal comprises an operator platform622above an inventory transit surface110of the goods storage and retrieval system100. The operator platform622comprises a goods access portal624that is accessible by an operator625from above the operator platform622and by the transporter500from below the operator platform622. As shown inFIG. 1A, the transporter500may be configured to elevate the transporter lifting surface to a height of the operator platform622. In embodiments, the height of the operator platform622may be approximately equal to the transporting height of the transporter500. When the transporter lifting surface is elevated to the height of the operator platform622, the target tote214may be accessed by the operator625. In an alternative embodiment, shown inFIG. 1B, the goods selection terminal620comprises a transporter raising surface626that is flush with the inventory transit surface110, aligned with the goods access portal624, and configured to elevate the transporter500from the inventory transit surface110of the goods storage and retrieval system100to the operator platform622. When the transporter500is elevated to the operator platform622, the target tote214may be accessed by the operator625.

Referring again toFIG. 1I, the warehouse management computing hub is in communication with the transporter500and the materials handling vehicle300, and is be programmed to instruct the transporter500and the materials handling vehicle300to coordinate engagement, transport, and disengagement of the mobile storage carts400and the target tote in the goods-to-man warehousing system600. The warehouse management computing hub may be configured to manage locations of the plurality of mobile storage carts400, the transporters500, the materials handling vehicles300, the mobile storage cart transfer nodes420, and the goods receiving stations610. More specifically, the aforementioned coordinated movement may apply to the transfer of the mobile storage carts400between the aisles220of the multilevel warehouse racking system200, the materials handling vehicle300, the mobile storage cart transfer node420, the transporter500, the goods receiving station610, or various combinations thereof. In addition, it is contemplated that these instructions may be presented in a variety of forms. For example, and not by way of limitation, these instructions may represent detailed turn-by-turn movements for the transporter500and materials handling vehicle300to accomplish the aforementioned coordination. Or, the instructions may merely represent a set of position and time coordinates necessary to accomplish the aforementioned coordination. In which case, the transporter500and materials handling vehicle300would be responsible for developing their own turn-by-turn travel paths to accomplish the aforementioned coordination. In any case, it is contemplated that those practicing the concepts of the present disclosure may rely on conventional or yet-to-be developed teachings related to warehouse traffic management and automated vehicle guidance to achieve the aforementioned coordination.

Referring toFIG. 14, a block diagram illustrates a computing device700, through which embodiments of the disclosure can be implemented. The computing device700described herein is but one example of a suitable computing device and does not suggest any limitation on the scope of any embodiments presented. For example, the computing device700in some embodiments is an example of the remote controller such as the hand-held drive unit described herein and/or other suitable mobile client devices that may be communicatively coupled to the hand-held drive unit. The computing device700may be communicatively coupled to one or more computing devices through a warehouse management system. Nothing illustrated or described with respect to the computing device700should be interpreted as being required or as creating any type of dependency with respect to any element or plurality of elements. In various embodiments, a computing device700may include, but need not be limited to, a desktop, laptop, server, client, tablet, smartphone, or any other type of device that can compress data. In an embodiment, the computing device700includes at least one processor702and memory (non-volatile memory708and/or volatile memory710). In embodiments, the one or more target TOF depth maps353and/or one or more warehouse maps362described herein may be stored in the memory. The computing device700can include one or more displays (such as the touch screen display of the hand-hand drive unit) and/or output devices704such as monitors, speakers, headphones, projectors, wearable-displays, holographic displays, and/or printers, for example. Output devices704may be configured to output audio, visual, and/or tactile signals and may further include, for example, audio speakers, devices that emit energy (radio, microwave, infrared, visible light, ultraviolet, x-ray and gamma ray), electronic output devices (Wi-Fi, radar, laser, etc.), audio (of any frequency), etc.

The computing device700may further include one or more input devices706which can include, by way of example, any type of mouse, keyboard, disk/media drive, memory stick/thumb-drive, memory card, pen, touch-input device, biometric scanner, voice/auditory input device, motion-detector, camera, scale, and the like. Input devices706may further include sensors, such as biometric (voice, facial-recognition, iris or other types of eye recognition, hand geometry, fingerprint, DNA, or any other suitable type of biometric data, etc.), video/still images, motion data (accelerometer, GPS, magnetometer, gyroscope, etc.) and audio (including ultrasonic sound waves). Input devices706may further include cameras (with or without audio recording), such as digital and/or analog cameras, still cameras, video cameras, thermal imaging cameras, infrared cameras, cameras with a charge-couple display, night-vision cameras, three-dimensional cameras, webcams, audio recorders, and the like. For example, an input device706may include the camera308described herein.

The computing device700typically includes non-volatile memory708(ROM, flash memory, etc.), volatile memory710(RAM, etc.), or a combination thereof. A network interface hardware712can facilitate communications over a network714via wires, via a wide area network, via a local area network, via a personal area network, via a cellular network, via a satellite network, etc. Suitable local area networks may include wired Ethernet and/or wireless technologies such as, for example, wireless fidelity (Wi-Fi). Suitable personal area networks may include wireless technologies such as, for example, IrDA, Bluetooth, Wireless USB, Z-Wave, ZigBee, and/or other near field communication protocols. Suitable personal area networks may similarly include wired computer buses such as, for example, USB and FireWire. Suitable cellular networks include, but are not limited to, technologies such as LTE, WiMAX, UMTS, CDMA, and GSM. Network interface hardware712can be communicatively coupled to any device capable of transmitting and/or receiving data via the network714. Accordingly, the network interface hardware712can include a communication transceiver for sending and/or receiving any wired or wireless communication. For example, the network interface hardware712may include an antenna, a modem, LAN port, Wi-Fi card, WiMax card, mobile communications hardware, near-field communication hardware, satellite communication hardware and/or any wired or wireless hardware for communicating with other networks and/or devices.

A computer-readable medium716may comprise a plurality of computer readable mediums, each of which may be either a computer readable storage medium or a computer readable signal medium. The computer-readable medium716may be non-transitory in that it excludes any transitory, propagating signal as a storage medium and may reside, for example, within an input device706, non-volatile memory708, volatile memory710, or any combination thereof. A computer readable storage medium can include tangible media that is able to store instructions associated with, or used by, a device or system. A computer readable storage medium includes, by way of example: RAM, ROM, cache, fiber optics, EPROM/Flash memory, CD/DVD/BD-ROM, hard disk drives, solid-state storage, optical or magnetic storage devices, diskettes, electrical connections having a wire, or any combination thereof. A computer readable storage medium may also include, for example, a system or device that is of a magnetic, optical, semiconductor, or electronic type. Computer readable storage media and computer readable signal media are mutually exclusive.

A computer readable signal medium can include any type of computer readable medium that is not a computer readable storage medium and may include, for example, propagated signals taking any number of forms such as optical, electromagnetic, or a combination thereof. A computer readable signal medium may include propagated data signals containing computer readable code, for example, within a carrier wave. Computer readable storage media and computer readable signal media are mutually exclusive.

The computing device700may include one or more network interface hardwares712to facilitate communication with one or more remote devices, which may include, for example, client and/or server devices. A network interface hardware712may also be described as a communications module, as these terms may be used interchangeably. For clarity, it is noted that usage of the term “in communication with” herein, with respect to theFIG. 14, or elsewhere, may refer to one-way communication or two-way communication.

A method800of operating the goods storage and retrieval system100according to one embodiment of the present disclosure is illustrated inFIG. 15and may be read in light of the goods storage and retrieval system100components ofFIGS. 1 and 12. As illustrated inFIG. 15, the method800includes a step802to start cart acquisition followed by a step804to receive information regarding a localized engagement position of the cart home position410. The method800further includes in step806, and through use of the navigation subsystem360and the vehicular controller(s), navigating the materials handling vehicle300along the inventory transit surface110to a localized engagement position and receiving information from the storage cart engagement field of view in step808. If in step810the cart home position410is not within the storage cart engagement field of view352, the method800returns to step806. Otherwise, if in step810the cart home position410is within the storage cart engagement field of view352, the method800continues on to step810and uses the cart engagement subsystem350to engage the mobile storage cart400by engaging the mobile storage cart400in the cart home position410with the fork carriage assembly310.

In embodiments, a method820of operating the goods storage and retrieval system100may include, as illustrated inFIG. 16, a step822to start tote engagement followed by a step824to receive information regarding a target tote position of a target tote214. The method820further includes, in step826, and through use of at least one of the navigation subsystem360, the picking attachment subsystem321, and the vehicular controller(s), navigating the materials handling vehicle300toward the target tote position and aligning the picking attachment320with the target tote214. In step828, information is received from the tote engagement field of view351. If in step830the target tote position is not within the tote engagement field of view351, the method820returns to step826. Otherwise, if in step830the target tote position is within the tote engagement field of view351, the method820continues on where the navigation subsystem360positions the materials handling vehicle300such that the target fiducial216is within a field of view of the vision system354to visualize the target fiducial216for identification purposes, where the vision system360may read the target fiducial216to identify the target tote214and/or verify that the correct target tote214is within the field of view of the vision system354. The method820then continues on to step832to generate a target tote depth map and, in step834, to use the picking attachment subsystem321to engage the target tote214based on the target tote depth map.

With either or a combination of the methods800or820, a velocity number may be assigned to a stock keeping unit (SKU) associated with a target tote214in the multilevel warehouse racking system200based on an order velocity indicative of a frequency of usage parameter associated with the target tote214. A relatively high velocity number may be associated with a low storage position on a low shelf of the multilevel warehouse racking system200, and a relatively low velocity number may be associated with a high storage position on a high shelf of the multilevel warehouse racking system200. For example, a lowest velocity number may be associated with a highest shelf, and a highest velocity number may be associated with a lowest shelf.

Further, the picking attachment320and the fork carriage assembly310may be used to move the target tote214from a portion of the multilevel warehouse racking system200associated with a relatively low velocity number to a portion of the multilevel warehouse racking system200associated with a relatively high velocity number based on an increase in the order velocity with respect to the target tote214. Further, the picking attachment320and the fork carriage assembly310may be used to move the target tote214from a portion of the multilevel warehouse racking system200associated with a relatively high velocity number to a portion of the multilevel warehouse racking system200associated with a relatively low velocity number based on a decrease in the order velocity with respect to the target tote214.

In embodiments, a first target tote may be engaged at a first storage position on a high shelf associated with a relatively low velocity number with the picking attachment320. The first target tote may be placed with the picking attachment320in the mobile storage cart400engaged by the fork carriage assembly310. Further, the materials handling vehicle300may be navigated to a second target tote when the second target tote is assigned a relatively high velocity number and is within a close distance to the first storage position. The second target tote may be engaged with the picking attachment320, which may lower the second target tote to a low shelf associated with the relatively high velocity number or place the second target tote in the mobile storage cart400. For example, the materials handling vehicle300may be navigated to a subsequent pick location when the second target tote is placed in the mobile storage cart400, and the second target tote may be placed on the low shelf associated with the relatively high velocity number while at the subsequent pick location.

In other embodiments, a first target tote may be engaged at a storage first position on a low shelf associated with the high velocity number with the picking attachment320, and the picking attachment320may place the first target tote in the mobile storage cart400engaged by the fork carriage assembly310. Further, the materials handling vehicle300may be navigated to a second target tote when the second target tote is assigned a relatively low velocity number and is within a close distance to the first position on the low shelf to engage the second target tote with the picking attachment320and either raise the second target tote to a high shelf associated with the relatively low velocity number or place the second target tote in the mobile storage cart400. For example, the materials handling vehicle300may be navigated to a subsequent pick location when the second target tote is placed in the mobile storage cart400, and the picking attachment320places the second target tote on the high shelf associated with the relatively low velocity number while at the subsequent pick location.

In embodiments, positioning the materials handling vehicle300may be positioned in a first aisle of the multilevel warehouse racking system200, and one or more target totes214may be placed with the picking attachment320in the mobile storage cart400engaged by the fork carriage assembly310. Further, the mobile storage cart400may be used as a temporary storage location to level inventory when one or more inventory orders are received such that the one or more target totes214are shuffled between the mobile storage cart400and a plurality of shelves240of the multilevel warehouse racking system200based on a respective order velocity indicative of a frequency of usage parameter associated with each target tote214to optimize a usage parameter with respect to the first aisle. Advantages from such inventory leveling may include fewer trips by the materials handling vehicle300back and forth through an aisle220and more picks and puts per distance traveled by the picking attachment320of the materials handling vehicle300to lower a cost per pick. It is contemplated that such an inventory leveling system may work in conjunction with a warehouse management system to control product flow and optimize pick and replenishment and to organize products based on an average or known velocity based on product demand.

With such an inventory leveling system, a relatively low velocity number associated with a high shelf of the multilevel warehouse racking system200may be assigned to a SKU associated with a first target tote that is stored in the mobile storage cart400, and a relatively high velocity number associated with a low shelf of the multilevel warehouse racking system200may be assigned to a SKU associated with a second target tote stored on a high shelf of the multilevel warehouse racking system200. Information may be received indicative of the second target tote being stored on the high shelf. The materials handling vehicle300may be navigated to a location of the multilevel warehouse racking system200associated with the high shelf during an off-peak picking time or an off shift time, and the mobile storage cart400engaged by the fork carriage assembly310may be moved to the high shelf. Once in position, the picking attachment320may exchange the first target tote stored in the mobile storage cart400with the second target tote stored on the high shelf to store the second target tote in the mobile storage cart400. Such an exchange is to level inventory and reduce the amount of fork carriage assembly310raising and lowering needed to retrieve target totes214. This would be particularly significant during, for example, peak periods or high volume shifts because it would reduce the time needed to fulfill an inventory order and the energy expended by the materials handling vehicle300.

In embodiments, one or more target totes214may be placed with the picking attachment320in the mobile storage cart400engaged by the fork carriage assembly310such that the mobile storage cart400is utilized as a temporary storage location. The picking attachment320pick and place operations may be interleaved by picking up and placing away multiple target totes214during a single trip of the materials handling vehicle300down an aisle220of the multilevel warehouse racking system200.

The first aisle may comprise a very narrow aisle (VNA). Further, use of the mobile storage cart400as a temporary storage location allows for multiple picks to be made in the aisle220or while the fork carriage assembly310is raised to a high storage location to minimize energy used to raise and lower the fork carriage assembly310. The mobile storage cart400may also be used to fill multiple inventory order in a batch and deliver the entire batch to a location or to a transfer node420for delivery to another location.

A first target tote213may be stored on a shelf of a plurality of shelves240in the first aisle of the multilevel warehouse racking system200, and a second target tote213may be stored in the mobile storage cart400. The first target tote213on the shelf in a shelf location may be engaged by the picking attachment320to pick up the first target tote213with the picking attachment320, which may remove the first target tote213from the shelf location and place the first target tote213on a container bay430of the mobile storage cart400. The picking attachment320may engage the second target tote213stored in the mobile storage cart400, remove the second target tote213from the mobile storage cart400, and place the second target tote213in the shelf location to place away the second target tote213.

In another embodiment, it is contemplated that the materials handling vehicle300may transfer mobile storage carts400to the transporter500. In this embodiment, the location of the storage cart transfer node420would correspond to the location of the transporter500.

A transporter500may travel outside of an aisle220, such as along the floor beneath a row of mobile storage carts400, which can help keep the aisle220clear as well as reduce the travel time of the transporter500and/or materials handling vehicle300.

The materials handling vehicle300lowers the mobile storage cart400onto the mobile storage cart transfer node420. The transporter500gets closer to the materials handling vehicle300and rotates toward the mobile storage cart transfer node420.

The transporter500arrives at the mobile storage cart transfer node420under the mobile storage cart400and carries the mobile storage cart400away in a suitable direction. Examples of transporters500are shown and described in more detail, for example, in U.S. Patent Application Publication US 2008/0166217 A1.

A warehouse management computing hub and the materials handling vehicle300may be collectively configured to execute a place operation comprising selection of a mobile storage cart transfer node420that is accessible by a transporter500and the materials handling vehicle300, and retrieval of a target mobile storage cart400from the mobile storage cart transfer node420by engaging the target mobile storage cart400with a lifting mechanism of the materials handling vehicle300.

A materials handling vehicle300arrives at a mobile storage cart transfer node420. Multiple transporters500, each carrying a mobile storage cart400, approach the materials handling vehicle300, with the first transporter500assigned to the mobile storage cart transfer node420.

The first transporter500carries the mobile storage cart400to the assigned mobile storage cart transfer node420in front of the materials handling vehicle300.

The materials handling vehicle300moves down the aisle220away from the mobile storage cart transfer node420. The first transporter500travels under the first level of the lower level of rack bays218of the multilevel warehouse racking system200in a suitable direction. More transporters500, each carrying a mobile storage cart400, move in the aisle220in a suitable direction. In some embodiments, transporters500follow the materials handling vehicle300like a train moving down the aisle220.

Referring again toFIG. 1I, this application further includes methods of operating a goods storage and retrieval system100. The method includes providing the goods storage and retrieval system100and navigating the materials handling vehicle300along the inventory transit surface110to the target tote through the use of the navigation subsystem360and the one or more vehicular controllers independent of movement of the transporter500within the goods storage and retrieval system100. The method includes engaging or disengaging the target tote with the picking attachment secured to the fork carriage assembly310through use of the X-Y-Z-Ψ positioner at the tote transfer zone219and at multiple levels of the multilevel warehouse racking system200independent of movement of the transporter500within the goods storage and retrieval system100.

Referring toFIGS. 1I, 1E, and 1F, the method further includes placing, with the picking attachment, the target tote on the tote transfer zone219or on a level of the multilevel warehouse racking system200and engaging the target tote214with the transporter500through use of the transporter-based engagement hardware540comprising a transporter lifting surface520. Engaging the target tote214with the transporter500may further include lifting the target tote214relative to a tote supporting surface219A of the tote transfer zone219with the transporter lifting surface520.

Referring again toFIG. 1I, in some embodiments, the method further includes transmitting, via the warehouse management computing hub, instructions to the materials handling vehicle300and the transporter500. The method may further comprise transporting the target tote with the transporter500to a goods receiving station610comprising a goods selection terminal620and removing the target tote from the transporter lifting surface. Removing the target tote may include elevating a transporter raising surface from an access height flush with the inventory transit surface to a selection height.

The method may further include providing a mobile storage cart400and engaging the mobile storage cart400with the fork carriage assembly310through the use of a cart engagement subsystem of the materials handling vehicle300. The method then includes placing, with the picking attachment, the target tote in the mobile storage cart400engaged by the fork carriage assembly310. In some embodiments, the method then further includes disengaging the mobile storage cart400with the fork carriage assembly310through the use of a cart engagement system of the materials handling vehicle300and engaging the mobile storage cart400with the transporter lifting surface. The method then includes transporting the mobile storage cart400with the transporter500to a goods receiving station610comprising a goods selection terminal620and removing the target tote from the mobile storage cart400.

Referring toFIGS. 11-12, this application is further directed to a materials handling vehicle900comprising a vehicle body301, a plurality of wheels306supporting the vehicle body301and defining a direction of travel902for the vehicle body301, a braking system371, a traction control unit372, and a steering assembly373, each operatively coupled to one or more of the plurality of wheels306, a mast assembly302, a monofork carriage assembly910coupled to the mast assembly302for movement along a lifting dimension of the mast assembly302, and a transport, engagement, or disengagement accessory configured to facilitate transport, engagement, or disengagement of materials by the materials handling vehicle900. The transport, engagement, or disengagement accessories may be any of the accessories previously described, such as, but not limited to, a picking attachment320, a picking attachment subsystem321, cart engagement subsystem350, a navigation subsystem360, a scanning laser, a vision system, a 3D Time of Flight (TOF) system, an obstacle-detecting sensor, or other automated storage and retrieval system hardware. Lastly, the monofork carriage assembly comprises a hollow body portion912accommodating at least a portion of the transport, engagement, or disengagement accessory therein. In embodiments, the hollow body portion912may include the cart engagement sensors355, as shown inFIG. 5B.

The monofork carriage assembly910defines an operator compartment width914that is oriented across the direction of travel902of the vehicle body, and the operator compartment width914may be between about 100 cm and about 125 cm. A “monofork” carriage assembly910can be distinguished from conventional materials handling vehicle lifting forks because the monofork carriage assembly910comprises a unitary materials handling platform916that is oriented across the direction of travel902of the vehicle body301and defines a platform width917parallel to the operator compartment width914. The platform width917may be at least about 75 cm and is less than the operator compartment width914. The unitary materials handling platform916may comprise a leading face918that is oriented across the direction of travel902of the vehicle body301. The leading face918of the platform916forms a protruding arc that extends across the platform width917and protrudes along the direction of travel902of the vehicle body301. Furthermore, the unitary materials handling platform916may comprise at least two opposing pairs of vertically oriented cart stabilizers919. The two opposing pairs of cart stabilizers919are located on opposite sides of the unitary materials handling platform916along the direction of travel902of the vehicle body301, and each cart stabilizer919comprises an inclined contact edge facing an opposing inclined contact edge of a cart stabilizer919on an opposite side of the unitary materials handling platform916. In this manner, the aforementioned cart stabilizers919will operate to automatically align a mobile storage cart or similar object that is slightly askew with respect to the materials handling platform916, as the materials handling platform916and the contact edges of the cart stabilizers919are lifted into contact with the mobile storage cart.

The monofork carriage assembly910may be removably coupled to the mast assembly302. In addition, the unitary materials handling platform916may engage the mobile storage cart through the use of mechanical latches, such as, but not limited to, dowels and corresponding holes. Specifically, the unitary materials handling platform916may comprise dowels that deviate from the parallel plane flush with the unitary materials handling platform916, and the mobile storage cart may comprise holes corresponding to the placement of dowels on the unitary materials handling platform916. These corresponding holes on the mobile storage cart are configured to receive the dowels on the unitary materials handling platform916, thereby securing the mobile storage cart in place on the unitary materials handling platform916.