Structure Verification System and Method
Patent Information
- Application Number
- KR1020267028369
- Authority / Receiving Office
- KR · KR
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2024-01-31
- Filing Date
- 2025-01-09
- Publication Date
- 2026-09-21
Smart Images
Figure P1020267028369_ABST
Abstract
Description
Technology Field
[0001] Related applications
[0002] This application claims the benefit of U.S. Provisional Application No. 63 / 627,349 filed on January 31, 2024, the full contents of said U.S. application are supplemented herein by reference.
[0003] Technology field
[0004] The present invention relates to an automatic storage and retrieval system, and specifically to the verification of the structure of such a system using mobile robots. Background Technology
[0005] Automated storage and retrieval systems play a crucial role in supply chain management. An example of this increasing demand can be seen in the grocery industry, where fulfillment centers are operated to efficiently procure customer orders. These facilities typically include storage compartments located alongside accessible sections that allow for the retrieval and storage of items as needed. These items can be stored in temperature-controlled zones within the storage compartments. Typically, totes or containers are used to store items in desired locations. A representative fulfillment center includes a multi-story structure equipped with horizontal rows that provide access to various storage compartments. Mobile robots can navigate these horizontal rows to retrieve or store totes as needed and support the procurement of customer orders.
[0006] Embodiments of an apparatus, system, and method for verifying a structure using a mobile robot are disclosed herein. This description includes drawings. Brief explanation of the drawing
[0007] FIGS. 1a and FIGS. 1b are drawings showing a robot storage and retrieval system according to various embodiments. FIG. 2 is a block diagram of a structure verification system according to various embodiments. FIG. 3 is a flowchart of a method for verifying a structure according to various embodiments. FIG. 4 is a flowchart showing a system initialization process according to various embodiments. FIG. 5 is a flowchart showing a continuous system verification process according to various embodiments. FIG. 6 is a drawing showing a mobile robot according to various embodiments. FIG. 7 is a flowchart showing a method for verifying a structure according to various embodiments. Specific details for implementing the invention
[0008] The elements in the drawings are illustrative for the sake of brevity and clarity and are not necessarily drawn in proportion. For example, to aid in understanding the various embodiments of the invention, the dimensions and / or relative positions of some elements in the drawings may be exaggerated compared to others. Additionally, to facilitate a clearer understanding of these various embodiments of the invention, general but well-known elements useful or necessary for commercially feasible embodiments are often not depicted. Specific actions and / or steps may be described or depicted in a specific order of occurrence, but those skilled in the art will understand that such specificity regarding the order is not actually required. The terms and expressions used herein have the general technical meanings as understood by those skilled in the art, except where otherwise stated.
[0009] Generally, systems, devices, and methods for verifying a structure using a mobile robot are provided according to various embodiments. In some embodiments, the techniques described herein relate to a structure verification system comprising a structure having a plurality of compartments configured to allow a mobile robot to pass through the structure, and a control circuit, wherein the control circuit is configured to perform the operations of receiving data captured from a sensor system of the mobile robot while the mobile robot passes through the compartments of the structure, detecting a deviation associated with the compartments by comparing the data captured by the sensor system with a design map of the structure, and updating a mapping file based on the deviation, and wherein the mobile robot is configured to subsequently drive on the structure based at least on the mapping file.
[0010] It should be understood that the embodiments described herein may be embodied in various forms and should not be interpreted as being limited to the embodiments presented herein. Rather, such embodiments are provided to ensure that the present disclosure is thorough and complete so as to fully convey the invention to those skilled in the art. In fact, such embodiments are intended to encompass alternative, modified, and equivalent examples of these embodiments that fall within the scope and spirit of the invention as defined by the appended claims. Furthermore, specific details are provided in the following detailed description to facilitate understanding of the embodiments described herein.
[0011] Referring now to FIGS. 1a and 1b, an example of a type of structure that can be verified by some embodiments of the system and method described herein is illustrated. In some embodiments, the system and method described herein can verify storage structures of different configurations and / or other types of structures. FIG. 1a is a drawing partially showing one embodiment of an order procurement facility (100) having a storage structure (102) comprising bays (104) of a plurality of storage locations (106).
[0012] In some embodiments, the storage structure (102) may be formed of a plurality of storage modules (110). Each of the bays (104) defined by the storage modules (110) includes a yz array of storage locations (106) in horizontal rows and level change towers along the rows, and the level change towers may be vertical towers in the embodiments. Mobile robots (148) may travel between storage levels in the z-direction within the level change towers. The storage modules (110) form multiple pairs of bays (104), and these bays (104) are arranged to face each other, separated by passageways (108). The passageways (108) may have a width that allows a mobile robot (148) traveling within the passageways (108) to transport containers to the bays (104) on both sides of the passageways (108). The mobile robots (148) can also transport totes containing items from the storage structure (102) to a portal for storing and retrieving items and from such a portal.
[0013] The order procurement facility (100) may further include decks (112) spaced apart at different horizontal levels of the storage structure (102). The decks (112) may extend between the passages, thereby allowing the mobile robots (148) to maneuver in the xy plane of each deck and travel between the different passages. At least one of the decks (112) extends into the corresponding passages, allowing technicians to walk into the passage (108) and inspect the components within the passage.
[0014] FIG. 1a also shows examples of integrated rotating decks (115). The rotating decks (115) may be located at different vertical positions between the storage modules (110). The rotating decks (115) may be equipped with a rotating deck input / output (115-I / O) that can be aligned with the passage (108) or another rotating deck input / output (115-I / O). The rotating deck (115) enables the mobile robot (148) to efficiently change its driving direction through the storage structure (102).
[0015] The order procurement facility (100) may further include a number of mobile robots (148) for transporting totes or other products or order containers to and from customer access portals and storage locations (106) within the bays (104). The mobile robots (148) may be self-guided and / or rail-guided to move horizontally and vertically within the passages (108) to transport totes or other product containers between the mobile robots (148) and the storage locations (106).
[0016] Referring now to FIG. 1b, a portion of a track system (180) that may be part of a storage structure (102) according to some embodiments is illustrated. The storage structure (102) is a multi-layered structure and the track system (180) includes horizontal rails (181) fixed at different vertical levels. The horizontal rails (181) allow access to storage shelves on both sides of a passage (108) in the x-direction on a given level. In some embodiments, the ends of one or more horizontal rails (181) are connected to decks (112) or rotating decks (115). In some embodiments, the storage structure (102) further includes vertical level changing towers (182) equipped with vertical tracks, within which the mobile robots can travel vertically in the z-direction between levels of storage locations (106). In some embodiments, the structure (102) may further include diagonal ramps that allow the mobile robots to move between levels via the incline. The storage structure (102) may also include other support elements such as diagonal braces (187) or vertical poles (186).
[0017] In some embodiments, the storage structure (102), the horizontal rails (181), the vertical level change towers (182), the rotating decks (115), the diagonal brace (187) and / or the vertical poles (186) may include various functions used by the mobile robot (148) for positioning and navigation within the storage structure (102). For example, structural features may include component connections (e.g., between the horizontal rails (181) and the decks (112), between the horizontal rails (181) and the vertical level change towers (182)), track gaps (e.g., between segments of the horizontal rails (181)), support elements (e.g., braces (187)), fastening devices (e.g., screws or clamps connecting one or more components of the structure), and / or electrical elements (e.g., charging rails or pads). In some embodiments, the features may include markers (185) that encode location identifiers providing navigation guidance. The markers (185) may be optical, electromagnetic, and / or physical markers. In some embodiments, the markers (185) may each include unique 3D coordinate values corresponding to the location of the marker within the structure. In some embodiments, the mobile robot (148) may store a map file of the storage structure (102) containing the locations of one or more markers (185). Upon receiving a destination, the mobile robot (148) may determine its location within the structure (102) and / or control its movement and operation based on its location relative to one or more detected markers (185). In some embodiments, the mobile robots (148) may be used to measure the dimensions and / or other characteristics of the components of the storage structure (102) through the features. Examples of the structural verification process are described in more detail here with reference to FIGS. 2 to 6.
[0018] Detailed information regarding available storage structures and mobile robots is described, for example, in the following U.S. patents and patent applications: U.S. Patent No. 9,139,363, titled "AUTOMATED SYSTEM FOR TRANSPORTING PAYLOADS," issued September 22, 2015; U.S. Patent No. 10,435,241, titled "STORAGE AND RETRIEVAL SYSTEM," issued October 8, 2019; U.S. Patent No. 11,142,398, titled "ORDER FULFILLMENT SYSTEM," issued October 12, 2021; and U.S. Patent No. 20, 2021, titled "PICKING WORKSTATION WITH MOBILE ROBOTS & MACHINE VISION VERIFICATION OF EACH TRANSFERS PERFORMED BY HUMAN OPERATORS." U.S. Patent No. 10,952,533, issued March 23, 2021, with the title of invention No. 10,984,375, “MODULAR STRUCTURE FOR AN AUTOMATED STORAGE AND RETRIEVAL SYSTEM”; U.S. Patent No. 11,267,651, issued March 8, 2022, with the title of invention “SYSTEM HAVING WORKSTATION WITH TOTE RETENTION AND RELEASE MECHANISM”; and U.S. Patent Application No. 63 / 127,762, filed December 18, 2020, with the title of invention “MICRO-FULFILLMENT CENTER WITH AUTOMATED DISPENSE AND RETURN USING MOBILE ROBOTS AND METHOD OF OPERATING SAME”. The full contents of these patents and patent applications are supplemented herein by reference.
[0019] Next, referring to FIG. 2, a block diagram of a pickup order procurement system is shown. The system includes one or more mobile robots (210) and a central computer system (220).
[0020] The central computer system (200) includes a control circuit (221), memory (223), and a network interface device (227). The central computer system (200) may include one or more of a server, a central computing system, a cloud-based computing engine, a desktop computer system, a personal computer, a portable device, etc. The control circuit (221) may include a processor, a microprocessor, a central processing unit (CPU), a graphics processing unit (GPU), an application-specific integrated circuit (ASIC), etc., and may be configured to execute computer-readable instructions stored on a computer-readable storage memory (223). The computer-readable storage memory (223) may include volatile and / or non-volatile memory and may store a set of computer-readable instructions that, when executed by the control circuit (221), cause the central computer system (220) to perform the operation of verifying a structure through the one or more mobile robots (210) and the operation of transmitting instructions to be executed by the one or more mobile robots (210). In some embodiments, the computer-readable instructions may cause the central computer system (220) and / or the control circuit (221) of the one or more mobile robots (210) to perform one or more functions described herein, such as the steps described with reference to FIGS. 3 through 5. In some embodiments, the memory (223) may further store a design map, such as a computer-aided design (CAD) model of a structure on which the mobile robot (210) travels. For example, the memory (223) may store a design map of a storage structure (102) described here with reference to FIG. 1a and FIG. 1b.In some embodiments, the design map may correspond to the designed configuration of the structure and may include dimensions and feature locations from the design model on which the structure was originally assembled. In some embodiments, the memory (223) may further store mapping files including a design map configured to be used for navigation by the robot and a delta file determined based on sensor data collected from the sensor systems of one or more mobile robots. In some embodiments, the delta file represents the difference between the design configuration and the construction configuration of the structure.
[0021] The network interface device (227) may include a data port, a wired or wireless network adapter, etc. In some embodiments, the central computer system (220) may communicate with the mobile robot (210) through one or more networks, such as a local network, a private network, a cloud computing network, or the Internet. In some embodiments, the central computer system (220) may further communicate with other systems and devices, such as an order database, an inventory database, a related user interface device, a customer user interface device, etc.
[0022] The mobile robot (210) is an electric unit configured to travel on a structure. In some embodiments, the mobile robot (210) may be configured to travel on a storage structure to retrieve and / or store items and / or totes. In some embodiments, the mobile robot (210) may be the mobile robot (148) described with reference to FIG. 1b. The mobile robot (210) includes a control circuit (211), a memory (213), a network interface (217), a sensor system (215), and a drive system (219).
[0023] The control circuit (211) may include a processor, a microprocessor, a central processing unit (CPU), a graphics processing unit (GPU), an application-specific integrated circuit (ASIC), etc., and may be configured to execute computer-readable instructions stored on a computer-readable storage memory (213). The computer-readable storage memory (213) may include volatile and / or non-volatile memory and may store a set of computer-readable instructions that, when executed by the control circuit (211), cause the mobile robot (210) to perform the operation of driving autonomously or semi-autonomously on a structure via the drive system (219) and the operation of collecting data via the sensor system (215). In some embodiments, the computer-readable instructions may cause the control circuit (211) of the mobile robot (210) to perform one or more functions described herein, such as the steps described with reference to FIGS. 3 through 5. In some embodiments, the memory (213) may further store a copy of a mapping file, such as a 3D navigation map based on a computer-aided design (CAD) model of a structure on which the mobile robot (210) travels. In some embodiments, the mapping file may further include a delta file determined based on sensor data collected based on a sensor system of one or more mobile robots, as described more specifically herein.
[0024] The sensor system (215) may include one or more sensors for providing data for autonomous navigation and / or storage and retrieval functions. In some embodiments, the sensor system (215) may include one or more of an optical sensor, a radio frequency identification (RFID) sensor, a vibration sensor, an acoustic sensor, a tachometer, an odometer, a pressure sensor, a voltmeter, an accelerometer, a gyroscope, a magnetometer, a temperature sensor, a humidity sensor, and / or an inertial measurement unit (IMU). In some embodiments, the sensor system (215) is configured to detect features on the structure, such as optical markers, RFID markers, structural features, track connections, track gaps, fastening elements (e.g., bolts, clamps), support elements (e.g., poles, braces), and / or electrical elements (charging rails or pads).
[0025] The above drive system (219) may include a system for providing and controlling the movement of the mobile robot (210) on the structure. In some embodiments, the drive system (219) may include motors, wheels, gears, etc.
[0026] An example of a mobile robot (210) is illustrated in FIG. 6. The mobile robot (210) includes an item / tote carrier (610), front drive wheels (630), a vertical climbing gear (635), a power storage device (620), rear trailer wheels (648), and charging contacts (640). In some embodiments, the sensors of the sensor system (215) may be connected to any part of the mobile robot (210). For example, optical sensors may be connected to the front, side, and / or rear of the mobile robot (210). In some embodiments, the sensor system (215) may be configured to detect features by measuring vibration, acceleration, speed, etc. through one or more of the drive wheels (630), the trailer wheels (648), and the vertical climbing gear (635). In some embodiments, the sensor system (215) may be configured to detect the presence of charging rails or pads through the contacts (640).
[0027] Next, referring to FIG. 3, a method for verifying a structure is illustrated. In some embodiments, one or more steps of FIG. 3 may be executed by a processor-based device that executes computer-readable instructions stored on a memory device. In some embodiments, one or more steps of FIG. 3 may be performed by a central computer system (200) and / or a mobile robot (210) or other similar devices described herein with reference to FIG. 2. In some embodiments, the process illustrated in FIG. 3 may be performed during the initial setup of the system, as part of periodic maintenance and inspection, and / or while the mobile robots perform tasks on the structure as continuous monitoring / scanning.
[0028] In step 310, the task is transmitted to the mobile robot for execution. In some embodiments, the task may be defined by a central computer system. In some embodiments, the task may be a structure verification task. For example, the mobile robot may be configured to travel at a normal speed for storing and retrieving items, and at a slower speed (e.g., 80%, 50%, etc.) for structure verification. In some embodiments, the task may be a storage and / or retrieval task, and the robot may capture data while going to or returning from a storage location. In some embodiments, the mobile robot may be one of a plurality of mobile robots configured to perform storage and retrieval tasks for the structure. In some embodiments, the mobile robot may be a unit specialized for structure verification, for example, a unit equipped with additional sensors. In some embodiments, the task may sequentially designate one or more destination locations within the structure. In some embodiments, the task may further designate one or more actions to be performed at one or more destination locations. For example, task instructions may specify a storage location for retrieving or returning the tot. In some embodiments, the mapping file may be transferred to the onboard memory of the mobile robot, such as the memory (213) of the mobile robot (210).
[0029] In step 320, the mobile robot travels on the structure and captures data. In some embodiments, the mobile robot may be configured to travel between locations indicated by the central computer system via a mapping file (390) of the structure representing routes and features on the structure, and to detect features on the actual structure. In some embodiments, the robot may travel based on a design map of the structure. In some embodiments, the design map may be a CAD model that serves as the basis for the initial construction or assembly of the structure. In some embodiments, for initial structure correction / verification, the mapping file may contain only the design map. In some embodiments, the robot may travel based further on a mapping file that includes delta values representing the difference between the actual structure and the design map and / or a model of the actual structure determined based on data measured from one or more mobile robots.
[0030] In some embodiments, the mobile robot may determine a route to a marked destination based on the map and time movements such as starting, stopping, turning, and / or transfer based on detecting features / markers on the structure along the route. For example, if the robot receives a task to retrieve a tote from position A, it may determine that it must travel x cm past feature point A along horizontal track A to climb vertical track A, or travel y cm past feature B along horizontal track B and stop to retrieve the tote. The mobile robot may determine when to slow down to switch tracks, when to start climbing, and when to stop to retrieve the tote based on detecting features such as markers on the structure.
[0031] The mobile robot captures data along the route through a sensor system such as the sensor system (215). In some embodiments, the sensor system includes an optical sensor, a radio frequency identification (RFID) sensor, a vibration sensor, an acoustic sensor, a tachometer, an odometer, a pressure sensor, a voltmeter, an accelerometer, a gyroscope, a magnetometer, a temperature sensor, a humidity sensor, and / or an inertial measurement unit (IMU). In some embodiments, the mobile robot may detect features such as optical markers, RFID markers, structural features, track connections, track gaps, fastening elements, support elements, and / or electrical elements. In some embodiments, the robot may measure the distance between features, detect acoustic or vibration characteristics of the track, measure track angles (e.g., upward slope or downward slope), measure electrical connections at charging contacts, and measure the torque of wheels or gears.
[0032] In some embodiments, the captured data may include one or more detected features associated with the capture location. In some embodiments, the capture location may be determined based on the distance traveled by the mobile robot's drive system from a reference point (e.g., another feature) within the structure. In some embodiments, the captured data includes unique 3D coordinate values of markers, said coordinate values corresponding to the location of said markers within the structure. In some embodiments, the data may correspond to data captured by the robot for navigation purposes. In some embodiments, the mobile robot may use additional sensors while in verification mode and / or collect data that is not typically collected for navigation purposes.
[0033] In step 330, the sensor data collected in step 320 is compared with the design map of the structure to detect differences. In some embodiments, step 320 may be performed by a central computer and / or a mobile robot. In some embodiments, the robot may determine expected feature locations based on the design map and record instances where discrepancies occur between the expected feature locations and the actual detected locations. For example, when the robot travels from Mark A to Mark B, if it arrives at Mark B earlier or later than expected based on the design map, the deviation may be identified and stored. In some embodiments, the recorded sensor data may be transmitted to the central computer system for analysis. In some embodiments, the central computer system may compare the collected data with a design model or system map containing more information than the mapping file stored on the mobile robot. In some embodiments, IMU or tachometer data may be used to determine whether the components are sufficiently level or angled as designed. In some embodiments, data may be compared to determine whether the system has expected acoustic, vibration, thermal, and / or texture characteristics. For example, acceptable acoustic, vibration, thermal, and / or texture ranges may be defined for one or more sections of a structure as designed, and measurements exceeding the acceptable ranges may be marked as deviations. In some embodiments, the central computer system and / or the mobile robot may simulate sensor data of the mobile robot along the corresponding sections based on the design map, wherein deviations are detected based on comparing the data captured by the sensor system with the simulated sensor data.
[0034] If no deviation is detected, the mobile robot can continue to move around the structure and perform tasks based on the mapping file. If a deviation is detected in step 340, the system can determine whether the deviation exceeds a correction threshold and / or is of a type requiring correction action for the accurate or efficient operation of the system. If the deviation is severe (e.g., exceeding the correction threshold or being of a type requiring correction action), a warning may be generated in step 360 to notify operators. For example, if the distance between two features differs by more than 30% from the design map, a notification may be sent to an employee to perform repair or adjustment of the structure. In some embodiments, due to severe deviations, system maps used by the central storage system and / or the central robot control system may also be updated. The warning may identify locations and measurements associated with the detected defect.
[0035] If the deviation is minor (e.g., below the correction threshold or if no correction action is required), the mapping file may be updated in step 350. For example, a delta file may be added to the mapping file (390) to reflect the detected deviation. In some embodiments, the mapping file may be updated. For example, the delta file may indicate that Marker A is 0.2 cm further away from Marker B compared to the design map. In some embodiments, the system may set a threshold difference (e.g., 0.05 cm) for updating the mapping file. In some embodiments, the mapping file may be determined based on data captured by multiple robots. For example, the delta value may be the average of the differences detected by the three most recent mobile robots traveling in the same area. In some embodiments, the mapping file (390) may include delta values associated with different features in different sections of the structure determined based on data from different mobile robots. In some embodiments, the updated mapping file (390) may be loaded onto the local memory devices of each mobile robot traveling on the structure. The mobile robots may then move the structure based on the updated mapping file, including the delta file, to obtain a more accurate map layout of the structure during construction. For example, the mobile robot may determine the timing for deceleration, stopping, or turning based on distances determined based on feature locations indicated in the delta file in addition to the design map.
[0036] Next, referring to FIG. 4, a process for initializing a system is illustrated. In some embodiments, one or more steps of FIG. 4 may be performed by a processor-based device that executes computer-readable instructions stored on a memory device, a human worker, and / or a combination thereof. In some embodiments, one or more steps of FIG. 4 may be performed by a central computer system (200) and / or a mobile robot (210) or other similar devices described herein with reference to FIG. 2.
[0037] In step 401, the system configuration is initially defined. In some embodiments, a design model that may include a 2D, 3D, or 4D (e.g., 3D over time) building information computer model, such as a Revit model, may be created in step 410. In step 405, a system map corresponding to the initial system configuration (e.g., 3D design model) is determined and stored. In step 407, a robot control system (RCS) map may also be stored for use by the robot control system. In some embodiments, the RCS may have a lower level of detail and a lower required accuracy compared to the mapping file used by the mobile robot. In step 409, an initial mapping file is determined based on the system design configuration. The mapping file may include a map of the structure using a coordinate code (e.g., Universal Coordinate Code (UCC)) and a structural local library (SLL) representing the dimensions and feature locations of the structures, components, and structural markers. In some embodiments, the structure markers may each encode a UCC corresponding to a location within the structure. In some embodiments, the design model of step 401, the system map of step 405, and the initial mapping file of step 409 may be referred to as a design map individually or collectively, as they correspond to the design configuration of the structure.
[0038] In step 402, bills of materials ("BOMs") for the system and one or more mobile robots are generated to proceed with manufacturing. In step 410, the system is manufactured. For example, tracks, fasteners, support elements, markers, etc., may be manufactured at one or more facilities based on the BOM. In step 411, the system is installed. In some embodiments, the system may be installed in a procurement facility for storing totes containing items for order procurement. In some embodiments, the installation of the system involves the assembly of structural components and markers, such as flags and RFID tags, according to the system design model.
[0039] In step 420, the mobile robots are manufactured. For example, the drive system, cockpit, wheels, etc., of the mobile robots are formed and assembled. The robots may also be "fingerprinted" to the system by loading data onto the mobile robot's local memory. The data may include individual data, such as driving restrictions, and trace data (e.g., current traces while moving). In step 421, the mobile robot is configured. In some embodiments, the configuration process includes loading a design mapping file from step 409 onto the robot to enable the mobile robot to move the structure automatically or semi-automatically and / or perform the tasks. In step 422, the mobile robots are guided into the system by, for example, physically placing the robot on the assembled structure and establishing a communication channel between the central computer system and the mobile robot. In step 412, the mobile robots and the structure undergo initial system-level fingerprinting after installation. For example, the robot can register trace data, such as the current trace of the climbing tower or the vibration signature of the gap, while driving on the structure.
[0040] In step 430, initial system scanning is performed. In some embodiments, the mobile robots may be sent to different destinations within the structure to capture data from different sections of the structure. In some embodiments, the mobile robots may be configured to enter a verification mode that reduces speed to collect data with high findelity. In step 431, a design map corresponding to the design configuration of the structure is compared with the data captured in step 430. In step 432, if the design map and the captured data match, or if all deviations are within a predetermined tolerance range, the mapping file is finalized and remains unchanged. If a discrepancy is identified in step 432, the degree of discrepancy is determined in step 434. If the discrepancy is greater than a correction threshold (e.g., threshold distance or percentage), a warning regarding a system problem may be generated in step 436. In the event of a system problem, the system map and / or the Robot System Control (RSC) map must be modified. In some embodiments, adjustments to the structure and / or system may be performed in response to the detection of a system problem. If the discrepancy in step 435 is below a correction threshold, delta files representing the differences may be generated and stored as configurational system data in step 440. In some embodiments, the configurational system data may be used to update or supplement mapping files used for navigation purposes by the mobile robots.
[0041] Next, referring to FIG. 5, a process for continuous verification of a structure is illustrated. In some embodiments, one or more steps of FIG. 5 may be performed by a processor-based device, a human worker, and / or a combination thereof, which executes computer-readable instructions stored on a memory device. In some embodiments, one or more steps of FIG. 5 may be performed by a central computer system (200) and / or a mobile robot (210) or other similar devices described herein with reference to FIG. 2.
[0042] In step 501, as the robot mobiles move on the structure and perform tasks, data is collected by the mobile robot and / or the system. In some embodiments, data may be collected by a number of components of the system, such as the RSC, a number of mobile robots, workstations, etc., during the normal operation of these components. In some embodiments, the generated data may include alarms, warnings, alerts, and individual and trace data (510). In some embodiments, the stored data may include individual and trace data of the equipment, failure data, and / or usage data. In step 520, the collected data may be used for bot-level analysis. Differences detected through the bot-level analysis may generate bot-level alarms / warnings / alarms in step 521. In some embodiments, workstations may also perform workstation-level analysis. In step 530, the collected data may also be used for system-level analysis on a server, such as a cloud-based server. Differences detected through the above system-level analysis may generate system-level alarms / warnings / alarms in step 531. In step 540, the bot or system-level alarms / warnings / alarms may lead to correction and / or preventive measures. In some embodiments, the correction and / or preventive measures may include adjustment of the system and / or updating of mapping files, such as delta files.
[0043] do 7 is a flowchart of a typical method for mapping a storage recovery system. In step 710, data is captured by the sensor system of the mobile robot while the mobile robot moves through a section of the structure. In some embodiments, the mobile robot may be the mobile robot (210) or a similar device. In some embodiments, step 710 may correspond to step 320.
[0044] In step 720, the data captured by the sensor system is compared with the design map of the structure to detect deviations associated with the corresponding section. In some embodiments, step 720 may be performed by the central computer system (220) and / or the control circuit of the mobile robot (210). In some embodiments, step 720 may correspond to steps 330 and 340.
[0045] In step 730, the mapping file is updated based on the deviation. In some embodiments, step 720 may be performed by the central computer system (220) and / or the control circuit of the mobile robot (210). In some embodiments, step 720 may correspond to step 350.
[0046] In some embodiments, the structure in the system and method described above is assembled based on a design model. In some embodiments, dimensions and locations (e.g., via UCC and SLL) may be determined based on the design model data to form a "design" map. However, due to various factors such as part tolerances, inaccuracies in site conditions, and inaccuracies in installation, the assembled system may not be identical to the original design model.
[0047] Manually adjusting maps used by robots to match the construction system can be cumbersome and time-consuming. Automating the inspection and calibration of dimensions and position markers through scans performed by mobile robots can save time and labor and reduce errors. In some embodiments, bots and systems may be fingerprinted to establish operational baselines to be compared with future events. In some embodiments, local monitoring of operational data for the original fingerprints provides a data source for analysis leading to predictive maintenance and reduced downtime. In some embodiments, enterprise-level monitoring of operational data across multiple sites also provides a data source for analysis leading to predictive maintenance and reduced downtime across the mobile robot fleet.
[0048] In some embodiments, the techniques described herein relate to a dispenser device, said dispenser device comprising: a cart storage compartment made of a size capable of storing a shopping cart and accessible from a procurement side and a pickup side; a temperature-controlled storage compartment located on said cart storage compartment and accessible from said procurement side and said pickup side; an access door on said pickup side; and an access control device configured to control access to said cart storage compartment and said temperature-controlled storage compartment through said access door.
[0049] In some embodiments, the techniques described herein relate to a product dispensing system, said product dispensing system comprises a plurality of dispenser devices—each dispenser device comprising a cart storage compartment, a temperature-controlled storage compartment, and an access door controlling access to said cart storage compartment and said temperature-controlled storage compartment from a pickup side—; and a central computer system comprising a control circuit—said to perform the operation of tracking the states of said dispenser devices based on communication with access control devices and / or sensor systems of said dispenser devices; and the operation of providing procurement commands based on the states of said dispenser devices.
[0050] In some embodiments, the techniques described herein relate to a method for distributing goods, said method for distributing goods comprising: receiving an order in a central computer system; associating the order with a goods dispenser in an order database, said goods dispenser comprising: a cart storage compartment made sized to accommodate a shopping cart and accessible from a procurement side and a pickup side; a temperature-controlled storage compartment located on said cart storage compartment and accessible from said procurement side and the pickup side; and an access control device configured to control access to said cart storage compartment and said temperature-controlled storage compartment through an access door on said pickup side; and unlocking said access door through said access control device in response to receiving an unlock request.
[0051] Those skilled in the art will recognize that various other modifications, changes, and combinations may be made in connection with the embodiments described above without departing from the scope of the invention, and that such modifications, changes, and combinations should be considered to be within the conceptual scope of the invention.
Claims
Claim 1 A structure verification system comprising: a structure having a plurality of sections configured to allow a mobile robot to move the structure; and a control circuit, wherein the control circuit is configured to perform the operation of receiving data from a sensor system of the mobile robot while the mobile robot moves through the sections of the structure; the operation of detecting a deviation associated with the sections by comparing the data captured by the sensor system with a design map of the structure; and the operation of updating the mobile robot based on the deviation, wherein the mobile robot is subsequently configured to drive on the structure based at least on the mapping file. Claim 2 A structure verification system according to claim 1, wherein the sensor system comprises an optical sensor, a radio frequency identification (RFID) sensor, a vibration sensor, an acoustic sensor, a tachometer, an odometer, a pressure sensor, a voltmeter, an accelerometer, a gyroscope, a magnetometer, a temperature sensor, a humidity sensor and / or an inertial measurement unit (IMU). Claim 3 A structure verification system according to claim 1, wherein the data includes one or more detected features associated with each capture location. Claim 4 In paragraph 3, the structure verification system, wherein the capture position is determined based on the distance traveled from a reference feature within the structure by the driving system of the mobile robot. Claim 5 A structure verification system according to claim 1, wherein the design map includes the locations of one or more features of the structure, and the one or more features include an optical marker, an RFID marker, a structure feature, a track connection, a track gap, a fastening element, a support element, and / or an electrical element. Claim 6 A structure verification system according to claim 1, wherein a deviation is detected based on detecting that each of the markers of the structure has encoded a unique 3D coordinate value corresponding to the position of the marker within the structure. Claim 7 A structure verification system according to claim 1, wherein the design map includes dimensions and feature location information from a computer-aided design (CAD) model that enables the structure to be assembled. Claim 8 A structure verification system according to claim 1, wherein the mapping file includes delta values representing changes to the design map, and the mobile robot is configured to control its movement based on the delta values and the design map. Claim 9 A structure verification system according to claim 1, wherein the control circuit is further configured to simulate sensor data of the mobile robot along the section based on the design map, and the deviation is detected based on comparing the data captured by the sensor system with the simulated sensor data. Claim 10 A structure verification system according to claim 1, wherein the control circuit is further configured to perform the operation of receiving additional data captured by a second sensor system of the second mobile robot while the second mobile robot moves through a section of the structure based on the mapping file; the operation of detecting additional deviations associated with the section by comparing the data captured by the second sensor system with a design map of the structure; and the operation of updating the mapping file based on the additional deviations. Claim 11 A structure verification system according to claim 1, wherein the mobile robot is configured to store a copy of the mapping file on a local memory storage device. Claim 12 A structure verification system according to claim 1, wherein the data is captured while the mobile robot is driving to a storage location of the structure to retrieve or store a storage totem. Claim 13 A structure verification system according to claim 1, wherein the mobile robot travels at a transfer speed for retrieving and returning storage totes and at a scanning speed slower than the transfer speed, and data from the sensor system is captured while the mobile robot is traveling at the scanning speed. Claim 14 A structure verification system according to claim 1, wherein the structure comprises a multi-layer structure and the section comprises a horizontal section, a vertical section, and / or a ramp. Claim 15 A structure verification system according to claim 1, wherein the mobile robot is configured to receive a destination identifier from a central computer system and autonomously move the structure toward a location associated with the destination identifier based on features and / or markers of the structure. Claim 16 A structure verification system according to claim 1, wherein the control circuit includes an onboard processor of the mobile robot. Claim 17 A structure verification system according to claim 1, wherein the control circuit comprises a central computer system configured to transmit commands to the mobile robot and update a mapping file stored on the mobile robot. Claim 18 A structure verification system according to claim 1, wherein the control circuit is further configured to determine whether the deviation exceeds a predetermined threshold and to generate a warning in response to the deviation exceeding the predetermined threshold. Claim 19 A structure verification system according to claim 1, wherein the mapping file is updated based on sensor data from a plurality of mobile robots. Claim 20 A method for mapping a storage and retrieval system, the method comprising: capturing data by a sensor system of a mobile robot while the mobile robot moves through a section of a structure; using a control circuit to compare the data captured by the sensor system with a design map of the structure to detect a deviation associated with the section; and using the control circuit to update a mapping file based on the deviation.