US 12,459,740 B2
Automated shuttle materials handling and storage systems and methods of using the same
Jarl Nicholas Sebastian, Charlotte, NC (US)
Assigned to INTELLIGRATED HEADQUARTERS, LLC, Mason, OH (US)
Filed by INTELLIGRATED HEADQUARTERS, LLC, Mason, OH (US)
Filed on Nov. 12, 2021, as Appl. No. 17/454,735.
Prior Publication US 2023/0150770 A1, May 18, 2023
Int. Cl. B65G 1/137 (2006.01); B65G 1/04 (2006.01); B65G 1/06 (2006.01)
CPC B65G 1/1375 (2013.01) [B65G 1/0492 (2013.01); B65G 1/065 (2013.01); B65G 1/1373 (2013.01)] 19 Claims
OG exemplary drawing
 
1. An automated storage and retrieval system comprising:
a plurality of storage aisles, each storage aisle comprising a plurality of storage locations positioned adjacent to an aisle track that extends along an aisle length;
a plurality of shuttles configured to travel throughout the automated storage and retrieval system to execute a materials handling operation;
at least one vertical lift;
a plurality of inter-aisle shuttle outlet tracks configured to facilitate shuttle traffic flow in at least substantially the same direction, the plurality of inter-aisle shuttle outlet tracks comprising:
a first inter-aisle shuttle outlet track configured to facilitate shuttle traffic flow to the at least one vertical lift via at least one lift interface position defined along the first inter-aisle shuttle outlet track; and
a second inter-aisle shuttle outlet track arranged in an at least substantially parallel configuration relative to the first inter-aisle shuttle outlet track;
wherein the plurality of inter-aisle shuttle outlet tracks is configured to enable a transfer of at least one of the plurality of shuttles between the first inter-aisle shuttle outlet track and the second inter-aisle shuttle outlet track at one or more transfer locations along the first inter-aisle shuttle outlet track;
wherein the aisle track of each storage aisle of the plurality of storage aisles is configured to facilitate shuttle traffic flow along the aisle length thereof in a first shuttle travel direction such that each of the plurality of storage aisles is defined in part by a unidirectional shuttle traffic flow pattern.
 
11. A method of operating an automated storage and retrieval system using a unidirectional shuttle traffic flow pattern, the method comprising:
providing the automated storage and retrieval system comprising a first storage aisle, the first storage aisle comprising an aisle track extending along an aisle length and a plurality of storage locations positioned at least substantially adjacent the aisle track, wherein the aisle track is configured to facilitate movement of a plurality of shuttles along the first storage aisle in a shuttle travel direction defined along the aisle length;
causing a first shuttle to travel to a first storage location provided within the first storage aisle such that the first shuttle moves along the aisle track of the first storage aisle in a first shuttle travel direction;
causing a second shuttle to travel to a second storage location provided within the first storage aisle such that the second shuttle moves along the aisle track of the first storage aisle in the first shuttle travel direction and such that both the first shuttle and the second shuttle are positioned within the first storage aisle at a first instance; and
causing the first shuttle to travel in the first shuttle travel direction from the first storage location to a first storage aisle outlet of the first storage aisle, wherein the automated storage and retrieval system comprises a plurality of inter-aisle shuttle outlet tracks configured to facilitate shuttle traffic flow in at least substantially the same direction, the plurality of inter-aisle shuttle outlet tracks comprising:
a first inter-aisle shuttle outlet track configured to facilitate shuttle traffic flow to at least one vertical lift via at least one lift interface position defined along the first inter-aisle shuttle outlet track; and
a second inter-aisle shuttle outlet track arranged in an at least substantially parallel configuration relative to the first inter-aisle shuttle outlet track;
wherein the plurality of inter-aisle shuttle outlet tracks is configured to enable a transfer of at least one of the plurality of shuttles between the first inter-aisle shuttle outlet track and the second inter-aisle shuttle outlet track at one or more transfer locations along the first inter-aisle shuttle outlet track.