Automatic storage and retrieval systems and methods having staging, sequencing and buffer systems and methods

Abstract

Some embodiments provide automated order fulfillment systems comprising: mobile robots to transport containers each containing a product; a storage structure comprising storage locations to store the containers; a first workstation; a first buffer sequence structure positioned cooperated between the storage structure and the first workstation, the first buffer sequence structure comprising multiple buffer lanes comprising: a unidirectional buffer lane to which each of a first set of mobile robots transporting a container is directed and instructed to stop and wait without releasing the container before proceeding to the first workstation; a second buffer lane where each of a second set of mobile robots is directed to pass therethrough to the first workstation without stopping; and a unidirectional return lane to which at least one of the first and second sets of mobile robots is to enter after leaving the first workstation.

Description

AUTOMATIC STORAGE AND RETRIEVAL SYSTEMS AND METHODSHAVING STAGING, SEQUENCING AND BUFFER SYSTEMS AND METHODSCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application No. 63 / 626,974 filed January 30, 2024, which is incorporated herein by reference in its entirety.TECHN ICAL FI ELD

[0002] This invention relates generally to automated inventory storage and retrieval.BACKGROU N D

[0003] The management of inventory can be critical to the operation of many industries. Some industries use systems to move inventory. There is a need to improve the control and distribution of inventory.BRI EF DESCRI PTION OF DRAWI NGS

[0004] Disclosed herein are embodiments of systems, apparatuses and methods pertaining controlling systems in implementing inventory management. This description includes drawings, wherein:

[0005] FIG. 1 shows a perspective view of an exemplary order fulfillment facility showing a storage structure, according to some embodiments.

[0006] FIG. 2 illustrates a simplified side view of an exemplary buffer sequence structure cooperated between transit planes of a storage structure and a workstation, in accordance with some embodiments.

[0007] FIG. 3 illustrates a simplified perspective view of an exemplary buffer sequence structure cooperated between transit planes of a storage structure and a workstation, in accordance with some embodiments.

[0008] FIG. 4 illustrates a simplified block diagram, overhead view of a portion of order fulfillment facility with a storage structure cooperated with multiple buffer sequence structures, in accordance with some embodiments.

[0009] FIG. 5 illustrates a simplified block diagram, side view of an exemplary buffer sequence structure cooperated with a plurality of transit planes and a workstation, in accordance with some embodiments.

[0010] FIG. 6 illustrates a simplified block diagram, side view of an exemplary buffer sequence structure cooperated with a plurality of transit planes and a workstation, in accordance with some embodiments.

[0011] FIG. 7 illustrates a simplified block diagram, partial perspective view of exemplary buffer sequence structures cooperated with a plurality of exemplary transit planes and exemplary workstations implemented within an exemplary fulfillment facility, in accordance with some embodiments.

[0012] FIG. 8 illustrates a simplified flow diagram of an exemplary process of fulfilling product orders through an automated order fulfillment system, in accordance with some embodiments.

[0013] FIG. 9 illustrates a simplified flow diagram of an exemplary process of fulfilling product orders through an automated order fulfillment system, in accordance with some embodiments.

[0014] FIG. 10 illustrates a simplified flow diagram of an exemplary process of fulfilling product orders through an automated order fulfillment system, in accordance with some embodiments.

[0015] FIG. 11 illustrates a simplified flow diagram of an exemplary process of fulfilling product orders through an automated order fulfillment system, in accordance with some embodiments.

[0016] FIG. 12 illustrates a simplified flow diagram of an exemplary process of fulfilling product orders through an automated order fulfillment system, in accordance with some embodiments.

[0017] FIG. 13 illustrates a simplified flow diagram of an exemplary process of managing fulfillments, in accordance with some embodiments.

[0018] FIG. 14 illustrates an exemplary system for use in implementing methods, techniques, devices, apparatuses, systems, servers, sources and providing product order fulfillment, decanting, consolidation and inventory management, in accordance with some embodiments.

[0019] Elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions and / or relative positioning of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of various embodiments. Also, common but well-understood elements that are useful or necessary in a commercially feasible embodiment are often not depicted in order to facilitate a less obstructed view of these various embodiments. Certain actions and / or steps may be described or depicted in a particular order of occurrence while those skilled in the art will understand that such specificity with respect to sequence is not actually required. The terms and expressions used herein have the ordinary technical meaning as is accorded to such terms andexpressions by persons skilled in the technical field as set forth above except where different specific meanings have otherwise been set forth herein.DETAI LED DESCRIPTION

[0020] Embodiments of the present technology will now be described with reference to the figures, which in general relate to an automatic storage and retrieval system having staging and sequencing locations and further to an automatic storage and retrieval system having dedicated routing paths for mobile robots. The embodiments described enable simplifying software complexity, for example, by simplifying or limiting the need for traffic management. Further and as will be described, the embodiments are intended to enable efficient transport of mobile robots to and from storage locations with simplified sequence constraints, scheduling constraints and congestion points.

[0021] It is understood that the present embodiments may be embodied in many different forms and should not be construed as being limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete and will fully convey the invention to those skilled in the art. Indeed, the embodiments are intended to cover alternatives, modifications and equivalents of these embodiments, which are included within the scope and spirit of the invention as defined by the appended claims. Furthermore, in the following detailed description, specific details are set forth in order to provide an understanding of the present embodiments.

[0022] The terms "top" and "bottom," "upper" and "lower" and "vertical" and "horizontal" as may be used herein are by way of example and illustrative purposes only and are not meant to limit the description of the embodiments inasmuch as the referenced item can be exchanged in position and orientation. Also, as used herein, the terms "substantially" and / or "about" mean that the specified dimension or parameter may be varied within an acceptable manufacturing tolerance for a given application. In one non-limiting embodiment, the acceptable manufacturing tolerance is ± .25%.

[0023] For purposes of this disclosure, a connection may be a direct connection or an indirect connection (e.g., via one or more other parts). In some cases, when a first element is referred to as being connected, affixed or coupled to a second element, the first and second elements may be directly connected, affixed or coupled to each other or indirectly connected, affixed or coupled to each other. When a first element is referred to as being directly connected, affixed or coupled to a second element, then there are no intervening elements between the first and secondelements (other than possibly an adhesive or weld used to connect, affix or couple the first and second elements).

[0024] FIG. 1 shows a perspective view of an exemplary order fulfillment facility 100 showing a storage structure 102, according to some embodiments. The order fulfillment facility 100, in some embodiments, can include a number of bays 104 or racks of storage locations 106. The bays 104 can each include a y-z array of storage locations 106 arranged in horizontal rows at multiple levels 105, and one or more storage level changing structures 107, channels, passages, towers or the like vertically extending along the aisles 108. Mobile robots 130 (sometimes referred to as "bots" and drones) may travel between storage levels in the z-direction within the storage level changing structures 107 (e.g., unidirectional up level changing structures 107a, and unidirectional down level changing structure 107b). Typically multiple storage level changing structures 107 can be cooperated with one or more aisles 108 at the multiple different levels 105 enabling mobile robots 130 to self-propel vertically up (e.g., via a unidirectional up level changing structure 107a) and vertically down (e.g., via a unidirectional down level changing structure 107b) to move between levels 105 and / or transit planes 112, decks or the like. In some embodiments, pairs of bays 104 are arranged to face each other, separated by aisles 108, with storage locations 106 spaced along each side of the aisle 108 at each of the multiple levels 105. An aisle 108 may have a width such that a mobile robot 130 traveling within an aisle 108 may transfer containers to and from the storage locations 106 on either side of the aisle 108. In some embodiments, the storage structure 102 comprises a three dimensional array of the multiple different storage locations 106 each configured to receive one of the numerous different containers that are each configured to receive one or more items. The multiple storage locations 106 can each be positioned along one of the multiple different vertically spaced storage levels 105 accessible by the multiple mobile robots 130.

[0025] The storage structure 102, in some embodiments, includes one or more transit planes 112 or other such transport structure spaced apart at different vertical levels 105 of the storage structure 102. The transit planes 112 may be arranged individually or grouped (e.g., in pairs) and extend between the aisles 108, typically at a single level, so that robots 130 can maneuver horizontally in the x-y plane of each transit plane to travel between different aisles 108 typically at the same level. In some embodiments, one or more of the transit planes 112 or suitable supporting structure may also extend into the respective aisles to allow technicians to walk into an aisle 108 to service components within the aisle. In some embodiments, transit planes 112enable transit of mobile robots 130 between aisles and / or between aisles and workstations 115. One or more of the transit planes 112 may be designated as unidirectional (e.g., a first transit plane at a first level is unidirectional in a +x direction, while a second transit plane at a second level is unidirectional in a -x direction).

[0026] One or more of the workstations 115 are equipped to receive one or more mobile robots 130. For example, a first mobile robot at a workstation can carry one or more containers, such as a product container, in combination with successive mobile robots with items for fulfilling product requests to make up an order. A second mobile robot at the workstation may carry one or more other containers, such as an order container, in combination with successive mobile robots as required, within which one or more items from one or more of the product containers are placed to fulfill product requests to make up an order with one or more order containers. One or more workers and / or robotic picking systems at respective workstations 115 can transfer items from product containers to order containers. In some embodiments, the transfer is under the guidance of an inventory control system at the workstation 115. The containers can have substantially any relevant size and / or shape that can be retrieved and transported by at least one of the mobile robots and / or be used by a workstation.

[0027] The order fulfillment facility 100 further includes a number of mobile robots 130 that transfer one or more containers (e.g., one or more product totes, order totes, bags, sub-totes, etc.) to and from workstations 115 and storage locations 106. The mobile robots 130 may be self- guided and / or rail-guided so as to move vertically through the storage structure and horizontally within aisles 108 to position and transfer containers to and from storage locations 106. For example, a track system including horizontal rails may be affixed to the bays 104 at the vertical levels. The horizontal rails provide access to storage shelves on either side of an aisle 108 on a given level. The vertical level changing structures 107 enable the mobile robots to travel vertically in the z-direction between levels of storage structure.

[0028] In some embodiments, the storage structure 102 further includes one or more buffer sequence structures 150 each positioned between and cooperated with both the storage structure 102 and one or more workstations 115. The transit planes 112, aisles 108, buffer sequence structures 150 and workstations are cooperated to enable mobile robots 130 to traverse through the order fulfillment facility 100 between storage locations 106 and workstations 115 while a flow of the robots are controlled to improve throughput, reduce congestion, reduce mobile robot demand, and other such benefits. The mobile robots 130 canmaneuver in the x-y plane of each transit plane 112 allowing transition between different aisles 108 as well as transition between different workstations 115 through the buffer sequence structures 150. The fulfillment facility 100 further includes one or more control circuits 101 and / or robot routing control circuits that are in wireless communication via one or more wireless and / or wired distributed communication networks 103 (e.g., wireless local area network (LAN), wired LAN, wide area network (WAN), cellular network, Wi-Fi, Bluetooth, Ethernet, other such communication network, or a combination of two or more of such networks). The one or more control circuits 101 can comprise one or more buffer control processors and buffer control memory communicatively coupled with the one or more buffer control processors and storing executable code that when executed by the buffer control processor is configured to identify storage locations 106 of containers 204 and workstations 115 to receive the storage containers based on the one or more items within the containers to fulfill orders. Additionally, in some embodiments, the control circuits determine buffering of the mobile robots 130 through the buffer sequence structure 150 in controlling the flow of the mobile robots 130 to the respective workstations 115.

[0029] The control circuit 101, in some embodiments, can be configured to track movement of the containers 204 and / or mobile robots 130 (e.g., through one or more sensors of the mobile robots 130, the storage structure 102, buffer sequence structures 150, workstations, and or other such locations) to determine sequencing, buffering and / or routing of the containers 204 and / or mobile robots 130 between the storage locations 106 and the workstations 115 through the buffer sequence structures 150 in managing flow, congestion and improving an overall efficiency of the order fulfillment facility 100. A challenge in a discrete pick design is the sequenced, steady flow of items from any location in the fulfillment facility 100 to any workstation 115 and / or from the workstations to any location in the fulfillment facility 100 in providing a flow of items efficiently sequenced with steady flow to and from locations in the fulfillment facility 100. In some embodiments, the buffer sequence structure 150 provides lanes, passages, framing and the like that can be used to enhance routing of mobile robots in staging and sequencing of containers transported by the mobile robots to facilitate management of congestion, improve speed of product transport, improve speed of order fulfillment, reduce numbers of mobile robots, enhance workstation utilization, reduce delays, increase utilization of the storage structure, and other benefits.

[0030] Further details of the workstations, storage structure and mobile robots which may be used are described for example in the following U.S. patents and patent applications: U.S. Patent No. 9,139,363, entitled "Automated System For Transporting Payloads," issued September 22, 2015; U.S. Patent No. 10,435,241, entitled "Storage and Retrieval System," issued October 8, 2019; U.S. Patent No. 11,142,398, entitled "Order Fulfillment System," issued October 12, 2021; U.S. application publication No. 2023 / 0095494, entitled "Automatic Storage and Retrieval System having Staging and Sequencing Buffer Locations and Segregated Storage", published March 30, 2023 (Attorney Docket No. 8842-157747-US_8182US03), U.S. application publication No. 2022 / 0063910, entitled Order Fulfillment System, published March 3, 2022, and U.S. Application Serial No. 18 / 268,204, entitled "Methods and Apparatus for Facilitating Transport of Items Between a Store and a Customer via a Customer Access Portal" (Attorney Docket No. 8842- 156750-US_8154US01); where each of these patents and applications are incorporated herein by reference in their entirety.

[0031] FIG. 2 illustrates a simplified side view of an exemplary buffer sequence structure 150 cooperated between transit planes 112 of a storage structure 102 and a workstation 115, in accordance with some embodiments. FIG. 3 illustrates a simplified perspective view of an exemplary buffer sequence structure 150 cooperated between transit planes 112 of a storage structure 102 and a workstation 115, in accordance with some embodiments. FIG. 4 illustrates a simplified block diagram, overhead view of a portion of order fulfillment facility 100 with a storage structure 102 cooperated with multiple buffer sequence structures 150, in accordance with some embodiments. Referring to FIGS. 1-4, the buffer sequence structures 150 comprise multiple buffer lanes 202. These multiple buffer lanes provide paths for the mobile robots 130 to move between the transit planes 112 and the workstation while sequencing and / or buffering the mobile robots within the buff sequence structure 150. In some embodiments, the buffer lanes include one or more and typically a plurality of unidirectional inbound of feed buffer lanes 202a-202b for which the mobile robots travel toward the workstation 115, and one or more and typically a plurality of unidirectional buffer lanes that are used by the mobile robots 130 to transport containers 204 away from the workstation (sometimes referred to below as "outbound" buffer lanes), and toward a transit plane 112 and / or a storage location 106 within the storage structure 102, another workstation 115, and / or other location within the facility. The dimensions of the buffer lanes 202 can be dependent on one or more factors, such as but not limited to size of mobile robots, expected rate of order fulfillment, expected maximum the number of mobile robots to bebuffered within a buffer lane 202a, other such factors, or a combination of two or more of such factors. The buffering of containers 204 improves efficiency, removes wait constraints of fulfilling overlapping orders and dwell times between orders, enables leapfrogging and / or reprioritizing of task assignments when there is threshold productivity gain and / or simplification, improves fulfillment facility equipment productivity, reduces costs, improves capacity, and other such benefits.

[0032] The control circuit 101, in some embodiments, can utilize the buffer lanes to temporarily stop and store mobile robots 130 in buffering the containers 204 being transported by the mobile robots until an order for which a product within the container 204 is to be processes at the workstation 115. The buffering of the mobile robots, and the containers 204 that are carried by the mobile robots, allows the control of the transport and sequencing of containers 204 based on orders being fulfilled at a respective workstation. The efficiency of routing of containers can be improved, in part, by allowing containers to be retrieved and temporarily held until other containers containing products of an order are also ready to be released to a particular workstation. As such, in some embodiments, a first set of one or more mobile robots 130, each transporting a container 204, can be directed and instructed to stop and wait without releasing the respective container before proceeding to the intended workstation 115.

[0033] It is noted that some mobile robots 130 are directed to pass through the buffer sequence structure 150 while other mobile robots are directed to temporarily stop within one of the feed buffer lanes 202a while the one or more containers 204 being transported by the mobile robot are maintained on the mobile robot as the mobile robot waits within the buffer sequence structure until a time when the order for which the container 204 is being transported is at a predefined stage and / or location within an order fulfillment queue. Accordingly, in some embodiments, the buffer sequence structure 150 can maintain one or more inbound passthrough or bypass buffer lanes 202b where mobile robots do not stop and wait, and instead pass directly through the buffer sequence structure 150. Some embodiments provide one or more bypass buffer lanes 202b where each of a second set of mobile robots is directed to pass therethrough to the respective workstation 115 without stopping.

[0034] The buffer lanes, in some embodiments, can include one or more outbound return lanes 202c that can be dedicated for mobile robots 130 moving away from a workstation 115 and / or a workstation side 206 of the buffer sequence structure 150. The return lanes 202c may, in some instances, be dedicated unidirectional return lanes to which the at least one of the first set ofmobile robots and at least one of the second set of mobile robots is to enter after leaving the workstation and / or moving away the workstation side 206 of the buffer sequence structure. The one or more feed buffer lanes 202a can be vertically spaced from each other, vertically spaced from the one or more bypass buffer lanes 202b and vertically spaced from the return lanes 202c. Similarly, the one or more bypass lanes 202b can be vertically separated from each other and vertically spaced from the one or more return lanes 202c, while the one or more return lanes 202c can be vertically separated from each other.

[0035] In some embodiments, each of the buffer sequence structures 150 can further include one or more workstation side vertical changing structures 220-221 positioned between and cooperated with some or all of the multiple buffer lanes 202 and one or more workstations 115. The workstation side vertical changing structures 220-221 provide vertical paths enabling the mobile robots 130 to self-propel vertically to or from a workstation 115. In some embodiments, the buffer sequence structure 150 includes one or more feed workstation side vertical changing structures 220 used by mobile robots moving toward the one or more workstations 115 feeding containers 204 to the one or more workstations, and one or more workstation side return vertical changing structures 221 providing a path for the mobile robots 130 moving away from the one or more workstations 115.

[0036] In some embodiments, one or more of the feed workstation side vertical changing structures 220 can be configured and / or used as a unidirectional down feed workstation side vertical changing structures 220 that restricts vertical movement in a unidirectional downward direction. Similarly, in some embodiments, one or more of the workstation side return vertical changing structures 221 can be configured and / or used as a unidirectional up workstation side return vertical changing structures 221 that can restrict vertical movement to an up direction. In other embodiments, however, one or more of the vertical workstation side vertical changing structures 220-221 or a portion of one of the vertical workstation side vertical changing structures 220-221 may allow bidirectional travel, or split with a portion enabling only down movement and another portion enabling only an up movement. The feed workstation side vertical changing structure 220 provides a feed path from the buffer lanes to the workstation. The mobile robots 130 moving through the buffer sequence structure 150 and toward a workstation 115, whether buffered to wait within one of the feed buffer lanes 202a or passing through via one of the bypass buffer lanes 202b, can exit the respective buffer lane, engage the feed workstation side vertical changing structure 220 and vertically propel itself toward the workstation 115 consistent with anintended fulfillment sequence and / or queue. The feed workstation side vertical level changing structure 220 can be cooperated with at least one and typically all of the buffer lanes 202a and at least one and typically all of the bypass lanes 202b. Further, the feed workstation side vertical level changing structure 220 cooperates with one or more workstations 115, and provides at least part of a feed path between the buffer sequence structure 150 and one or more workstations 115. The feed vertical level changing structures 220, in some embodiments, enable the mobile robots 130 to self-propel themselves vertically down and / or up to a level corresponding with an input workstation feed level 240 of an assigned workstation 115. Tracks, rails, decks and / or other such structures can couple the buffer lanes 202a and bypass lanes 202b with the feed workstation side vertical level changing structure 220, and / or the feed vertical level changing structure 220 with one or all of the workstation feed level 240 and / or exit levels 242 enabling mobile robots to transition from the buffer lanes and bypass lanes to the feed workstation side vertical level changing structure 220 and to the assigned workstation 115.

[0037] Similarly, the workstation side return vertical level changing structure 221 can be cooperated with one or more workstations 115 and at least one, and typically all, of the more return lanes 202c providing at least part of a return path between a workstation 115 and the return lanes 202c. The return vertical level changing structures 221, in some embodiments, enable the mobile robots 130 to self-propel themselves vertically up and / or down to a level corresponding to one of the return lanes 202c. Tracks, rails, decks and / or other such structures can couple the return vertical level changing structure 221 with the workstation exit levels 242 and one or more return lanes 202c enabling mobile robots to transition from the return vertical level changing structure 221 to the assigned return lane 202c. The control circuit 101, in some embodiments communicates routing of the mobile robots to a respective one of the return lanes 202c based on an intended destination of the container 204 and / or products being transported by the respective mobile robot 130. In some embodiments, for example, the control circuit 101 identifies a particular storage location within the storage structure where a container 204 is to be returned and a level 105 at which that return storage location is positioned. Based on the level 105 of the particular storage location, the control circuit 101 may identify a respective one of the return lanes 202c that is vertically closest to the level 105 of the particular storage location and direct the mobile robot to self-propel vertically from the workstation 115 to the identified return lane 202c to move through the buffer sequence structure 150 in route to the particular storage location into which the container 204 being transported by the mobile robot is returned.Additionally or alternatively, the control circuit 101 may select a return lane 202c based on congestion within the storage structure, the one or more transit planes and / or other potential congestion areas. For example, the control circuit may identify an initial transit plane 112 within a vertical threshold of a level 105 of the storage structure 102 where a container is to be returned, but select a different transit plane and an alternate route based on congestion approaching and / or on the initial transit plane and / or other issues associated with an initial route that would utilize the initial transit plane.

[0038] In some embodiments, one or more or all of the buffer return lanes 202c are vertically positioned to vertically align with a respective one of the transit planes 112 enabling mobile robots 130 to pass directly through the buffer sequence structure 150, via a respective one of the return lanes 202c, without stopping and move horizontally directly out from the buffer sequence structure 150 onto a respective one of the transit planes 112 at an intended level. This allows the mobile robots 130 to then transition laterally on the transit plane along the storage structure 102 to an intended aisle 108. As introduced above, the storage structure 102, in some embodiments, can include one or more storage level changing structures 107. The mobile robots can move from the transit plane 112 to engage a storage level changing structure 107 at an intended aisle 108, vertically self-propel itself to climb up or down to an intended level 105 consistent with a storage location to which the mobile robot 130 is directed.

[0039] The mobile robots 130 are configured to autonomously move through the storage structure 102, buffer sequence structure 150, workstations 115 and / or other parts of the order fulfillment facility 100. The one or more control circuits 101 and / or one or more routing control circuits or systems can communicate with the mobile roots 130 to provide routing instructions to the one or more mobile robots 130 that are implemented by the mobile robots 130 in coordinating the movement of the mobile robots to provide intended sequences of robots to a particular workstation 115 based on respective orders so that items contained within containers 204 are sequentially arrive at the workstation 115 to fulfill at least part of an order that is assigned to the respective workstation. For example, when an order to be fulfilled includes four different items, and those four different items are retained within four different containers 204, the control circuit 101 can direct four different mobile robots 130 to four different storage locations 106 within the storage structure 102 to each retrieve one of the four containers. These four mobile robots can then move to a first buffer sequence structure 150 of the multiple buffer sequence structures based on the single workstation 115 that is to collect the four different items of theorder. Because the containers are at different storage locations, it is common for the mobile robots 130 to arrive at the buffer sequence structure 150 at different times. Taking advantage of the buffering, the three mobile robots 130 arriving first at the buffer sequence structure 150 can be directed to one or more of the feed buffer lanes 202a to stop and wait until all four mobile robots assigned to the order are at the buffer sequence structure (and the order has reached a threshold position within an order fulfillment queue and / or buffer queue), and then release the four mobile robots from the buffer sequence structure such that the four mobile robots reach the assigned workstation 115 sequentially enabling the four items of the order to be sequentially retrieved one after the other as the four mobile robots 130 sequentially move into and through the assigned workstation 115. The release of the four mobile robots, in some embodiments, can include directing the last to arrive mobile robot to a bypass buffer lane 202b such that the last arriving mobile robot is not buffered and instead merely passes through the bypass buffer lane. In other embodiments, the last arriving mobile robot associated with an order may additionally be directed to a feed buffer lane 202a to stop and wait until the order reaches the threshold position within the order fulfillment queue.

[0040] The workstations 115 provide access to the interior of the containers 204. In some embodiments, a worker 302 and / or one or more automated picking systems (e.g., articulated arm or other such systems) can retrieve one or more items from a container positioned within an access bay or opening of the workstation. In some embodiments, one or more of the workstations comprise multiple access bays 304a-304b. Workstations and multi-access bay workstations can be implemented similarto those described in U.S. Patent Nos. 9,139,363; 10,435,241; 11,142,398; U.S. application publication No. 2023 / 0095494; and U.S. Provisional Application Serial No. 63 / 626,967, (Attorney Docket No. 8842-157459-USPR_8291US01) and entitled RETAIL FULFILLMENT DISPENSE AND DECANT SYSTEMS AND METHODS, each of which is incorporated herein by reference in its entirety. Further, in some embodiments, the workstation can be a multilevel workstation with one or more workstation feed levels 240, and one or more workstation exit levels 242. Further the workstations, in some embodiments, include workstation vertical changing structures or channels that are engaged and used by the mobile robots to advance vertically to position the respective container at the access bay, move down away from the access bay to vertically align with one of the one or more workstation exit levels 242, and advance out of the workstation 115. One non-limiting example, workstations in some embodiments includes a single workstation feed level 240 and single workstation exit level 242 (e.g., see FIG. 2). As another non-limiting example, a workstation may include three workstation feed levels 240 and one workstation exit level 242 (e.g., see FIGS. 3-5).

[0041] FIG. 5 illustrates a simplified block diagram, side view of an exemplary buffer sequence structure 150 cooperated with a plurality of transit planes 112 and a workstation 115, in accordance with some embodiments. In managing and controlling container flow through the fulfillment facility, the control circuit 101 can be configured in some embodiments to identify, for example, a first set of containers 204 each containing an item are associated with a first fulfillment order, and further identify and / or assign a first set of mobile robots to retrieve each of the first set of containers. Instructions can be communicated to each of the mobile robots of the first set of mobile robots with a respective location within the fulfillment facility and enabling the mobile robots to autonomously route through the storage facility and / or storage structure 102 to retrieve a respective container of the first set of containers 204. In some embodiments, the control circuit 101 can further identify that a first mobile robot 130a, of a first set of mobile robots, is associated with the first fulfillment order and is arriving at the buffer sequence structure 150 prior to one or more other mobile robots of the first set of mobile robots and issue commands to the first mobile robot to buffer itself within the buffer sequence structure 150. This buffering command, in some embodiments, can direct the first mobile robot to a first buffer lane 202a_l and cause the first mobile robot to stop within the first buffer lane 202a_l while retaining the respective container and wait while one or more other mobile robots of the first set of mobile robots are in position to be routed to a workstation. Similarly, in some embodiments, the control circuit 101 can identify that a second mobile robot 130b of the first set of mobile robots is transporting a second container associated with the first fulfillment order and that the first mobile robot 130a is buffered (and / or is to route to the buffer sequence structure and buffer itself) in the first buffer lane 202a_l while retaining a first container. Based on the first mobile robot 130a being associated with the first fulfillment order and being buffered in the first buffer lane 202a_l, the control circuit 101 can in some implementations direct the second mobile robot 130b to the first buffer lane 202a_l while the first mobile robot is waiting in the first buffer lane 202a_l, and cause the second mobile robot to wait in the first buffer lane 202a_l behind the first mobile robot while retaining the second container on the second mobile robot without releasing the second container. This can align the second mobile robot 130b (and the second container) with the first mobile robot 130a (and the first container) while awaiting one or more other mobile robots and / or the first fulfillment order to be ready to process at an assigned workstation.

[0042] The control circuit 101, in some embodiments, can further be configured to direct both the first mobile robot 130a and the second mobile robot 130b to depart the first buffer lane 202a_l and continue to an assigned first workstation 115 following a buffer period of time during which at least the first mobile robot waited on the first buffer lane. The buffer period of time can be dependent on one or more factors, such as but not limited to the duration of time for the remaining one or more mobile robots of the first set of mobile robots to be in position within the facility, the expected time to move through the facility and / or buffer sequence structure, the order fulfillment queue of one or more other fulfillment orders to be processed at the first workstation prior to the first fulfillment order, the number of containers and mobile robots associated with the fulfillment order earlier in the order fulfillment queue, and expected rate of processing each of the containers at the first workstation 115, other such factors, or a combination of two or more of such factors.

[0043] As another example, the control circuit 101 can, in some embodiments, be further configured to identify that a third mobile robot 130c and / or third container being transported by the third mobile robot is associated with a second fulfillment order that is different than the first fulfillment order and to be fulfilled by a workstation 115 cooperated with the buffer sequence structure 150. Based on the order fulfillment queue, the control circuit 101 can direct, while the first mobile robot 130a is waiting on the first buffer lane 202a_l and based on the third mobile robot 130c being associated with the different second fulfillment order, the third mobile robot 130c to a second buffer lane 202a_2, different than the first buffer lane, and cause the third mobile robot 130c to wait in the second buffer lane 202a_2 while retaining the third container on the third mobile robot without releasing the third container.

[0044] As introduced above, in some instances, a mobile robot may be directed to a bypass buffer lane 202b to pass directly through the buffer sequence structure without stopping to wait for a buffer period of time. Still referring to FIG. 4, in some embodiments, the control circuit 101 can identify that a fourth mobile robot 130d and / or fourth container being transported by the fourth mobile robot is associated with a fourth fulfillment order to be fulfilled by a workstation 115 cooperated with the buffer sequence structure 150. Based on the order fulfillment queue, the control circuit 101 can direct, while the first mobile robot 130a is waiting on the first buffer lane 202a_l and based on the fourth mobile robot 130d being associated with the different fourth fulfillment order, the fourth mobile robot 130d to a first bypass buffer lane 202b_l, different than the first and second buffer lanes, and cause the fourth mobile robot 130d to pass directly throughthe buffer sequence structure 150 while retaining the fourth container and advance directly to the workstation 115 and / or be positioned in a workstation queue of one or more other mobile robots leading to the workstation to enter and be processed at the workstation 115.

[0045] The buffer sequence structure 150 can further optimize movement of containers by limiting the distance traveled by the containers. For example, in some instances, the control circuit 101 can identify that a container already at the buffer sequence structure and / or the workstation includes an item that can be used to satisfy at least part of an order that is to be subsequently fulfilled. As such, that control circuit can avoid having the container returned to the storage structure 102 and instead be rerouted back into one of the buffer sequence structures 150 associated with a workstation 115 intended to fulfill the subsequent order. As such, the travel of the container can significantly be reduced, while reducing the time to implement the fulfillment, reduce congestion and other such benefits.

[0046] FIG. 6 illustrates a simplified block diagram, side view of an exemplary buffer sequence structure 150 cooperated with a plurality of transit planes 112 and a workstation 115, in accordance with some embodiments. As introduced above, the buffer sequence structure 150, in some embodiments, includes one or more feed side vertical level changing structures 230 on a storage structures side 208 of the buffer storage structure. The one or more feed side vertical level changing structures 230 can be used to vertically move mobile robots into and align with the different buffer lanes. It is noted that in some embodiments, the buffer sequence structure is configured with a single feed side vertical level changing structure 230 positioned between the storage structure and the multiple buffer lanes 202, which can in part reduce the area or footprint of the buffer sequence structure. Further, the flow of mobile robots 130 within a feed side vertical level changing structure 230 may be restricted such that the feed side vertical level changing structure allows a unidirectional flow of mobile robots (e.g., vertically up). The control circuit 101 can be configured to identify that a fifth container 204e, transported by a fifth mobile robot 130e, leaving a first workstation 115, is holding a first item or product that is identified in a fifth fulfillment order to be subsequently fulfilled, and identify that the fifth fulfillment order is to be fulfilled by the first workstation. Based on the order fulfillment queue and / or predicted timing of fulfilling the fifth fulfillment order, the control circuit can further identify that the fifth mobile robot 130e can be used to satisfy at least part of the fifth fulfillment order, and be rerouted the fifth mobile robot 130e to the buffer sequence structure 150 without having the fifth container 204e returned to the storage structure 102. A return instruction can be communicated to the fifthmobile robot 130e to cause the fifth mobile robot 130 to proceed to a first return lane 202c_l and travel through the buffer sequence structure to access the feed side vertical level changing structure 230. The fifth mobile robot 130e can use the feed side vertical level changing structure 230 to self-propel and advance vertically to a third buffer lane 202a_3 of the multiple buffer lanes (or a bypass lane depending on the order fulfillment queue), without the fifth mobile robot 130e returning to the storage structure 102, in routing the fifth mobile robot 130e to the workstation 115 in fulfilling the fifth fulfillment order.

[0047] Referring back to FIG. 1, as described above, the fulfillment facility 100 can include multiple buffer sequence structures 150 each cooperated with one or more workstations 115. Further, the buffer sequence structures are typically each cooperated with one or more transit planes 112 enabling mobile robots to move laterally (e.g., in x-axis and y-axis directions) to an assigned buffer sequence structure 150, workstation 115 and / or aisle 108 of the storage structure 102. The one or more transit planes can, in some implementations, be positioned between the storage structure 102 and one or more feed side vertical level changing structures 230 that are each cooperated with one of the buffer sequence structures 150. Some embodiments further improve efficiency, reduce travel, reduce congestion and / or other such benefits in routing containers between buffer sequence structures 150 and workstations 115 without having to return a container to the storage structure 102. The buffer sequence structures 150 enable one or more mobile robots 130 to temporarily buffered in preparation for fulfillment of an order in accordance with an order fulfillment queue of a particular workstation 115. Separate order fulfillment queues are typically maintained for each workstation 115 and / or buffer sequence structure 150.

[0048] FIG. 7 illustrates a simplified block diagram, partial perspective view of exemplary buffer sequence structures 150a-150c cooperated with a plurality of exemplary transit planes 112a-112d and exemplary workstations 115a-115c (shown as transparent) implemented within an exemplary fulfillment facility 100, in accordance with some embodiments. The work each cooperated with one of the buffer sequence structures 150a-150c. One or more transit planes 112a-112d or transit planes can extend laterally (e.g., in an x-axis and y-axis) to provide a horizontal planner surface over which mobile robots 130 can transit between the storage structure 102 (not shown in FIG. 7) and one or more of the buffer sequence structures 150a-150c. Further, in some embodiments, the one or more transit planes 112a-112d can extend laterally to cooperate with two or more or all of the buffer sequence structures 150a-150c providing a lateral path for the mobile robotsbetween two or more of the buffer sequence structures 150a-150c and / or the storage structure 102. Further, in some embodiments, the transit planes 112a-112d can be positioned between the storage structure 102 (not shown in FIG. 7) and a respective feed side vertical level changing structure 230 of the first buffer sequence structure. As described above, in some embodiments, the control circuit 101 can direct the routing of one or more mobile robots to reduce traffic flow, improve fulfillment efficiency, reduce congestion, and / or other such benefits by in part reducing the transport of containers 204 back to the storage structure.

[0049] Referring to at least FIGS. 1-2 and 7, the control circuit 101, in some embodiments, can be configured to identify that a container 204, transported by a mobile robot 130 that is leaving the first workstation 115a, is holding a product and that the product is identified in a second fulfillment order to be subsequently fulfilled. In some instances, the control circuit can further identify that the second fulfillment order is to be fulfilled by a second workstation 115c that is different than the first workstation 115a. An order fulfillment queue corresponding to the second workstation 115c can be evaluated. This queue evaluation can include a determination an expected timing of fulfillment of the second fulfillment order, a comparison of expected timing of fulfillment relative to one or more timing thresholds (e.g., buffer wait threshold, order fulfillment duration threshold, etc.), number of orders in the order fulfillment queue, expected and / or estimated duration to fulfill the one or more orders of the order fulfillment queue, congestion levels, mobile robot buffer positions within the buffer sequence structure, number of open buffer lanes, number of open mobile robot buffer positions unoccupied, other such factors or a combination of two or more of such factors.

[0050] The control circuit 101 can communicate a return instruction to the mobile robot 130 causing the mobile robot to exit the workstation 115a, engage a unidirectional workstation side return vertical changing structure 221, vertically propel itself and proceed to a return lane 202c- 1 (e.g., assigned by the control circuit or a default return lane) to access one of the transit planes (e.g., a second transit plane 112b). In some instances, the selected return lane 202c_l can vertically align with the assigned second transit plane 112b. The return instructions can further include directing the mobile robot 130 to travel along the second transit plane 112b to the second buffer sequence structure 150c cooperated with the second transit plane 112b and a second workstation 115c without the mobile robot 130 returning to the storage structure 102. Still further, the control circuit may direct the mobile robot to a particular buffer lane (e.g., buffer lane 202a_l) to temporarily stop and wait while retaining the container, or to a bypass buffer lane of 1the second buffer sequence structure when the second order is to be fulfilled and the mobile robot is not to wait. Again, this direct routing of the mobile robots between workstations directly to the same or a different buffer sequence structure 150 can improve efficiency, reduce fulfillment times, improve the utilization of mobile robots, reduce mobile robot demand, reduce congestion and / or other such benefits. In some embodiments, one or more catwalks within the storage structure can be positioned at levels 105 that align with the transit planes 112.

[0051] In some embodiments, one or more of the return lanes 202c can be unidirectional return lanes where the control circuit restricts movement of mobile robots to a direction toward the transit planes 112 and away from the workstation side 206 of the buffer sequence structure 150. Further, in some embodiments, the return lanes 202c can be vertically positioned to vertically align with one of the transit planes 112 provides direct horizontal paths through the buffer sequence structure 150 to the transit planes. The return lane 202c selected for a particular mobile robot 130 can be dependent on one or more factors, such as but not limited to an intended next destination for the container 204 being transported by a mobile robot (e.g., a storage location 106, a buffer lane in the same or a different buffer sequence structure, a decant station, other stations and / or other locations of the fulfillment facility), congestion, something blocking a potential route, a location of a subsequent container to be transported by the mobile robot, other such factors, or a combination of two or more of such factors. In some embodiments, for example, the control circuit 101, in determining a route of a first mobile robot that is to move away from a workstation, can be configured to identify a storage location 106 within the storage structure 102 where a subsequent container is positioned and is to be retrieved by the first mobile robot 130 of the multiple mobile robots. Based on the location of the subsequent container to be retrieved, the control circuit can be configured, in some embodiments, to identify a storage level 105, within the storage structure 102, in which the subsequent container is located. The control circuit can identify a first return lane 202c, of the multiple return lanes, that is a closest in a vertical orientation to the identified storage level 105, and communicate a first return instruction, of the return instructions, to route the first mobile robot to the first return lane 202c based on the first return lane being the closest in the vertical orientation of the identified storage level. Further, in some embodiments, one or more mobile robots 130 can be stopped and buffered in one or more return lanes 202c to await movement out onto the transit planes 112 (e.g., await an opening in a flow of mobile robots moving along a particular transit plane), await routing, wait due to congestion, other such factors, or a combination of two or more of such factors.

[0052] Utilizing the return instructions and intended route, the first mobile robot upon exiting the workstation can, in some embodiments, move to return workstation side return vertical changing structures 221 and self-propel to a level aligned with the first return lane 202c and advance along the first return lane and through the buffer sequence structure 150. In some instances, the route may direct the first mobile robot to use the feed side vertical level changing structures 230 to move vertically up or down to an intended transit plane 112. In other instances, however, the route may continue horizontally from the assigned return lane 202c directly to the transit plane 112 that is vertically aligned with the assigned return lane. When the first mobile robot is at the level of the assigned transit plane, whether moving directly from the assigned return lane 202c or after vertically moving through the feed side vertical level changing structures 230, the first mobile robot can advance onto the assigned transit plane 112 and continue along the intended route, whether across or laterally before moving across to the storage structure 102. In some embodiments, the first mobile robot may engage a storage level changing structure 107 on the storage structure side 310 of the transit planes 112, and vertically self-propel to an intended level 105 within the storage structure. The mobile robot can then advance from the storage level changing structure 107 horizontally along the aisle to the intended storage location 106 where the first container being transported by the first mobile robot can be moved from the mobile robot into the intended storage location. The first mobile robot can then be routed to perform another task, such as but not limited to retrieving another container 204, retrieve an empty order container or tote, move to a decant station, and / or other such actions.

[0053] The control circuit 101, in some embodiments, can further manage order fulfillment based on priorities of received orders. The priorities can be defined based on one or more factors, such as but not limited to time an order is received, the one or more items requested in the order, expected duration to fulfill the order, availability of items requested, one or more locations within the storage structure 102 of respective one or more items in an order, number of mobile robots 130, number of available mobile robots 130, occupancy of one or more buffer sequence structures 150 (e.g., the number of mobile robots buffered and waiting in one or more buffer lanes 202a and / or number of open spaces within one or more buffer lanes of one or more buffer sequence structures available to receive mobile robots), number of empty buffer lanes 202a within one or more buffer sequence structures, number of workstations in operation and / or expected to be in operation in a predicted future period of time, a customer or entity submitting the order, a customer level associated with the customer submitting the order, whether a requestfor a higher priority was submitted with an order (e.g., based on payment, utilization of points or other rewards, coupon, etc.), other such factors, or a combination of two or more factors. Further, the control circuit 101 may modify over time the priorities of orders based on one or more of the above factors, changes to the one or more above factors and / or other factors (e.g., changes in location of items based on other orders, congestion, need to induct additional items into the storage structure, etc.).

[0054] In some embodiments, the control circuit 101 can be configured to identify that a first container 204, transported by a first mobile robot of a first set of mobile robots, is buffered and waiting in a first buffer lane 202a of a first buffer sequence structure 150, and that the first container is holding multiple of a first product with at least one of the multiple first products being routed to a first workstation to satisfy a first fulfillment order. The control circuit can further identify that a second fulfillment order is pending and / or queued within an order fulfillment queue of fulfillment orders to be fulfilled subsequent to fulfillment of the first fulfillment order, and that the second fulfillment order includes at least one of the first product. In some embodiments, based at least in part on the first mobile robot already being present at the first buffer sequence structure 150 and transporting the first product, the control circuit can be configured to reprioritize the second fulfillment order to adjust a position within the queue of fulfillment orders. This reprioritization may enable the routing of the first mobile robot so that the first container is not returned to the storage structure and instead is re-buffered into one of the one or more buffer storage structures associated with an intended workstation assigned to fulfill the second fulfillment order. Similarly, the control circuit, based on the reprioritization of the second order, can direct one or more additional mobile robots to retrieve one or more other containers 204 from respective one or more storage locations 106 and / or other workstations, other buffer sequence structures and / or other areas of the fulfillment facility in directing the different containers to the fulfilling workstation, when other containers are needed, in order to complete the fulfillment of the second order consistent with the reprioritization.

[0055] In some embodiments, a mobile robot and / or the control circuit 101 can route the mobile robot in order to induce recharging of power storage systems of the mobile robot. Some or all of the mobile robots include rechargeable power storage systems which can include rechargeable batteries, capacitors, supercapacitors, ultracapacitors and / or other such rechargeable storage. Some or all of the vertical changing structures comprise charging rails that can be engaged by the recharging systems of the mobile robots 130 to draw power from and recharge the rechargeablepower storage system (e.g., batteries, super-capacitors, etc.) while ascending and / or descending. The mobile robots and / or the control circuit and / or the mobile robot control circuits of the mobile robots themselves can direct mobile robots to vertical changing structures when power storage is less than a threshold to enable recharging. For example, in some embodiments, the feed side vertical level changing structure 230, the feed workstation side vertical changing structure 220, and / or other vertical changing structures can include charging rails. The control circuit 101 and / or a mobile robot control circuit can be configured to detect that a first mobile robot 130 has a charge level that has a predefined relationship with a charge threshold, and direct the first mobile robot to a bypass lane 202b of a buffer sequence structure 150 to pass through the bypass buffer lane and enter the feed workstation side vertical changing structure 220 and engage a first charge rail of the feed workstation side vertical changing structure 220 while simultaneously recharging the first mobile robot. In some embodiments, the first mobile robot can be directed to vertically move along the workstation side vertical changing structure to a vertical level corresponding with a return lane 202c, and direct the first mobile robot to enter and pass through the return lane 202c to engage the feed side vertical level changing structure 230, and advance vertically through the feed side vertical level changing structure while engaging a second charge rail of the feed side vertical level changing structure further recharging the first mobile robot, until the first mobile robot is vertically aligned with the same or a different buffer lane 202a or bypass buffer lane 202b depending on a position of a corresponding order within the order fulfillment queue with which the first mobile robot is associated. This recharge loop can be implemented without the first mobile robot returning to the storage structure in routing the first mobile robot to the first workstation in fulfilling the corresponding fulfillment order.

[0056] Some embodiments utilize the different buffer lanes 202 in organizing different products of a single fulfillment order. The control circuit 101, in some embodiments, can identify that a first mobile robot, of a first set of mobile robots intended for fulfilling first fulfillment order, is transporting a first product, within a first container, that is associated with a first product grouping, and identify that a second mobile robot of the first set of mobile robots is transporting a container carrying a second product that is associated with a second product grouping that is different than the first product grouping. The control circuit can be configured to direct, while the first mobile robot is buffered and waiting in a first buffer lane and based on the second product being associated with the different second product grouping, the second mobile robot to a second buffer lane and cause the second mobile robot to stop and wait in the second buffer lane whileretaining the second container without releasing the second container. For example, different products may be associated with different product groups (e.g., some products may not be combined with other products (e.g., chemical products with edible products), frozen products, warm products, etc.), and the control circuit can organize the mobile robots within different buffer lanes 202a of a buffer sequence structure 150 in part based on the different groups.

[0057] In some embodiments, one or more mobile robots 130 may transport order containers to the workstation to receive one or more products retrieved from other containers transported to the workstation in compiling products to fulfill an order. Multiple product containers, transported by multiple different mobile robots, can pass through the workstation while a single order container transported by a separate mobile robot can be maintained at the workstation while different items from the multiple product containers are retrieved and placed into the order container. For example, when the workstation includes multiple access bays 304a-304b, an order container may be positioned at a first access bay and maintained at the first access bay while multiple different mobile robots move respective different product containers into alignment with a second access bay exposing the interior of the different product containers enabling a worker or picking system to retrieve one or more items of an order from the product container and be placed into the order container maintained at the first access bay. The control circuit, in some embodiments can the control circuit be configured to direct each of a set of mobile robots, which are transporting order containers scheduled to receive items at a workstation 115 in fulfilling different respective orders, to one of a set of buffer lanes of the multiple buffer lanes in queuing the order containers, and cause each of the set of mobile robots to access the workstation from the set of buffer lanes to position the respective order containers with an access bay of the workstation 115. For example, in some embodiments, a set of one or more lowest oriented inbound or feed buffer lanes of a buffer sequence structure may be used as order container buffer lanes to queue one or more mobile robots transporting order containers to the workstation. Such order container assigned mobile robots may, in some embodiments, can exit the workstation similar to that of the other mobile robots while being routed to one of the return lanes 202c in route to moving the order containers to an order pickup location within the fulfillment facility 100, to a storage location 106 to await subsequent pickup and / or other location within the fulfillment facility. In other embodiments, the order container assigned mobile robots may be routed to a predefined return lane 202c intended for mobile robots transporting order containers in routing those mobile robots to one or more predefined locations for order totes.

[0058] In some embodiments, the buffer sequence structures 150 can be constructed to streamline container movement and reduce congestion by buffering the mobile robots 130 while the containers 204 are maintained on the mobile robots. As such, the mobile robots do not have to release the container it is carrying into a staging location. Based on the rate of movement of containers 204, it has been discovered that the buffer duration is typically relatively short. The time to release a container 204 from a mobile robot 130 into a staging location and a subsequent time of a mobile robot to then retrieve that container from the staging location often results in additional delays and / or waisted time, can often result in the use of more mobile robots, can increase the complexity of the routing of the multiple mobile robots and other such factors. By keeping the containers 204 on the mobile robots 130 as the mobile robots are buffered in buffer lanes 202a the routing can be greatly simplified, while still achieving the intended buffering and staging to improve and streamline order fulfillment. Still further, the cost of construction of the buffer sequence structure 150 can be reduced because the buffer sequence structure does not have the additional structure of the additional staging locations, and the buffer sequence structure 150 can have a significantly reduced floor area footprint than other systems that include container staging areas. The buffer sequence structures 150 can constructed with a width that is approximately the width of the mobile robots 130 while carrying the containers 204. The buffer sequence structures do not have to include the additional width of the staging locations to receive containers 204. Further, the buffer sequence structures 150 enable staging and sequencing of containers in collecting product containers of given fulfillment orders and releasing groups of those buffered respective mobile robots transporting those containers to a workstation as a given group of containers making up a given order. The staging and sequence provide buffering that can, in part, ease the criticality of and simplifies product container arrival and queueing.

[0059] FIG. 8 illustrates a simplified flow diagram of an exemplary process 800 of fulfilling product orders through an automated order fulfillment system, in accordance with some embodiments. In step 802, mobile robots 130 are directed to each transport at least one container 204 that each contain one or more products through the storage structure 102 and / or the order fulfillment facility 100 accessible by the mobile robots. In step 804, each of a first set of one or more mobile robots transporting a container are directed to a first buffer lane 202a of a first buffer sequence structure 150 positioned between and cooperated with both the storage structure 102 and at least a first workstation 115. The first buffer sequence structure 150 can comprises multiple buffer lanes, in routing the respective containers 204 to the first workstation.

[0060] In step 806, each of the first set of mobile robots 130 can be instructed to stop and wait in the first buffer lane 202a without releasing the respective container 204 before proceeding to the first workstation 115. In step 808, each of a second set of one or more mobile robots, of the multiple robots, can be directed to a second buffer lane (e.g., a bypass lane 202b) to pass therethrough to the first workstation 115 without stopping in the second bypass buffer lane 202b. In step 810, at least one of the first set of mobile robots 130 and at least one of the second set of mobile robots 130 can be directed to a return lane 202c after leaving the first workstation 115. In some embodiments, the first buffer lane 202a is vertically spaced from the second buffer lane 202b and the return lane 202c, and the second buffer lane 202b is vertically spaced from the return lane 202c. In directing the at least one of the first set of mobile robots and the at least one of the second set of mobile robots to the return lane, some embodiments direct the at least one of the first set of mobile robots and the at least one of the second set of mobile robots to selfpropel along at least a portion of a workstation side return vertical level changing structure 221 positioned between and cooperated with the first workstation and the return lane providing a vertical return path between the first workstation and the return lane 202c.

[0061] FIG. 9 illustrates a simplified flow diagram of an exemplary process 900 of fulfilling product orders through an automated order fulfillment system, in accordance with some embodiments. In step 902, a first mobile robot of a set of one or more mobile robots can be directed to a first buffer lane 202a_l of a first buffer sequence structure 150. In step 904, the first mobile robot can be instructed to stop and wait in the first buffer lane. In step 906, it can be identified that the first mobile robot 130, of the first set of mobile robots, is associated with a first fulfillment order and is buffered and waiting in the first buffer lane 202a_l while retaining a first container 204. In step 908, it can be identified that a second mobile robot 130 is associated with the first fulfillment order. In step 910, the second mobile robot can be directed to the first buffer lane 202a_l while the first mobile robot is waiting in the first buffer lane, and cause the second mobile robot to stop and wait in the first buffer lane with the first mobile robot while retaining a second container on the second mobile robot without releasing the second container. The direction of the second mobile robot to the first buffer lane 202a_l can be dependent, in some implementations, upon a confirmation that the first fulfillment order is not being processed by the first workstation at the time the second mobile robot is moving toward the first buffer sequence structure and the first fulfillment order is at a threshold position or later within an order fulfillment queue corresponding to the first workstation. The threshold position within the orderfulfillment queue can be dependent on an expected time it will take the second mobile robot to reach the first buffer lane and a predicted time to fulfill the first fulfillment order at the first workstation. Some embodiments include step 912, where it is identified that a third mobile robot is associated with a second fulfillment order that is different than the first fulfillment order. In step 914, the third mobile robot can be directed to a second buffer lane 202a-2, while the first mobile robot is waiting on the first buffer lane 202a_l and based on the third mobile robot being associated with the second fulfillment order, and cause the third mobile robot to stop and wait on the second buffer lane while retaining a third container on the third mobile robot without releasing the third container. Again, in some embodiments, the directing of the third mobile robot to the second buffer lane can be dependent on the expected processing at the first workstation of the second fulfillment order. In step 916, both the first mobile robot and the second mobile robot can be directed to depart the first buffer lane 202a_l and continue to the first workstation 115 following a buffer period of time during which at least the first mobile robot waited in the first buffer lane. In step 918, the third mobile robot can be directed to depart the second buffer lane 202a_2 and proceed to the first workstation in preparation for fulfilling the second fulfillment order at the first workstation. Again, the release of the third mobile robot from the second buffer lane 202a_2 can, in some embodiments, be dependent at least in part on a position of the second fulfillment order in the order fulfillment queue corresponding to the first workstation.

[0062] FIG. 10 illustrates a simplified flow diagram of an exemplary process 1000 of fulfilling product orders through an automated order fulfillment system, in accordance with some embodiments. In step 1002, a first container, transported by a first mobile robot and intended for fulfillment of a first fulfillment order by a first workstation 115, is identified holding a first product that is similarly identified in a second fulfillment order to be subsequently fulfilled following fulfillment of the first fulfillment order. In step 1004, it is identified that the second fulfillment order is to be fulfilled by the first workstation 115. In step 1006, a return instruction is communicated to the first mobile robot causing the first mobile robot, upon exiting the first workstation as part of fulfilling the first fulfillment order, to proceed, via a return vertical level changing structure 221, to a first return lane 202c to access a feed side vertical level changing structure 230, without the first mobile robot returning to the storage structure, in routing the first mobile robot to the first workstation in fulfilling the second fulfillment order. In some embodiments, the feed side vertical level changing structure 230 can be positioned between the storage structure 202 and the multiple buffer lanes 202 of a buffer sequence structure. In step1008, the first mobile robot is caused to proceed, consistent with the return instruction, to the first return lane to access the feed side vertical level changing structure 230 and advance vertically to a second buffer lane without returning to the storage structure.

[0063] In step 1010, it can be identified that a second container, transported by a second mobile robot of the multiple mobile robots in fulfilling a third fulfillment order at the first workstation, is holding a second product and that the second product is identified in a fourth fulfillment order to be subsequently fulfilled after the third fulfillment order. In step 1012, it can be identified that the fourth fulfillment order is to be fulfilled by a second workstation that is different than the first workstation. In step 1014, a second return instruction can be communicated to the second mobile robot causing the second mobile robot to proceed to a return lane to access a transit plane vertically aligned with the return lane and travel along the transit plane to a second buffer sequence structure cooperated with the second workstation without the second mobile robot returning to the storage structure.

[0064] FIG. 11 illustrates a simplified flow diagram of an exemplary process 1100 of fulfilling product orders through an automated order fulfillment system, in accordance with some embodiments. In step 1102, it is identified that a first container, transported by a first mobile robot of a first set of mobile robots, is buffered and waiting in a first buffer lane of a first buffer sequence structure 150, and that the first container is holding multiple of a first product with at least one of the multiple first products being routed to a first workstation cooperated with the first buffer sequence structure to satisfy a first fulfillment order. In step 1104, it is identified that a second fulfillment order is queued, within an order fulfillment queue of orders, to be fulfilled subsequent to fulfillment of the first fulfillment order, and that the second fulfillment order includes at least one of the first product. In step 1106, the second fulfillment order is reprioritized to adjust a position within the order fulfillment queue based on the first mobile robot already being present at the first buffer sequence structure and transporting the first product.

[0065] FIG. 12 illustrates a simplified flow diagram of an exemplary process 1200 of fulfilling product orders through an automated order fulfillment system, in accordance with some embodiments. In step 1202, a first storage location 106 is identified within the storage structure 102 of a subsequent container to be retrieved by a first mobile robot that is at a first workstation cooperated with a first buffer sequence structure. In step 1204, a storage level, within the storage structure, is identified in which the subsequent container is located. In step 1206, a return lane, of multiple return lanes of the first buffer sequence structure, is identified that is a closest in avertical orientation to the identified storage level. In step 1208, the first mobile robot is routed to the return lane based on the return lane being the closest in the vertical orientation of the identified storage level.

[0066] FIG. 13 illustrates a simplified flow diagram of an exemplary process 1300 of managing fulfillments, in accordance with some embodiments. In step 1302, fulfillment orders are received. Order intake can include new orders and order updates (e.g., changes to items ordered, quantity ordered, dispatch time, completion time, etc.). An Intake process, in some embodiments, can perform inventory verification and consolidation planning (e.g., bag planning, order container planning, etc.). A result in some implementations can include, in step 1304, one or more order container level orders added to an unassigned order pool (e.g., planning to the order container order level). Typically, the orders are not yet assigned to workstations and not yet bound to a product container. Inventory verification, in some embodiments, considers quantity on hand versus a demand of one or more products and / or orders. When an on-hand inventory quantity is insufficient to satisfy an order intake request, an exception process may be implemented.

[0067] In step 1306, fulfillment orders are assigned to one or more workstations 115 for fulfillment. The assignment process, in some embodiments, select specific, available product containers as needed to fulfill a respective order and creates a task for each product tote (e.g., mobile robot retrieval). In some embodiments, an available product container comprise a container that is not currently assigned to another workstation or already assigned to the same workstations, or when the pick from a container has been completed at another workstation. The order fulfillment queue can depend on one or more factors. In some embodiments, reserved product containers and / or assigned orders to a workstation can be based in part on ((order line threshold + average order size) 2) * number of workstations). A task may be created, but specific mobile robots may not yet be assigned. In some embodiments, with a pick of a product at a workstation, a count of order lines assigned to the workstation can be checked. When a corresponding order fulfillment queue is below a configurable threshold, some embodiments assign another order to the workstation. Order selection can include optimization logic to select an order with least system overhead for the workstation receiving the order. Orders with earlier dispatch times, in some embodiments, can be assigned a higher priority. Additionally or alternatively some embodiments assign priorities to orders with inventory matching product containers already assigned to a same workstation (having sufficient inventory and not yet picked). These product containers can recirculate in the buffer sequence structure 150 and avoid 1a round trip to the storage structure. Orders with high quantity of candidate product totes in the same district as the workstation can reduce processing time, reduced TP movement, improve efficiency and other benefits.

[0068] In step 1308, unassigned container tasks are identified. Unassigned tasks can include, for example, tasks that have not yet been assigned to a mobile robot. Whenever a mobile robot completes a task, or if a mobile robot is idle, the system can find a next best task based on a cost function (e.g., Weighted priority of a task type (self-serve dispense vs. associate dispense vs. order pick vs. replenishment, ... etc.); location of a next container assignment relative to the a current location of a mobile robot; number of mobile robots already serving a destination workstation (this may augment a max count or "overdrive" for mobile robots assigned to a workstation, where instead of a fixed threshold value it is incorporated into overall cost); and / or other costs specific to a task type (e.g., pick task vs. replenishment task, etc.). In some embodiments, tasks may include user requests 1310, which may include user input mechanism that generates a demand- driven task (e.g., dispense, replenish, induct, inspect, etc.); and system requests 1312 is any system-generated task triggered by other activity (such as a staging move). In step 1314, mobile robots are assigned to tasks. In some embodiments, the task assignments can include assignments of a container tasks to a mobile robot, which can include container pickup location and destination location. Some embodiments generate and distribute active routing in step 1316 and / or track active routing of mobile robots.

[0069] The buffer sequence structures 150 can improve equipment productivity (e.g., decrease mobile robot cycle time, reduces system implementation costs per site (e.g., fewer mobile robots to meet capacity), increases maximum capacity (e.g., higher numbers of orders fulfilled per day), and other such advantages. The use of buffer sequence structures 150 and / or appropriately sized buffer sequence structures of a facility can expand the work pool. The system can be more selective in assigning mobile robots to tasks. Sequencing, as a subset of the buffer's ability can allows upstream activities to work as efficiently as possible without regard to work sequence, can remove wait constraints of overlapping orders and dwell time between orders, enable leapfrog task assignment when there is significant productivity gain, and / or other such benefits. In addition to buffering and sequencing containers 204 originating from storage locations 106, the buffer sequence structures 150 further allow containers to be recirculated when inventory will meet a subsequent order slotted to the same or a different workstation.

[0070] In accordance with an example embodiment a non-transitory program storage device readable by a machine may be provided, such as memory, for example, tangibly embodying a program of instructions executable by the machine for performing operations, the operations comprising: calculating routing of mobile robots and containers to stage and sequence mobile robots and containers as disclosed above and below.

[0071] Any combination of one or more computer readable medium(s) may be utilized as the memory. The computer readable medium may be a computer readable signal medium or a non- transitory computer readable storage medium. A non-transitory computer readable storage medium does not include propagating signals and may be, for example, but not limited to, an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, or device, or any suitable combination of the foregoing. More specific examples (a non-exhaustive list) of the computer readable storage medium would include the following: an electrical connection having one or more wires, a portable computer diskette, a hard disk, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or Flash memory), an optical fiber, a portable compact disc read-only memory (CD-ROM), an optical storage device, a magnetic storage device, or any suitable combination of the foregoing.

[0072] Further, the circuits, circuitry, systems, devices, processes, methods, techniques, functionality, services, servers, mobile robots, sources and the like described herein may be utilized, implemented and / or run on many different types of devices and / or systems. FIG. 14 illustrates an exemplary system 1400 that may be used for implementing any of the components, circuits, circuitry, systems, functionality, apparatuses, processes, or devices of the fulfillment facility 100, the control circuit 101, the mobile robots 130, the workstations 115, and / or other above or below mentioned systems or devices, or parts of such circuits, circuitry, functionality, systems, apparatuses, processes, or devices. For example, the system 1400 may be used to implement some or all of the control circuit 101, the mobile robots 130, the workstations 115, point of sale systems, the inventory systems, databases, the customer computing systems, purchasing systems, customer profile system, product profile systems, and / or other such components, circuitry, functionality and / or devices. However, the use of the system 1400 or any portion thereof is certainly not required.

[0073] By way of example, the system 1400 may comprise one or more control circuits or processor modules 1412, one or more memory 1414, and one or more communication links, paths, buses or the like 1418. Some embodiments may include one or more user interfaces 1416,and / or one or more internal and / or external power sources or supplies 1440. The control circuit 1412 can be implemented through one or more processors, microprocessors, central processing unit, logic, local digital storage, firmware, software, and / or other control hardware and / or software, and may be used to execute or assist in executing the steps of the processes, methods, functionality and techniques described herein, and control various communications, decisions, programs, content, listings, services, interfaces, logging, reporting, etc. Further, in some embodiments, the control circuit 1412 can be part of control circuitry and / or a control system 1410, which may be implemented through one or more processors with access to one or more memory 1414 that can store instructions, code and the like that is implemented by the control circuit and / or processors to implement intended functionality. In some applications, the control circuit and / or memory may be distributed over a communications network 103 (e.g., LAN, WAN, Internet) providing distributed and / or redundant processing and functionality. Again, the system 1400 may be used to implement one or more of the above or below, or parts of, components, circuits, systems, processes and the like.

[0074] The user interface 1416 can allow a user to interact with the system 1400 and receive information through the system. In some instances, the user interface 1416 includes a display 1422 and / or one or more user inputs 1424, such as buttons, touch screen, track ball, keyboard, mouse, etc., which can be part of or wired or wirelessly coupled with the system 1400. Typically, the system 1400 further includes one or more communication interfaces, ports, transceivers 1420 and the like allowing the system 1400 to communicate over a communication bus, a distributed computer and / or communication network 103 (e.g., a local area network (LAN), the Internet, wide area network (WAN), etc.), communication link 1418, other networks or communication channels with other devices and / or other such communications or combination of two or more of such communication methods. Further the transceiver 1420 can be configured for wired, wireless, optical, fiber optical cable, satellite, or other such communication configurations or combinations of two or more of such communications. Some embodiments include one or more input / output (I / O) ports 1434 that allow one or more devices to couple with the system 1400. The I / O ports can be substantially any relevant port or combinations of ports, such as but not limited to USB, Ethernet, or other such ports. The I / O interface 1434 can be configured to allow wired and / or wireless communication coupling to external components. For example, the I / O interface can provide wired communication and / or wireless communication (e.g., Wi-Fi, Bluetooth, cellular, RF, and / or other such wireless communication), and in some instances may include any known wiredand / or wireless interfacing device, circuit and / or connecting device, such as but not limited to one or more transmitters, receivers, transceivers, or combination of two or more of such devices.

[0075] In some embodiments, the system may include one or more sensors 1426 to provide information to the system and / or sensor information that is communicated to another component, such as the control circuits 101, the mobile robots 130, the workstations 115, other such systems or a combination of two or more of such systems. The sensors can include substantially any relevant sensor, such as movement sensors, distance measurement sensors (e.g., optical units, sound / ultrasound units, etc.), optical-based scanning sensors to sense and read optical patterns (e.g., bar codes), radio frequency identification (RFID) tag reader sensors capable of reading RFID tags in proximity to the sensor, accelerometers, gyroscopes, and other such sensors. The foregoing examples are intended to be illustrative and are not intended to convey an exhaustive listing of all possible sensors. Instead, it will be understood that these teachings will accommodate sensing any of a wide variety of circumstances in a given application setting.

[0076] The system 1400 comprises an example of a control and / or processor-based system with the control circuit 1412. Again, the control circuit 1412 can be implemented through one or more processors, controllers, central processing units, logic, software and the like. Further, in some implementations the control circuit 1412 may provide multiprocessor functionality.

[0077] The memory 1414, which can be accessed by the control circuit 1412, typically includes one or more processor-readable and / or computer-readable media accessed by at least the control circuit 1412, and can include volatile and / or nonvolatile media, such as RAM, ROM, EEPROM, flash memory and / or other memory technology. Further, the memory 1414 is shown as internal to the control system 1410; however, the memory 1414 can be internal, external or a combination of internal and external memory. Similarly, some or all of the memory 1414 can be internal, external or a combination of internal and external memory of the control circuit 1412. The external memory can be substantially any relevant memory such as, but not limited to, solid- state storage devices or drives, hard drive, one or more of universal serial bus (USB) stick or drive, flash memory secure digital (SD) card, other memory cards, and other such memory or combinations of two or more of such memory, and some or all of the memory may be distributed at multiple locations over one or more communications and / or computer networks. The memory 1414 can store code, software, executables, scripts, data, content, lists, programming, programs, log or history data, user information, customer information, product information, and the like.While FIG. 14 illustrates the various components being coupled together via a bus, it is understood that the various components may actually be coupled to the control circuit and / or one or more other components directly.

[0078] In some embodiments, automated order fulfillment systems comprise: multiple mobile robots configured to transport at least one container each containing at least one product; a storage structure accessible by the mobile robots and comprising storage locations configured to store the containers; a first workstation; a first buffer sequence structure positioned between and cooperated with both the storage structure and the first workstation, the first buffer sequence structure comprising multiple buffer lanes comprising: a unidirectional buffer lane to which each of a first set of mobile robots transporting a container is directed and instructed to stop and wait without releasing the respective container before proceeding to the first workstation; a second buffer lane where each of a second set of mobile robots is directed to pass therethrough to the first workstation without stopping; and a unidirectional return lane to which at least one of the first set of mobile robots and at least one of the second set of mobile robots is to enter after leaving the first workstation.

[0079] Some embodiments provide methods of fulfilling product orders through an automated order fulfillment system, the methods comprising: directing multiple mobile robots to each transport at least one container containing at least one product through a storage structure accessible by the mobile robots and comprising storage locations configured to store the containers; directing each of a first set of one or more mobile robots, of the multiple mobile robots, each transporting a respective container to a first buffer lane of a first buffer sequence structure positioned between and cooperated with both the storage structure and a first workstation, wherein the first buffer sequence structure comprising multiple buffer lanes, in routing the respective containers to a first workstation; instructing each of the first set of mobile robots to stop and wait in the first buffer lane without releasing the respective container before proceeding to the first workstation; directing each of a second set of one or more mobile robots, of the multiple mobile robots, to a second buffer lane to pass therethrough to the first workstation without stopping in the second buffer lane; and directing at least one of the first set of mobile robots and at least one of the second set of mobile robots to a return lane after leaving the first workstation.

[0080] Some embodiments provide automated order fulfillment systems comprising multiple mobile robots configured to transport totes each containing at least one product; a storagestructure accessible by the mobile robots and comprising storage locations configured to store the totes received from the mobile robots; a first workstations; a first buffer sequence tower positioned between and cooperated with both the storage structure and the first workstation, and the first buffer sequence tower comprise multiple vertically separated buffer lanes, wherein the multiple buffer lanes comprise: a first set of unidirectional buffer lanes to which each of a first set of mobile robots of the multiple mobile robots is directed and instructed to stop and wait, for a respective buffer duration, within the respective assigned buffer lane of the first set of buffer lanes without releasing the respective tote while stopped in the respective buffer lane before proceeding when scheduled to the first workstation; a second set of buffer lanes of the multiple buffer lanes where each of a second set of mobile robots, of the multiple mobile robots, is directed to one of the second set of buffer lanes and directed to pass through the respective one of the second set of buffer lanes without stopping in the respective buffer lane in proceeding to the first workstation; and multiple dedicated unidirectional return lanes vertically spaced among the multiple buffer lanes; and a return vertical level changing tower positioned between and cooperated with the first workstation and each of the multiple buffer lanes wherein return instructions are communicated to each of the multiple mobile robots, as they sequentially leave the first workstation, directing the multiple mobile robots to access the return vertical level changing tower and vertically travel to an assigned different one of multiple return lanes as a function of a vertical level of a destination location within a storage structure. A control circuit can be included in some embodiments that communicatively couples with the multiple mobile robots, and can comprise at least one buffer control processor and buffer control memory storing executable code that when executed by the buffer control processor is configured to: identify that a first mobile robot, of the first set of mobile robots, transporting a first tote is associated with a first fulfillment order, of the different fulfillment orders to be fulfilled, and is buffered and waiting in a first buffer lane of the multiple buffer lanes; identify that a second mobile robot, of the first set of mobile robots, is associated with the first fulfillment order based on a second product within a second tote transported by the second mobile robot to be included in the first fulfillment order; and direct, based on the first mobile robot and the second mobile robot both being associated with the first fulfillment order, the second mobile robot to the first buffer lane while the first mobile robot is stopped in the first buffer lane, and causing the second mobile robot to stop and wait in the first buffer lane behind the first mobile robot and while retaining the second tote on the second mobile robot without releasing the second tote.

[0081] The control circuit can be configured to: identify that the first mobile robot is transporting a first product, within the first tote, that is associated with a first product grouping; identify that a third mobile robot of the first set of mobile robots is associated with the first fulfillment order, and is transporting a third tote carrying a third product that is associated with a second product grouping that is different than the first product grouping; direct, while the first mobile robot is buffered and waiting in the first buffer lane and based on the second product being associated with the different second product grouping, the third mobile robot to a second buffer lane of the first set of buffer lanes, and cause the third mobile robot to stop and wait in the second buffer lane while retaining the third tote on the third mobile robot without releasing the third tote. In some embodiments, the control circuit can be configured to direct each of a third set of mobile robots, of the multiple mobile robots and transporting order totes scheduled to receive products at the workstation in fulfilling respective orders, to one of a third set of lowest level buffer lanes of the multiple buffer lanes and causing each of the third set of mobile robots to access the first workstation from the third set of lowest level buffer lanes to position the respective order tote with an order tote bay of the first workstation.

[0082] Some embodiments provide methods of fulfilling product orders through an automated order fulfillment system, comprising: assigning multiple mobile robots, each associated with a different fulfillment order and each transporting a respective tote carrying a product, to a first workstation; directing each of a first set of mobile robots of the multiple mobile robots to one of a first set of buffer lanes of multiple vertically separated unidirectional buffer lanes of a first buffer sequence tower corresponding to the first workstation and causing each of the first set of mobile robots to stop and wait, for a respective buffer duration, within the respective assigned buffer lanes without releasing the respective tote while stopped in the respective buffer lane before proceeding when scheduled to the first workstation; directing each of a second set of mobile robots of the multiple mobile robots to one of a second set of buffer lanes of the multiple buffer lanes and causing each of the second set of mobile robots to pass through the respective one of the second set of buffer lanes without stopping in the respective buffer lane in proceeding to the first workstation; and communicating return instructions to each of the multiple mobile robots, as they sequentially leave the first workstation, to access, via a return vertical level changing tower, assigned different ones of multiple dedicated unidirectional return lanes of the first buffer sequence tower as a function of a vertical level of a destination location within a storage structure.

[0083] This application incorporates by reference the entirety of each of the following U.S. patent publications: U.S. Publication No. 2014 / 0288696 published September 25, 2014, having U.S. Application Serial No. 14 / 213,187, filed on March 14, 2014, and entitled "Automated system for transporting payloads" (Applicant Ref. No. ALRT-001-101); U.S. Patent Publication No. 2017 / 0313514 published November 2, 2017, having U.S. Application Serial No. 15 / 591,956, filed on May 10, 2017, and entitled "Order fulfillment system" (Applicant Ref. No. ALRT-003-101); U.S. Patent Publication No. 2019 / 0270591 published September s, 2019, having U.S. Application Serial No. 16 / 419,910, filed on May 22, 2019, and entitled "Order fulfillment system" (Applicant Ref. No. ALRT-003-2); U.S. Patent Publication No. 2018 / 0134492 published May 17, 2018, having U.S. Application Serial No. 15 / 816,832, filed on November 17, 2017, and entitled "Automated-service retail system and method" (Applicant Ref. No. ALRT-004-101); U.S. Patent Publication No. 2018 / 0194556 published July 12, 2018, having U.S. Application Serial No. 15 / 867,373, filed on January 10, 2018, and entitled "Interchangeable automated mobile robots with a plurality of operating modes configuring a plurality of different robot task capabilities" (Applicant Ref. No. ALRT-007-101); U.S. Patent Publication No. 2018 / 0150793 published May 31, 2018, having U.S. Application Serial No. 15 / 826,045, filed on November 29, 2017, and entitled "Automated retail supply chain and inventory management system" (Applicant Ref. No. ALRT- 008-101); U.S. Patent Publication No. 2018 / 0305123 published October 25, 2018, having U.S. Application Serial No. 15 / 956,346, filed on April 18, 2018, and entitled "Picking workstation with mobile robots & machine vision verification of each transfers performed by human operators" (Applicant Ref. No. ALRT-009-102); U.S. Patent Publication No. 2018 / 0247257 published August 30, 2018, having U.S. Application Serial No. 15 / 903,993, filed on February 23, 2018, and entitled "Inventory management system and method" (Applicant Ref. No. ALRT-018-101); U.S. Patent Publication No. 2018 / 0341908 published November 29, 2018, having U.S. Application Serial No. 15 / 987,736, filed on May 23, 2018, and entitled "Fully automated self-service store" (Applicant Ref. No. ALRT-022- 101); U.S. Patent Publication No. 2019 / 0047787 published February 14, 2019, having U.S. Application Serial No. 16 / 058,065, filed on August 8, 2018, and entitled "Universal gripper for tote and sub-tote transport" (Applicant Ref. No. ALRT-023-001); U.S. Patent Publication No. 2020 / 071076 published March 5, 2020, having U.S. Application Serial No. 16 / 554,512, filed on August 28, 2019, and entitled "Tote handling for chilled or frozen goods" (Applicant Ref. No. ALRT- 032-101); U.S. Patent Publication No. 2020 / 0156871 published May 21, 2020, having U.S. Application Serial No. 16 / 676,732, filed on November 7, 2019, and entitled "System having roboticworkstation" (Applicant Ref. No. ALRT-034-101); U.S. Patent Publication No. 2020 / 0223630 published July 16, 2020, having U.S. Application Serial No. 16 / 742,119, filed on January 14, 2020, and entitled "System having workstation with tote retention and release mechanism" (Applicant Ref. No. ALRT-039-101); U.S. Patent Publication No. 2021 / 0300664 published September 30, 2021, having U.S. Application Serial No. 16 / 831,468, filed on March 26, 2020, and entitled "Tote handling for chilled or frozen goods" (Applicant Ref. No. ALRT-041-001); U.S. Provisional Application Serial No. 63 / 013,504, filed on April 21, 2020, and entitled "Transport Rack Cartridge" (Applicant Ref. No. ALRT-042-001); and U.S. Provisional Application Serial No. 63 / 067,759, filed on August 19, 202, and entitled "High Density Micro Fulfillment Center "HD-MFC" with Nightly G2P Storage Batch Pick Replenishment from Store Floor and Method of Operating Same" (Applicant Ref. No. ALRT-046- 001).

[0084] Those skilled in the art will recognize that a wide variety of other modifications, alterations, and combinations can also be made with respect to the above described embodiments without departing from the scope of the invention, and that such modifications, alterations, and combinations are to be viewed as being within the ambit of the inventive concept.

Claims

Claims1. An automated order fulfillment system comprising: multiple mobile robots configured to transport at least one container each containing at least one product; a storage structure accessible by the mobile robots and comprising storage locations configured to store the containers; a first workstation; a first buffer sequence structure positioned between and cooperated with both the storage structure and the first workstation, the first buffer sequence structure comprising multiple buffer lanes comprising: a unidirectional buffer lane to which each of a first set of mobile robots transporting a container is directed and instructed to stop and wait without releasing the respective container before proceeding to the first workstation; a second buffer lane where each of a second set of mobile robots is directed to pass therethrough to the first workstation without stopping; and a unidirectional return lane to which at least one of the first set of mobile robots and at least one of the second set of mobile robots is to enter after leaving the first workstation.

2. The order fulfillment system of claim 1, wherein the unidirectional buffer lane is vertically spaced from the second buffer lane and the unidirectional return lane, and the second buffer lane is vertically spaced from the unidirectional return lane.

3. The order fulfillment system of claim 2, wherein first buffer sequence structure further comprises: a return vertical level changing structure positioned between and cooperated with the first workstation and the unidirectional return lane providing a return path between the first workstation and the unidirectional return lane.

4. The order fulfillment system of claim 1, further comprising: a control circuit communicatively coupled with the multiple mobile robots, wherein the control circuit comprise at least one buffer control processor and buffer control memory storing executable code that when executed by the buffer control processor is configured to:identify that a first mobile robot, of the first set of mobile robots is associated with a first fulfillment order and is buffered and waiting in the unidirectional buffer lane while retaining a first container; identify that a second mobile robot is associated with the first fulfillment order; and direct the second mobile robot to the unidirectional buffer lane while the first mobile robot is waiting in the unidirectional buffer lane, and causing the second mobile robot to wait in the unidirectional buffer lane behind the first mobile robot while retaining a second container on the second mobile robot without releasing the second container.

5. The order fulfillment system of claim 4, wherein the control circuit is further configured to direct both the first mobile robot and the second mobile robot to depart the unidirectional buffer lane and continue to the first workstation following a buffer period of time during which at least the first mobile robot waited on the unidirectional buffer lane.

6. The order fulfillment system of claim 4, wherein the control circuit is further configured to: identify that a third mobile robot is associated with a second fulfillment order; direct, while the first mobile robot is waiting on the unidirectional buffer lane and based on the third mobile robot being associated with the second product order, the third mobile robot to a third buffer lane, and cause the third mobile robot to wait in the third buffer lane while retaining a third container on the third mobile robot without releasing the third container.

7. The order fulfillment system of claim 1, the first buffer sequence structure further comprises: a single feed side vertical level changing structure positioned between the storage structure and the multiple buffer lanes; a control circuit communicatively coupled with the multiple mobile robots comprising at least one buffer control processor and buffer control memory storing executable code that when executed by the buffer control processor is configured to: identify that a first container, transported by a first mobile robot and leaving the first workstation, is holding a first product that is identified in a second fulfillment order to be subsequently fulfilled; identify that the second fulfillment order is to be fulfilled by the first workstation; andcommunicate a return instruction to the first mobile robot to cause the first mobile robot to proceed to the unidirectional return lane to access the feed side vertical level changing structure, and advance vertically via the feed side vertical level changing structure to a third buffer lane of the multiple buffer lanes, without the first mobile robot returning to the storage structure, in routing the first mobile robot to the first workstation in fulfilling the second fulfillment order.

8. The order fulfillment system of claim 7, further comprising: a second buffer sequence structure; and a first transit plane positioned between the storage structure and the feed side vertical level changing structure of the first buffer sequence structure; wherein the control circuit is further configured to: identify that a second container, transported by a second mobile robot of the multiple mobile robots and leaving the first workstation, is holding a second product and that the second product is identified in a third fulfillment order to be subsequently fulfilled; identify that the second fulfillment order is to be fulfilled by a second workstation that is different than the first workstation; and communicate a second return instruction to the second mobile robot causing the second mobile robot to proceed to the unidirectional return lane to access the first transit plane aligned with the unidirectional return lane and travel along the first transit plane to the second buffer sequence structure cooperated with the second workstation without the second mobile robot returning to the storage structure.

9. The order fulfillment system of claim 1, further comprising: a control circuit communicatively coupled with the multiple mobile robots comprising at least one buffer control processor and buffer control memory storing executable code that when executed by the buffer control processor is configured to: identify that a first container, transported by a first mobile robot of the first set of mobile robots, is buffered and waiting in the unidirectional buffer lane, and that the first container is holding multiple of a first product with at least one of the multiple first products being routed to the first workstation to satisfy a first fulfillment order;identify that a second fulfillment order is queued, within a queue of fulfillment orders, to be fulfilled subsequent to fulfillment of the first fulfillment order, and that the second fulfillment order includes at least one of the first product; and reprioritize the second fulfillment order to adjust a position within the queue of fulfillment orders based on the first mobile robot already being present at the first buffer sequence structure and transporting the first product.

10. The order fulfillment system of claim 1, further comprising: multiple return lanes, comprising the unidirectional return lane; a control circuit communicatively coupled with the multiple mobile robots comprising at least one buffer control processor and buffer control memory storing executable code that when executed by the buffer control processor is configured to: identify a first storage location within the storage structure of a subsequent container to be retrieved by a first mobile robot of the multiple mobile robots; identify a storage level, within the storage structure, in which the subsequent container is located; identify a first return lane, of multiple return lanes comprising the unidirectional return lane, that is a closest in a vertical orientation to the identified storage level; and communicate a first return instruction, of the return instructions, to route the first mobile robot to the first return lane based on the first return lane being the closest in the vertical orientation of the identified storage level.

11. A method of fulfilling product orders through an automated order fulfillment system, the method comprising: directing multiple mobile robots to each transport at least one container containing at least one product through a storage structure accessible by the mobile robots and comprising storage locations configured to store the containers; directing each of a first set of one or more mobile robots, of the multiple mobile robots, each transporting a respective container to a first buffer lane of a first buffer sequence structure positioned between and cooperated with both the storage structure and a first workstation, wherein the first buffer sequence structure comprising multiple buffer lanes, in routing the respective containers to a first workstation;instructing each of the first set of mobile robots to stop and wait in the first buffer lane without releasing the respective container before proceeding to the first workstation; directing each of a second set of one or more mobile robots, of the multiple mobile robots, to a second buffer lane to pass therethrough to the first workstation without stopping in the second buffer lane; and directing at least one of the first set of mobile robots and at least one of the second set of mobile robots to a return lane after leaving the first workstation.

12. The method of claim 11, wherein the first buffer lane is vertically spaced from the second buffer lane and the return lane, and the second buffer lane is vertically spaced from the return lane.

13. The method of claim 12, wherein directing the at least one of the first set of mobile robots and the at least one of the second set of mobile robots to the return lane further comprises: directing the at least one of the first set of mobile robots and the at least one of the second set of mobile robots to self-propel along at least a portion of a return vertical level changing structure positioned between and cooperated with the first workstation and the return lane providing a vertical return path between the first workstation and the return lane.

14. The method of claim 11, further comprising: identifying that a first mobile robot, of the first set of mobile robots, is associated with a first fulfillment order and is buffered and waiting in the first buffer lane while retaining a first container; identifying that a second mobile robot is associated with the first fulfillment order; and directing the second mobile robot to the first buffer lane while the first mobile robot is waiting in the first buffer lane, and causing the second mobile robot to stop and wait in the first buffer lane with the first mobile robot while retaining a second container on the second mobile robot without releasing the second container.

15. The method of claim 14, further comprising: directing both the first mobile robot and the second mobile robot to depart the first buffer lane and continue to the first workstation following a buffer period of time during which at least the first mobile robot waited in the first buffer lane.

16. The method of claim 14, further comprising: identifying that a third mobile robot is associated with a second fulfillment order; and directing, while the first mobile robot is waiting on the first buffer lane and based on the third mobile robot being associated with the second fulfillment order, the third mobile robot to a third buffer lane, and causing the third mobile robot to stop and wait on the third buffer lane while retaining a third container on the third mobile robot without releasing the third container.

17. The method of claim 11, further comprising: identifying that a first container, transported by a first mobile robot and intended for fulfillment of a first fulfillment order, is holding a first product that is identified in a second fulfillment order to be subsequently fulfilled following fulfillment of the first fulfillment order; identifying that the second fulfillment order is to be fulfilled by the first workstation; and communicating a return instruction to the first mobile robot causing the first mobile robot, upon exiting the first workstation as part of fulfilling the first fulfillment order, to proceed, via a return vertical level changing structure, to the return lane to access a feed side vertical level changing structure, positioned between the storage structure and the multiple buffer lanes, and advance vertically to a third buffer lane of the multiple buffer lanes of the first buffer sequence structure, without the first mobile robot returning to the storage structure, in routing the first mobile robot to the first workstation in fulfilling the second fulfillment order.

18. The method of claim 17, further comprising: identifying that a second container, transported by a second mobile robot of the multiple mobile robots, is holding a second product and that the second product is identified in a third fulfillment order to be subsequently fulfilled; identifying that the third fulfillment order is to be fulfilled by a second workstation that is different than the first workstation; and communicating second return instruction to the second mobile robot causing the second mobile robot to proceed to the return lane to access a transit plane vertically aligned with the return lane and travel along the transit plane to a second buffer sequence structure cooperated with the second workstation without the second mobile robot returning to the storage structure.

19. The method of claim 11, further comprising: identifying that a first container, transported by a first mobile robot of the first set of mobile robots, is buffered and waiting in the first buffer lane, and that the first container is holding multiple of a first product with at least one of the multiple first products being routed to the first workstation to satisfy a first fulfillment order; identifying that a second fulfillment order is queued, within an order fulfillment queue of orders, to be fulfilled subsequent to fulfillment of the first fulfillment order, and that the second fulfillment order includes at least one of the first product; and reprioritizing the second fulfillment order to adjust a position within the order fulfillment queue based on the first mobile robot already being present at the first buffer sequence structure and transporting the first product.

20. The method of claim 11, further comprising: identifying a first storage location within the storage structure of a subsequent container to be retrieved by a first mobile robot of the multiple mobile robots; identifying a storage level, within the storage structure, in which the subsequent container is located; identifying a second return lane, of multiple return lanes of the first buffer sequence structure, that is a closest in a vertical orientation to the identified storage level; and routing the first mobile robot to the second return lane based on the second return lane being the closest in the vertical orientation of the identified storage level.