Storage and retrieval system

An automated storage-and-retrieval system, comprising:

• a multi-level storage structure comprising a plurality of rack modules separated by aisles, each rack module comprising a set of horizontal supports configured to store objects at a plurality of storage levels within each aisle and a set of horizontal tracks associated with each of the storage levels, and at least one set of inclined or vertical tracks disposed between and connecting levels of the multi-level storage structure;
• and
• at least one mobile robot comprising:
• one or more horizontal drives that propel the at least one mobile robot in at least one direction along at least one horizontal dimension;
• and
• one or more vertical drives that propel the at least one mobile robot in at least one direction along at least one vertical dimension;
• wherein the one or more horizontal drives engage with the set of horizontal tracks of the multi-level storage structure, and the one or more vertical drives engage with the inclined or vertical tracks of the multi-level storage structure;
• and
• wherein the at least one mobile robot propels itself horizontally along the aisles of the multi-level storage structure, and propels itself vertically from level to level of the multi-level storage structure using the inclined or vertical tracks of the multi-level storage structure.

A transfer mechanism, comprising:

• at least one flexible load carrier, comprising:
• a support frame;
• a first horizontal support bar slidably coupled with the support frame;
• a second horizontal support bar slidably coupled with the support frame;
• a flexible sheet coupled at a first end with the first horizontal support bar and at a second end, opposite the first end, with the second horizontal support bar;
• and
• a handle coupled with the flexible sheet;
• and
• at least one manipulator, comprising:
• first and second linear motion motors that propel the first horizontal support bar or the second horizontal support bar linearly along the support frame;
• a grasper device adapted to grasp the handle;
• and
• a motorized load carrier, attached by cable to the handle, adapted to extend or retract the cable to lower or raise objects into or out of the at least one flexible load carrier.

An automated order fulfillment system, comprising:

• a multi-level tote storage structure storing one or more totes;
• one or more mobile robots configured to:
• pick, transport, and place the one or more totes;
• propel themselves horizontally across levels of the multi-level tote storage structure;
• and
• propel themselves vertically from level to level within the multi-level tote storage structure using one or more stationary inclined or vertical tracks;
• one or more workstations configured to accommodate a picker that transports one or more caches from one of the one or more totes on one of the one or more mobile robots to a put location;
• and
• an input/output interface where product is inducted into the order fulfillment system and where fulfilled orders are discharged from the order fulfillment system.

A mobile robot, comprising:

• a frame chassis;
• a transfer mechanism coupled to the frame chassis;
• a drive axle;
• one or more fixed gear wheels mounted on the drive axle;
• one or more cylindrical drive wheels mounted on the drive axle;
• wherein the one or more fixed gear wheels are configured to engage with a stationary track in inclined orientation, and the one or more cylindrical drive wheels are configured to travel along a stationary track in horizontal orientation;
• and wherein the mobile robot is configured to operate with a stationary track that utilizes switches to direct the mobile robot between a desired stationary track in inclined orientation or a desired stationary track in horizontal orientation.

A mobile robot, comprising:

• a frame chassis;
• a transfer mechanism coupled to the frame chassis;
• a drive axle;
• one or more fixed gear wheels fixed mounted on the drive axle;
• one or more cylindrical drive wheels mounted on the drive axle;
• wherein the one or more fixed gear wheels are configured to engage with a stationary track in inclined orientation, and the one or more cylindrical drive wheels are configured to travel along a stationary track in horizontal orientation;
• and
• wherein the drive axle is extendable and retractable to engage or disengage the one or more fixed gear wheels and the one or more cylindrical drive wheels with a desired stationary track of the inclined orientation or a desired stationary track of the horizontal orientation.

A mobile robot, comprising:

• a frame chassis;
• a transfer mechanism coupled to the frame chassis;
• a drive axle;
• one or more fixed gear wheels mounted on the drive axle;
• one or more cylindrical drive wheels mounted on the drive axle;
• wherein the one or more fixed gear wheels arc configured to engage with a stationary track in vertical orientation, and the one or more cylindrical drive wheels are configured to travel along a stationary track in horizontal orientation;
• and
• wherein the drive axle is extendable and retractable to engage or disengage the one or more fixed gear wheels and the one or more cylindrical drive wheels with either a track of vertical orientation or a track of horizontal orientation in such a way that enables the mobile robot to select a desired stationary track of the vertical orientation or a desired stationary track of horizontal orientation without requiring an active track switch.

An automated order fulfillment system, comprising:

• a multi-level tote storage structure for storing one or more totes;
• one or more mobile robots configured to:
• pick, transport, and place the one or more totes;
• move horizontally across levels of the multi-level tote storage structure;
• and
• move vertically between levels from level to level within the multi-level tote storage structure using one or more stationary inclined or vertical tracks;
• one or more workstations configured to accommodate a picker that transports one or more caches from one of the one or more totes on one of the one or more mobile robots to a put location;
• and
• an input/output interface where product is inducted into the order fulfillment system and where fulfilled orders are discharged from the order fulfillment system.

A mobile robot, comprising:

• one or more horizontal drives having wheels that propel the mobile robot in at least one direction along at least one horizontal dimension;
• and
• one or more vertical drives having wheels that propel the mobile robot in at least one direction along at least one vertical dimension;
• wherein the one or more horizontal drives are configured to engage with horizontal tracks of a multi-level storage structure, and the one or more vertical drives are configured to engage with inclined or vertical tracks of the multi-level storage structure;
• and
• wherein the wheels of the one or more horizontal drives and/or the wheels of the one or more vertical drives are moveable such that the robot can selectively engage with the horizontal tracks and with the inclined or vertical tracks.

An order vending machine, comprising:

• a multi-level container storage structure;
• a mobile robot operable within the multi-level container storage structure to store and retrieve containers, the mobile robot having direct access to all container storage locations;
• a customer access port;
• wherein the mobile robot positions the container for access by a customer at the customer access port.