Patent Publication Number: US-2023150768-A1

Title: Systems and methods for transporting containers

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of U.S. patent application Ser. No. 16/448,578, filed Jun. 21, 2019, which claims priority to U.S. Provisional Patent Application No. 62/692,522 entitled “Container Filling” and filed Jun. 29, 2018, U.S. Provisional Patent Application No. 62/692,544 entitled “Container Quick-Release” and filed Jun. 29, 2018, U.S. Provisional Patent Application No. 62/692,550 entitled “Robotic Container Connection” and filed Jun. 29, 2018, U.S. Provisional Patent Application No. 62/692,606 entitled “Container Transportation” and filed Jun. 29, 2018, which are all hereby incorporated by reference in their entireties. 
    
    
     TECHNICAL FIELD 
     Among other things, the present application relates to automated transportation of containers. 
     BACKGROUND 
     Warehouses can store many different kinds of items in bins (i.e., longer term storage containers). When a customer places a remote order (e.g., an online order), an employee can load the ordered items from the bins into pockets (i.e., shorter term storage containers). The pockets can be moveably suspended from a rail system. Motors in the rail system can slide (e.g., roll) the pockets along tracks from a loading station to a packing station. 
     When a pocket arrives at a packing station, an employee can manually remove the pocket and/or the item stored therein. The employee can place the item in a box (e.g., a shipping container). The process can be repeated until the box contains the customer&#39;s complete order. The employee can mark the packed box for shipment. A customer&#39;s order can include many different items and a warehouse can receive many different simultaneous orders. As a result, the rail system may incorporate thousands of pockets. When pockets are transferred to various locations in the warehouse, an employee may need to manually move the pockets and/or manually remove the pockets from the rail system to another system. Such manual removal can be time-consuming. 
     SUMMARY 
     Among other things, a connection assembly for motion along a rail is disclosed. The connection assembly can include a first plate assembly, a second plate assembly, and a release assembly. The first plate assembly can include a first base, a first bearing mounted to the first base, and a first stop mounted to the first base. The second plate assembly can be disposed proximate the first plate assembly. The second plate assembly can include a second base, a second bearing mounted to the second base, a second stop mounted to the second base, and a post mounted to the second base. 
     The release assembly can include a rod and a spring. The rod can include an outward extension. The spring can be disposed between the extension and the second stop. The release assembly can be configured to occupy: a first state such that the spring pushes the extension against the first stop and thereby biases the first base away from the second base; and a second state such that the spring pushes the extension against the post. 
    
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
       The Figures show some of the illustrative embodiments disclosed herein. As further explained below, the claimed inventions are not limited to the illustrative embodiments and therefore are not limited to the embodiments shown in the Figures. 
       For clarity and ease of reading, some Figures omit views of certain features. The relative dimensions shown in the Figures can be aspects of a few illustrative embodiments. Therefore, relative dimensions shown in the Figures can serve as original support. Other illustrative embodiments lack any dimensional relationship to the Figures. The claimed inventions are not limited to any absolute or relative dimensions shown in the Figures unless explicitly stated otherwise. 
       The present disclosure generally uses the terms “longitudinal”, “transverse”, and “vertical” to give the reader context when viewing the Figures. Referring to the Figures, depth along the X-axis can be “transverse”, depth along the Y-axis can be “longitudinal”, and depth along the Z-axis can be “vertical”. The X, Y, and Z-axes are consistent across the Figures. 
         FIG.  1    is an isometric view of a container connection assembly (“CCA”), in accordance with some embodiments. 
         FIG.  2    is an isometric view of the CCA in  FIG.  1   , in accordance with some embodiments. 
         FIG.  3    is a schematic elevational view of a portion of the CCA in  FIG.  1    in a fully coupled state and moveably disposed in a rail, in accordance with some embodiments. The rail is shown in cross section. The CCA is in a different orientation than shown in  FIG.  1   . 
         FIG.  4    is a view of a vehicle including a plurality of containers and rails, in accordance with some embodiments. Each container can include the CCA in  FIG.  1   . Each CCA can be disposed as shown in  FIG.  3   . 
         FIG.  5    is a schematic front elevational view of first and second retainers of the CCA in  FIG.  1    in an uncoupled state, in accordance with some embodiments.  FIG.  5    can represent a cross section from plane  5 - 5  in  FIG.  8   . 
         FIG.  6    is from the same perspective as  FIG.  5   , but shows the first and second retainers of the CCA in  FIG.  1    in a fully coupled state, in accordance with some embodiments. 
         FIG.  7    is a bottom plan view of the CCA in  FIG.  1   , in accordance with some embodiments. 
         FIG.  8    is a top plan view of the CCA in  FIG.  1   , in accordance with some embodiments. 
         FIG.  9 A  is a schematic top plan view of the CCA in  FIG.  1    with alternate first and second retainers, in accordance with some embodiments. The CCA is in a fully coupled resting position. For clarity, a spring is identified as a box with a first stippling pattern while a rod is identified with a second stippling pattern. 
         FIG.  9 B  is a schematic side elevational view from plane  9 B- 9 B in  FIG.  9 A , in accordance with some embodiments. 
         FIG.  10    is a schematic top plan view of the CCA in  FIG.  9 A , in accordance with some embodiments. The CCA remains fully coupled. The rod has been twisted 90 degrees. 
         FIG.  11    is a schematic top plan view of the CCA in  FIG.  9 A , in accordance with some embodiments. The CCA is in the process of decoupling as spring force overcomes retaining force. 
         FIG.  12    is a schematic top plan view of the CCA in  FIG.  9 A , in accordance with some embodiments. The CCA is decoupled. 
         FIG.  13    is a schematic elevational view of the CCA in  FIG.  9 A , in accordance with some embodiments.  FIG.  13    can be from the same perspective as  FIG.  3   . The CCA has been decoupled to an extent sufficient to remove the CCA from a rail. The CCA can be in the same position shown in  FIG.  12    or further decoupled. 
         FIG.  14    is a schematic top plan view of the CCA in  FIG.  9 A , in accordance with some embodiments. The CCA is in the process of recoupling, but is still decoupled. The rod has been rotated 90 degrees. 
         FIG.  15    is a schematic top plan view of the CCA in  FIG.  9 A , in accordance with some embodiments. The CCA has been recoupled. The rod has been transversely pushed such that cylindrical projections thereof have cleared posts. 
         FIG.  16    is a schematic top plan view of the CCA in  FIG.  9 A , in accordance with some embodiments. The CCA remains recoupled. The rod has been rotated 90 degrees. The rod has been released such that the spring is pushing the rod back into engagement with the posts. 
         FIG.  17    is a schematic top plan view of the CCA in  FIG.  1    showing additional projections for keeping the CCA linked together, even when fully decoupled. 
     
    
    
     DETAILED DESCRIPTION 
     While the features, methods, devices, and systems described herein may be embodied in various forms, there are shown in the drawings, and will hereinafter be described, some illustrative (i.e., example) embodiments. The claimed inventions are not limited to the illustrative embodiments. Therefore, some implementations of the claimed inventions will have different features than those set out in this disclosure. 
     Further, implementations of the claimed inventions can make changes with respect to the claims without departing from the spirit or scope of the application. Therefore, the claimed inventions are intended to embrace their full-range of equivalents. 
     Unless otherwise indicated, any directions reflect the orientations of the components shown in the corresponding drawings and do not limit the scope of the present disclosure. Any absolute term (e.g., large, small) can be replaced with a corresponding relative term (e.g., larger, smaller). 
       FIGS.  1  and  2    are isometric views of a container connection assembly (“CCA”)  100 . CCA  100  can include a first transverse plate assembly  200 , a second transverse plate assembly  300 , and a release assembly  400 . First plate assembly  200  can include one or more first transverse bearing assemblies  202  configured to longitudinally slide (e.g., roll) within a rail  1000  ( FIG.  3   ). Second plate assembly  300  can include one or more second transverse bearing assemblies  302  and one or more vertical bearing assemblies  304  configured to longitudinally slide (e.g., roll) within rail  1000  ( FIG.  3   ). 
       FIG.  3    schematically shows a cross-section of rail  1000 , to which CCA  100  is moveably connected. Note that CCA  100  has a different vertical orientation in  FIG.  3    than in  FIGS.  1  and  2   . Rail  1000  can define a first transverse and longitudinally extending channel  1002  in which the one or more first transverse bearing assemblies  202  are slideably (e.g., rollably) disposed. Rail  1000  can define a second transverse and longitudinally extending channel  1004  in which the one or more second transverse bearing assemblies  302  are slideably disposed. Rail  1000  can define a third vertical and longitudinally extending channel  1006  in which the one or more vertical bearing assemblies  304  are slideably disposed.  FIG.  3    omits various features of CCA  100  for clarity. 
     Referring to  FIG.  3   , bearing assemblies  202 ,  302 ,  304  (also called bearings) can both enable longitudinal movement along rail  1000  and retain CCA  100  within rail  1000 . First transverse bearing assemblies  202  can discourage movement of CCA  1000  along the positive Z-axis and along the positive X-axis. Second transverse bearing assemblies  302  can discourage movement of CCA  1000  along the positive Z-axis and along the negative X-axis. Vertical bearing assemblies  304  can discourage movement of CCA along the X-axis (both positive and negative) and further discourage movement of CCA  100  along the negative Z-axis. 
     Bearings  202 ,  302 ,  304  can be roller bearings. Bearings  202 ,  302 ,  304  can be rotatable about the central axes (not labeled) of the cylinders shown in the Figures. Alternatively, the cylinders shown in the Figures can serve as housings confining circumferentially disposed bearings, each respectively rotatable about a different central axis (not shown). 
       FIG.  4    shows an embodiment of rail  1000  disposed in a vehicle  2000 . According to other embodiments (not shown), rail  1000  is permanently fixed in a static position (e.g., suspended from a warehouse ceiling). In  FIG.  4   , rail  1000  suspends a plurality of containers  500 . Each container  500  can include a vessel  510  defining a chamber  512  for storing an item (not shown), a linkage assembly  520 , and a CCA  100 . CCA  100  can moveably dispose and retain container  500  in rail  1000 . Linkage assembly  520  can couple vessel  510  with CCA  100 . 
     It may be desirable to temporarily decouple a container  500  from rail  1000 . Decoupling would, for example, enable a user to reorder containers  500  or to remove containers  500  for repair. But, as shown in  FIG.  3   , and for the reasons described above, CCA  100  can be incapable of sufficient movement in the transverse and vertical directions to remove container  500  from rail  1000 . 
     As such, and according to some embodiments, a container  500  can only be removed from rail  1000  by: (a) disassembling container  500  or (b) sliding (e.g., rolling) container  500  until reaching a longitudinal end  1010  of rail  1000  (see  FIG.  4   ). If containers  500  (e.g., containers  500   a  and  500   b ) are longitudinally disposed between the rail end  1010  and the container  500  to be removed (e.g, container  500   c ), then disassembly may be a more attractive option than sliding the container  500  to be removed off a longitudinal rail end  1010 . 
     Accordingly, various embodiments of CCA  100  enable quick disassembly (also called quick release) to decouple a container  500  from rail  1000  without sliding container  500  from a longitudinal end  1010  of rail  1000 . More specifically, and according to some exemplary embodiments, first transverse plate assembly  200  can be decoupled (e.g., partially decoupled) from second transverse plate assembly  300  until transverse space sufficient for removing CCA  100  from rail  1000  is defined between first and second transverse bearings  202 ,  302 . 
     According to some embodiments (discussed below), first and second transverse plate assemblies  200 ,  300  can be completely disconnected from each other. According to other embodiments (discussed below), first and second transverse plate assemblies  200 ,  300  remain linked together by release assembly  400  when fully decoupled. Release assembly  400  can simplify the decoupling process by biasing CCA  100  to the decoupled (i.e., the at least partially decoupled) state. These, and other features, are further discussed below. 
     Referring to  FIGS.  1  and  2   , first transverse plate assembly  200  can include a first corner plate  210  (also called a “first base”) with an L-shaped profile in the X-Z plane. Second transverse plate assembly  300  can include a second corner plate  310  (also called a “second base”) with an L-shaped profile in the X-Z plane. 
     First corner plate  210  can include first retainers  212 . Second corner plate  310  can include second retainers  312 . First and second retainers  212 ,  312  can cooperate to lock first and second transverse plate assemblies  200 ,  300  in the fully-coupled state. According to some embodiments, first transverse bearings  202  and second transverse bearings  302  are equidistant from vertical bearings  304  when plate assemblies  200 ,  300  are in a fully coupled state. As further discussed below,  FIGS.  1  and  2    can show CCA  100  in a non-fully coupled state. 
     As shown in  FIGS.  1  and  2   , first retainers  212  can be pockets (i.e., blind holes) for receiving corresponding second retainers  312  (shown as fingers in the exemplary embodiments of  FIGS.  1  and  2   ) of second transverse plate assembly  200 . If pockets, then first retainers  212  can include snap features for engaging with counter-snap features of second retainers  312 . 
     For example,  FIG.  5    shows first retainer  212  as a pocket defining longitudinally extending grooves  602  for receiving vertical projections  604  extending from second retainer  312  (which can be the finger shown in  FIGS.  1  and  2   ).  FIG.  6    shows the vertical projections  604  engaging grooves  602  to thereby retain first and second transverse plate assemblies  200 ,  300  in the fully coupled state. Although not shown, second retainer  312  can define grooves  602  and first retainer  212  can include projections  604 . 
     The above discussed features are only exemplary. First and second retainers  212 ,  312  can have any structure suitable for fully coupling first and second transverse plate assemblies  200 ,  300 . For example, first and second retainers  212 ,  312  can be magnets with poles oriented to bias and bind first and second transverse plate assemblies  200 ,  300  into the fully coupled state. 
     The one or more first transverse bearings  202  can be directly mounted to first corner plate  210 . A first transverse rod  214  can be directly secured to corner plate  210  at a transverse end  216 . An intermediate section of transverse rod  214  can be supported by, and rest directly on, a cradle  218  for reducing bending stress. The bending stress can be induced by one or more features secured to the opposing transverse end  220  of transverse rod  214 . 
     According to some embodiments, linkage assembly  520  connects with the longitudinal end  220  of transverse rod  214  (e.g., the transverse rod  214  can be an aspect of linkage assembly  520 ). Thus, at least a portion of the weight of items disposed in vessel  510  can be transmitted through transverse rod  214 , from corner plate  210  into first transverse bearings  202 , and onto rail  1000  via first transverse channel  1002 . As shown in  FIG.  1   , second transverse plate assembly  300  can include the same features (i.e., a transverse rod  314 , a cradle  318 , etc.). The central axis of second transverse rod  314  can be collinear with the central axis of first transverse rod  214 , as shown in  FIG.  8   . 
     For similar reasons, a pair of vertical rods  330  can include longitudinal ends  332  directly secured to second corner plate  310 . As with transverse rods  214 ,  314 , vertical rods  330  can be aspects of linkage assembly  520  or in mechanical communication therewith. Vertical rods  330  can transmit the mechanical load of items disposed within vessel  510  to second bearings  302  (as shown in  FIG.  3    vertical bearings  304  can be for alignment, but not for bearing weight). 
     Referring to  FIG.  2   , a first stopping plate  240  (also called a “first stop”) can vertically project from first corner plate  210 . A second stopping plate  340  (also called a “second stop”) can vertically project from second corner plate  310 . Plates  240 ,  340  can define circular apertures  242 ,  342  with collinear central axes. A pair of posts  350  can vertically project from second corner plate  310 . Plates  240 ,  340  along with posts  350  can interact with release assembly  400 . 
     Referring to  FIG.  8   , release assembly  400  can include a rod  410  disposed within the apertures  242 ,  342 , a transversely compressible spring  430  helically coiled thereabout, and a washer  450  stopped directly against second stopping plate  340  against which one end of spring  430  is seated. Rod  410  can include opposing cylindrical projections  420  (also called “outward extensions”) against which the opposing end of spring  430  is seated. 
     Rod  410  can be rotatable about its central axis and translatable in the transverse direction, subject to cylindrical projections  420  interfering with posts  350  and first stopping plate  240 . Spring  430  can exist in a compressed state. The biasing force that spring  430  exerts can be transversely transmitted as rod  410  bears against (a) posts  350  or (b) first stopping plate  240 . 
     When rod  410  (by virtue of projections  420  in  FIG.  1   ) bears against posts  350 , then spring  430  is exclusively squeezed between components directly affixed to second corner plate  310 . As such, the net transverse force in the positive X direction applied to second stopping plate  340  is canceled out by the net transverse force in the negative X direction applied to posts  350 . 
     However, when spring  430  compressively bears on first stopping plate  240 , net transverse motion can occur since first and second corner plates  212 ,  312  are separable when the locking force between retainers  212 ,  312  is overcome. More specifically, spring  430  can transmit a force in the negative X direction through projections  420 , through first stopping plate  240 , and into first corner plate  210 . Spring  430  can simultaneously transmit force in the positive X direction through washer  450 , through second stopping plate  340 , and into second corner plate  320 . As such, spring  430  can bias first and second corner plates  210 ,  310  transversely apart (i.e., release first corner plate  210  from second corner plate  310 ). 
     If the biasing force exerted by spring  430  is sufficient to overcome the transverse locking force exerted by first and second retainers  212 ,  312 , then release assembly  400  can separate first transverse plate assembly  200  from second transverse plate assembly  300  at least until CCA  100  is extractable from rail  1000  by virtue of transverse bearings  202 ,  302  being simultaneously withdrawable from channels  1002 ,  1004 . According to various embodiments, spring  430  is configured to exert a biasing force in excess of the locking force and thus separate first and second transverse plate assemblies  200 ,  300  until CCA  100  (and thus container  500 ) is extractable from rail  1000 . 
       FIGS.  9 A- 16    schematically illustrate the various states and effects of release assembly  400 . In  FIG.  9 A , spring  430  is compressively retained between posts  350  and second stopping plate  340 . Projections  420  are seated within ring grooves  352  defined in posts  420  such that a portion of each projection  420  transversely arcs therein ( FIG.  9 B ). In this embodiment, second transverse plate assembly  300  includes a single retainer  312 , which is centrally disposed and transversely extending finger configured to be locked (magnetically, mechanical, or otherwise, as discussed above) within first transverse plate assembly  200 . The opposing transverse forces that spring  430  exerts cancel each other out. First and second transverse plate assemblies  200 ,  300  remain locked together. 
     In  FIG.  10   , rod  410  is twisted to align projections  420  with the vertical. As such, posts  350  no longer obstruct the transverse pathway defined between projections  420  and first stopping plate  240 . Spring  430  pushes projections  420  toward first stopping plate  240 . By  FIG.  11   , projections  420  have contacted first stopping plate  240  and spring  430 , which is still compressed, biases first and second transverse plate assemblies  200 ,  300  apart. The spring biasing force exceeds the locking force that retainers  212 ,  312  exert, causing retainers  212 ,  312  to disengage. 
     In  FIG.  12   , the centrally disposed second retainer  312  has withdrawn from the pocket defined by first retainer  212 .  FIGS.  1  and  2    illustrate CCA  100  in an equivalent state. Spring  430  continues to decouple first and second transverse plate assemblies  200 ,  300  at least until reaching the state shown in  FIG.  13    where CCA  100  is removable from rail  1000 . According to some embodiments,  FIG.  13    exaggerates the dimensions of bearings  202 ,  302 ,  304  relative to rail  1000  such that bearings  302 ,  304  are removable in the absence of first transverse bearings  202 . 
     Recoupling can occur in reverse. In  FIG.  14   , rod  410  is twisted to misalign projections  420  and posts  350 . In  FIG.  15   , rod  410  has been transversely pushed to compress (e.g., further compress) spring  430  and translate projections  420  beyond posts  350 . Retainers  212 ,  312  have engaged. In  FIG.  16   , rod  410  has been twisted to realign projections  420  with posts  350 . Spring  430  now pushes rod  410  into the state of  FIG.  9   . 
     Referring to  FIG.  17   , rod  410  can include a second pair of projections  460  and/or a third pair of projections  470  to prevent spring  430  from pushing first corner plate  210  until rod  410  releases from first aperture  242  and/or second aperture  342 . As such, release assembly  400  can keep first and second transverse plate assemblies  200 ,  300  linked together, even when decoupled. Second and/or third projections  460 ,  470  can be disposed, and rod  410  can be sized, such that projections  460 ,  470  do not interfere with the above-discussed states or positions.