Bag-loading for order-fulfillment

Abstract

Workstations of an automated storage and retrieval system comprise a first level coupled to a pathway of an automated storage and retrieval system and configured to receive a mobile robot transporting a tote, the tote received at the first level being empty, a second level located above the first level and configured to receive the mobile robot moving from the first level and to provide access to the tote when the mobile robot is at the second level, and a bag feeder disposed between the first level and the second level, the bag feeder comprising a plurality of bags, each of the bags configured to fit into at least a portion of the tote, wherein one or more of the plurality of bags are configured to be loaded into the at least the portion of the tote as the mobile robot moves from the first level to the second level.

Description

BAG-LOADING FOR ORDER-FULFILLMENTCross-Reference to Related Applications

[0001] The present application claims priority to U.S. Provisional Patent Application No. 63 / 627,327, filed on January 31, 2024, which is incorporated by reference herein in its entirety.Technical Field

[0002] This invention relates generally to an order fulfillment system, and more specifically to an order fulfillment system that uses bags for containing items for orders.Background

[0003] In conventional order fulfillment systems that use totes, one or more bags may be loaded into empty totes before the items / eaches are placed into the totes. However, loading bags into each tote may be a time-consuming step and may affect the cycle time of preparing and fulfilling customers’ orders. This step often requires manual handling or the use of inefficient machinery, which can lead to bottlenecks in high-volume environments. Additionally, the accuracy of bag placement may vary, leading to inconsistencies in the order preparation process. As a result, labor costs may increase, and overall productivity can decrease. Therefore, a need exists for improved methods / sy stems of dispensing bags for loading into the empty totes that are more efficient, accurate, and scalable, thereby streamlining the order fulfillment process and reducing operational costs for retailers.Brief Description of the Drawings

[0004] Disclosed herein are embodiments of workstations relating to order fulfillment via an automated storage and retrieval system. This description includes drawings, wherein:

[0005] FIG. 1 shows a simplified perspective view of a workstation of an order fulfillment system in accordance with some embodiments;

[0006] FIG. 2A is a perspective view of an example of the workstation with a bag loading system in accordance with some embodiments;

[0007] FIG. 2B is a simplified side view of the workstation of FIG. 2A without showing the bag loading system in accordance with some embodiments;

[0008] FIG. 3 A illustrates a perspective view of a portion of the workstation including a bag loading system, showing a stage of bag loading where the empty tote is located at a bag loading position between the first and second levels of the workstation in accordance with some embodiments;

[0009] FIG. 3B illustrates a perspective view of the portion of the workstation of FIG. 3 A, but showing a stage of bag loading where three bags have been pulled out by a slider from a bag feeder illustrates a perspective view of a portion of the workstation;

[0010] FIG. 3C illustrates a perspective view of the portion of the workstation of FIG. 3B, showing a stage of the bag loading where a presser is located at the position corresponding to one of the pulled-out bags in accordance with some embodiments;

[0011] FIG. 3D illustrates a perspective view of the portion of the workstation of FIG. 3C, showing a stage of the bag loading where the presser pushes down one of the pulled-out bags into the empty tote located at the bag loading position between the first and second levels of the workstation in accordance with some embodiments;

[0012] FIG. 3E illustrates a perspective view of the portion of the workstation of FIG. 3D, showing a stage of the bag loading where a tote is positioned in the second level with three bags loaded thereinto in accordance with some embodiments;

[0013] FIG. 4 shows a perspective view of a workstation including a bag loading system of an order fulfillment system in accordance with some embodiments;

[0014] FIGS. 5A is an enlarged perspective view of a portion of the workstation of FIG. 4 to further illustrate the bag loading system in accordance with some embodiments;

[0015] FIG. 5B is a perspective view of the portion of the workstation of FIG. 5A in operation in accordance with some embodiments;

[0016] FIG. 6 shows a perspective view of a workstation including a bag loading system of an order fulfillment system in accordance with some embodiments;

[0017] FIG. 7A is an enlarged perspective view of a portion of the workstation of FIG. 6 to illustrate operation of the bag loading system in accordance with some embodiments;

[0018] FIG. 7B is an enlarged perspective view of a portion of the workstation of FIG. 6 to illustrate operation of the bag loading system in accordance with some embodiments;

[0019] FIG. 7C is an enlarged perspective view of a portion of the workstation of FIG. 6 to illustrate operation of the bag loading system in accordance with some embodiments;

[0020] FIG. 8 A is a perspective view of a portion of the workstation of FIG. 6 to illustrate operation of the bag loading system in accordance with some embodiments; and

[0021] FIG. 8B is a perspective view of a portion of the workstation of FIG. 6 to illustrate operation of the bag loading system in accordance with some embodiments;

[0022] 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 of the present invention. 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 embodiments of the present disclosure. 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 and expressions by persons skilled in the art as set forth above except where different specific meanings have otherwise been set forth herein.Detailed Description

[0023] The following description is not to be taken in a limiting sense, but is made merely for the purpose of describing the general principles of exemplary embodiments. Reference throughout this specification to “one embodiment,” “an embodiment,” “some embodiments”, “an implementation”, “some implementations”, “some applications”, or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the invention. Thus, the phrases “in one embodiment,” “in an embodiment,” “in some embodiments”, “in some implementations”, and similar language throughout the application may, but do not necessarily all refer to the same embodiment.

[0024] Generally speaking, pursuant to various embodiments, systems, apparatuses, and methods are provided herein useful to load one or more bags into a tote for an order fulfdlment system. In some embodiments, a workstation of an automated storage and retrieval system comprises a first level coupled to a pathway of an automated storage and retrieval system and configured to receive a mobile robot transporting a tote, the tote received at the first level being empty, a second level located above the first level and configured to receive the mobile robot moving from the first level and to provide access to the tote when the mobile robot is at the second level, and a bag feeder disposed between the first level and the second level, the bag feeder comprising a plurality of bags, each of the bags configured to fit into at least a portion of the tote, wherein one or more of the plurality of bags are configured to be loaded into the at least the portion of the tote as the mobile robot moves from the first level to the second level.

[0025] Some embodiments provide bag loading systems or dynamic workstations of orderfulfillment systems with the bag loading systems for use in supply chains, for example in retail supply chains. Various embodiments and examples of bag loading systems and workstations are described herein. In some embodiments, the workstations may be a part of the order fulfilment system. The order fulfillment system may have product totes and order totes with autonomous mobile robots or vehicles that transfer and transport the totes. Further, the order fulfillment system may include a storage structure with structural support that stores totes. The mobile robots can operate and move in three dimensions throughout the order fulfillment system to transport totes throughout the order fulfillment system along tracks, vertical channels, decks, ramps and / or other sub-structures of the order fulfillment system such as workstations.

[0026] In some embodiments, the workstations may be utilized in loading bags into the totes transported by the mobile robots. The workstation may further enhance the decanting of products received into a facility and / or improve the fulfillment of product orders in part by providing a product flow through the workstation to enable items to more easily be acquired and moved in a reduced amount of time. In some embodiments, these workstations may be utilized in fulfilling orders from retail stores for products received from manufacturers, in fulfilling orders for discreet product units contained in such cases, that may be referred to as “eaches” (other commonly used synonyms include “pieces”, “articles”, “items”), or generally any articles ordered by stores or individual consumers in less-than-case quantities. Additionally or alternatively, at least some of the dynamic workstations may be utilized in decanting or separating items in pallets, casesand / or other such groupings into cases, sub-groups, eaches and / or other such reduced quantities. While embodiments may be used in other applications, such as storage and retrieval of parts and work-in-process within manufacturing operations, one field of use is loading bags into the totes for order-fulfillment in retail supply chains.

[0027] Workstations and the order fulfilment systems may have features as described and / or may have in any suitable combination features as described in U.S. patent Nos. 9,139,363, entitled “Automated Systems for Transporting Payloads”; 11,142,398 entitled “Order Fulfillment System”; and 10,435,241 entitled “Storage and Retrieval System”, each of which is hereby incorporated by reference in its entirety.

[0028] In the order fulfillment process using totes, one or more bags may be loaded into empty totes before items / eaches are put into the totes. However, loading bags to each tote may be a time-consuming process and may affect the cycle time of preparing and fulfilling customers’ orders. In some embodiments, a workstation is provided which may efficiently load one or more bags into an empty tote. A workstation according to some embodiments may reduce the motions (e g., a user’s motions) to load bags into the totes and therefore may increase the processing speed of order fulfillment. Some embodiments of the disclosed devices or systems provide at least partially automated bag-loading to the totes.

[0029] In some embodiments, the order fulfillment system may comprise a memory and a control circuit. The memory may include a volatile and / or non-volatile memory. In some embodiments, the memory may include a random-access memory (RAM). The memory may serve to store computer instructions that, when executed by the control circuit, cause the control circuit to behave as described herein. In some embodiments, the memory may serve, for example, to non- transitorily store computer instructions. As used herein, this reference to "non-transitorily" will be understood to refer to a non-ephemeral state for the stored contents (and hence excludes when the stored contents merely constitute signals or waves) rather than volatility of the storage media itself and hence the memory may include both non-volatile memory (such as read-only memory (ROM) as well as volatile memory (such as an erasable programmable read-only memory (EPROM). The memory may provide storage for codes executable by the control circuit and, when executed by the control circuit, the codes cause the control circuit to operate devices, systems, apparatuses, and / or to perform specific steps, actions, and / or functions described herein. In some embodiments,the control circuit may operably / communicatively couple to the memory, electrical components of the order fulfillment system including, but not limited to, mobile robots, the workstation, and the bag loading systems. The control circuit may access the memory and execute the codes stored in the memory. In some embodiments, the memory may be integral to the control circuit or may be physically discrete in whole or in part from the control circuit as desired. The memory may also be local with respect to the control circuit (where, for example, both share a common circuit board, chassis, power supply, and / or housing) or may be partially or wholly remote with respect to the control circuit (where, for example, the memory is physically located in another housing or remotely location). In some embodiments, the memory may be distributed in multiple locations.

[0030] The control circuit may be configured, for example, by using corresponding programming and / or using the modules stored in memory, to carry out, direct, and / or send signals to carry out one or more of the steps, actions, and / or functions described herein. The control circuit may comprise structure that includes at least one (and typically many) electrically-conductive paths (such as paths comprised of a conductive metal such as copper or silver) that convey electricity in an ordered manner, which path(s) will also typically include corresponding electrical components (both passive (such as resistors and capacitors) and active (such as any of a variety of semiconductor-based devices) as appropriate) to effect one or more of the steps, actions, and / or functions described herein. The control circuit, for example, may comprise a fixed-purpose hardwired hardware platform (including but not limited to an application-specific integrated circuit (ASIC) (which is an integrated circuit that is customized by design for a particular use, rather than intended for general -purpose use), a field-programmable gate array (FPGA), and the like) or can comprise a partially or wholly-programmable hardware platform (including but not limited to microcontrollers, microprocessors, and the like).

[0031] FIGS. 1-8B are provided to illustrate various embodiments. When describing certain embodiments, certain features may be shown in one or more of FIGS. 1-8B. Although the present embodiments will be described with reference to the embodiments shown in the figures, it should be understood that the present concepts may be embodied with many forms of alternative embodiments. In addition, any suitable size, shape or type of materials or elements may be used.

[0032] FIG. 1 depicts a simplified view of a workstation 100 of an order fulfillment system, in accordance with some embodiments. In some embodiments, the workstation 100 may receive amobile robot 1 10 transporting a tote 1 12 and provide access to the tote 112 for a user and / or an object manipulator such as a manipulation robot / device (e.g., a picker, a gripper, etc.) configured to manipulate and / or transfer objects from one position to another position. In some embodiments, via the access provided by the workstation 100, the user and / or the object manipulator may select / pick items from one tote 112 and / or place the selected / picked items into another tote 112.

[0033] In some embodiments, the workstation 100 may include a first level 101 and a second level 102 located above the first level 101. The mobile robot 110 may move from the first level 101 to the second level 102 along a rail / track 105 connecting the first and second levels 101, 102. The first level 101 and the second level 102 may be coupled to pathways 104 of an automated storage and retrieval system.

[0034] The automated storage and retrieval system may have features as described and / or may have in any suitable combination features as described in U.S. Patent Nos. 9,139,363; 10,435,241; and 11,142,398, all of which are incorporated herein by reference. The operation and movement of the mobile robots 110 and the totes 112 are further described in U.S. Patent Nos. 9,139,363; 10,435,241; and 11,142,398, all of which are incorporated herein by reference.

[0035] In some aspects, the first level 101 may receive mobile robots 110 transporting totes 112 and the second level 102 may receive the mobile robots 110 moving to the second level 102 from the first level 101. In some implementations, the totes 112 transported by the mobile robots 110 and received at the first level 101 may be empty totes 112. In some embodiments, the totes 112 transported by the mobile robots 110 from the first level 101 and received at the second level 102 may be empty totes 112. In some embodiments, the totes 112 transported by the mobile robots 110 from the first level 101 and received at the second level 102 may be totes 112 loaded with one or more bags. In some embodiments, the second level 102 may provide access (e.g., for a human worker and / or an object manipulator such as a robotic device) to the totes 112 when the mobile robot 110 is located at the second level 102.

[0036] In some embodiments, the workstation 100 may include a bag loading system 120. The bag loading system 120 may be disposed between the first level 101 and the second level 102. The bag loading system 120 may include a bag feeder including a plurality of bags, each of the bags configured to fit into at least a portion of an empty tote 112. In some embodiments, the bag feeder may be a bag cartridge including a plurality of bags configured to fit into at least a portionof the empty tote 1 12. The one or more of the plurality of bags may be loaded into at least a portion of the empty tote 112 when the mobile robot 110 with the empty tote 112 moves from the first level 101 to the second level 102.

[0037] FIG. 2A is a perspective view of an example of the workstation 100 including a bag loading system 220 in accordance with some embodiments. FIG. 2B is a simplified side view of the workstation 100. For ease of illustration, the bag loading system 220 is not illustrated in FIG. 2B. In some embodiments, the workstation 100 may further include a third level 103, as shown in FIG. 2A. Although FIG. 2B illustrates the third level 103 below the first level 101, the third level 103 may be located between the first and second levels 101, 102 in some implementations. In some embodiments, the mobile robots 1 10 transporting totes 112 may move from a lower level (e.g., first level 101) to an upper level (e.g., second level 102) of the workstation 100.

[0038] FIGS. 3A-3E illustrate a portion of the workstation 100 including a bag loading system 220 and operation of the bag loading system 220 in accordance with some embodiments. In certain aspects, the bag loading system 220 may include a bag feeder 221 disposed between the first level 101 and the second level 102.

[0039] The bag feeder 221 may comprise a plurality of bags 330 each configured to fit into at least a portion of an empty tote 112. In some embodiments, the bag feeder 221 may include a plurality of bags 330 in the form of a roll of bags. For example, one end of each bag 330 may be connected to the other end of the next bag via a weakened boundary line 331, and the connected bags 330 may be rolled to form a roll of bags.

[0040] In some embodiments, one or more bags 330 may be loaded to the tote 112 when the mobile robot 110 moves from the lower level to the upper level (e.g., from the first level 101 to the second level 102). FIG. 3A shows a stage of bag loading where the empty tote 112 is located at a bag loading position between the first and second levels 101, 102 of the workstation 100.

[0041] In some embodiments, the bag loading system 220 may include a slider 322 configured to pull out one or more bags 330 from the bag feeder 221 to deploy the one or more bags 330 between the first level 101 and second level 102 of the workstation 100. FIG. 3B illustrates a stage of bag loading where three bags 330 have been pulled out by the slider 322 from the bag feeder 221. In some embodiments, the slider 322 may grip the end of the leading bag ofthe plurality of bags in the bag feeder 221 before pulling out one or more bags 330 from the bag feeder 221 and may move along a slider guide rail 323.

[0042] In some embodiments, the slider guide rail 323 may be parallel to one edge of the tote 112 at the bag loading position. In some embodiments, the one or more bags may be pulled out after / before the empty tote 112 arrives the bag loading position. When the one or more bags are pulled out from the bag feeder 221 and the empty tote 112 arrives the bag loading position, the pulled-out bags may be placed above the tote 112 adjacent to or at the top edge of the tote 112. In some embodiments, the slider 322 may operate / move automatically based on the direction signals from the control circuit, e.g., using a motor or other actuator. In some other embodiments, the slider 322 may be operated / moved manually, e g., by a worker at the workstation.

[0043] In some embodiments, the bag loading system 220 may include a presser 324 configured to press a portion of the one or more bags 330 pulled out from the bag feeder 221 and deployed between the first and second level 101, 102 of the workstation 100 to load the one or more bags into at least portion of the empty tote 112. In some embodiments, before being pressed by the presser 324, the bags 330 may be folded / distorted / pressed and may have a flat configuration to facilitate forming the roll of bags. When the presser 324 pushes down the portion (e.g., the middle portion) of each of the folded / distorted / pressed bags 330, the bags 330 may be unfolded and then may have a space containing / accommodating items / products and be loaded into at least the portion of the tote 112. In some embodiments, the bag loading system 220 may include a presser guide rail 325 and the presser 324 may move along the presser guide rail 325. When the one or more bags 330 are loaded into the tote, the presser 324 may move along the presser guide rail 325 and stop at a position corresponding to each bag (where the presser 324 overlies a bag 330) to press / push down each bag 330 to unfold and load the bags 330.

[0044] FIG. 3C illustrates a stage of the bag loading where the presser 324 is located at the position corresponding to and overlying one of the pulled-out bags 330 in accordance with some embodiments. FIG. 3D illustrates a stage of bag loading where the presser 324 pushes down one of the pulled-out bags 330 into the empty tote 112 located at the bag loading position between the first and second levels 101, 102 of the workstation 100. Referring to FIG. 3D, in some embodiments, the presser 324 may include a first moving unit 324a and a second moving unit 324b. The first moving unit 324a may be coupled to the presser guide rail 325 and move along thepresser guide rail 325. The second moving unit 324b may be physically coupled to the first moving unit 324a such that the second moving unit 324b may move along the presser guide rail 325 when the first moving unit 324a moves along the presser guide rail 325. The second moving unit 324b may be further configured to move up and down (e.g., perpendicularly to the moving direction of the first moving unit 324a) to push down the portion of the bags 330 into the totes 112. In some embodiments, the presser 324 may operate / move automatically based on the direction signals from the control circuit. In some other embodiments, the presser 324 may be operated / moved manually.

[0045] In some embodiments, at least a portion of the pulled-out bags 330 may remain in a fixed position (e.g., the position corresponding to the top edge of the tote 112 in the bag loading location) when the presser 324 presses them down into the tote 112. This allows the bags pushed by the presser 324 to transition from being folded to being unfolded into the shape having a space accommodating / containing items / products, rather than just being pushed down as a whole. In some embodiments, to hold the portion of the pulled-out bags 330 in a fixed position, the presser 324 may push down the bags 330 before the pulled-out bags 330 are released from the remaining bags in the bag feeder 221. In some embodiments, to fix the portion of the bags in a fixed position, the slider 322 may keep gripping the end of the leading bag of the plurality of bags 330.

[0046] In some embodiments, the bag loading system 220 may include a cutter 326 configured to release one or more bags 330 pulled out from the bag feeder 221 from the remaining bags in the bag feeder 221 . The cutter 326 may release the one or more bags 330 pulled out from the bag feeder 221 by cutting the connecting weakened boundary line 331 (FIG. 3D) between the pulled-out bags 330 and the remaining bags 330. In some embodiments, the connecting weakened boundary line 331 may be a weakened boundary with a perforation line. In some embodiments, the cutter 326 may cut the connecting weakened boundary line 331 of the bags by moving along a cutter guide rail 327. In some embodiments, the pulled-out bags 330 may be released from the remaining bags 330 by the cutter 326 after loading the bags into the tote 112. In some embodiments, the cutter 326 may operate / move automatically based on the direction signals from the control circuit. In some other embodiments, the cutter 326 may be operated / moved manually. For example, the cutter 326 may include a handle 328 at the top of it and a user may move / slide the cutter using the handle 328 to release the pulled-out bags 330 from the bag feeder 221.

[0047] FIG. 3E illustrates a tote 1 12 in the second level 102 with three bags 330 loaded thereinto. In some embodiments, after loading the bags 330 into the tote 112 at the bag loading position between the first and second level 101, 102, tote 112 may be transported by the mobile robot 110 to the second level to provide (e.g., a human worker or a robotic device) access to the tote 112 that is loaded with bags 330. When the mobile robot 110 with the tote 112 is at the second level 102, items (e.g., retail products) may be placed into the bags 330 loaded into the tote 112 to fulfill orders made by customers.

[0048] FIG. 4 is a perspective view of another example of the workstation 100 with the bag loading system 420 in accordance with some embodiments. FIGS. 5A is an enlarged view of a portion of the workstation 100 to illustrate the bag loading system 420 and FIG. 5B illustrates an example of the bag loading system 420 in operation. The bag loading system 420 may include one or more features of the bag loading system 220 as described and / or may have in any suitable combination features of bag loading system 220 as described.

[0049] In some embodiments, the bag loading system 420 may include the bag feeder 221, the slider 322, and the cutter 326. In some embodiments, the bag loading system 420 may be operated manually. To facilitate the manual operation, the slider 322 may include a handle 542 configured to be used and held by a user when the user moves / slides the slider 322 along the slider guide rail 323. In some embodiments, the handle 542 may further include a button 544 to control the gripping of the bag using the slider 322. For example, the user may push the button 544 to grip the end of the leading bag of the plurality of bags 330 before the user pulls out the one or more bags 330 from the bag feeder 221 by sliding the slider 322. In some embodiments, when the user releases the pushed button 544, the slider 322 may release the gripped bag 330. FIG. 5B shows the one or more bags 330 pulled out by sliding the slider 322.

[0050] In some embodiments, the bag loading system 420 may not include the presser 324 and after pulled out the bags from the bag feeder 221, the user may manually press / push down the bags deployed at the top of the tote by with a hand or other tools to unfold and load the bags into the tote 112. In some aspects, the user may release the pulled-out bags from the bag feeder 221 by manually moving / sliding the cutter 326 using the cutter handle 328. In some embodiments, to facilitate the manual operation of the bag loading system 420, the bag loading system 420 may be at the second level 102 of the workstation 100 such that the user may have access to the bag loadingsystem 420 when the user has access to the tote 112. In this case, the one or more bags bag 330 may be loaded into the tote 112 when the tote 112 arrives the second level 102.

[0051] FIG. 6 is a perspective view of another example of the workstation 100 with the bag loading system 620 in accordance with some embodiments. FIGS. 7A-7C are enlarged views of a portion of the workstation 100 to show an example of the bag loading system 620 in operation. FIGS. 8A-8B are perspective views of the workstation 100 with the bag loading system 620 to illustrate the operation of the bag loading system 620. The bag loading system 620 may include one or more features of the bag loading systems 220, 420 as described and / or may have in any suitable combination features of bag loading system 220, 420 as described.

[0052] In some embodiments, the bag loading system 620 may include a bag feeder 621 including a plurality of bags 730 and a slider 722 configured to pull out one or more bags 730 from the bag feeder 621 by sliding along a slider rail 723. In some embodiments, the bag feeder 621 may include a plurality of bags 730 in a form of a stack of bags. In some embodiments, the plurality of bags 730 may be stacked side by side to form the stack of bags 730.

[0053] In some embodiments, the bag loading system 620 may include a wedge 752 configured to be lowered to open a leading bag 730 (e.g., top bag, forefront bag, etc.) of the stack of bags 730. The wedge 752 may be physically coupled to the slider 722 and configured to move up and down while being coupled to the slider 722. The wedge 752 may have a thin edge 752a facing the opening of the bags 730.

[0054] When the bags 730 are in the form of the stack of the bags, the bags 730 may be folded such that the opening of the bags 730 may be very small such that the bags 730 are substantially in a closed configuration. By lowering the wedge 752 and causing the insertion of a thin edge 752a of the wedge 752 into the opening of the leading bag 730 of the stack of the folded bags 730, the remaining (thicker) portion of the wedge 752 may inserted into the leading bag 730 and the wedge 752 may open the leading bag 730 or at least enlarge the opening of the top bag 730.

[0055] FIG. 7A illustrates the wedge 752 before lowering and FIG. 7B illustrates a lowered wedge 752 inserted into the top bag 730 in a stack of bags 730. After inserting the wedge 752 into the top bag 730 of the stack of bags 730, by sliding the slider 722, the top bag 730 (and or onemore additional bags 730) may be pulled out from the bag feeder 621 and deployed at the travel path of the tote 112 as shown in FIG. 7C.

[0056] In some embodiments, the bag loading system 620 may further include a retaining lever 754 (shown in FIGS. 7B-7C) to hold an edge of the top bag 730 of the stack of the bags 730 while the top bag 730 (and one or more additional bags 730 from the stack) are being pulled out from the bag feeder 621. The retaining lever 754 may grip / abut the edge of the top bag 730 after the wedge 752 opens the top bag 730 and / or broadens the opening of the top bag 730. In some embodiments, the retaining lever 754 may be rotatable about a hinge 755. For example, before the wedge 752 opens the top bag 730 in the stack of the bags 730 and / or broadens the opening of the top bag 730, the retaining lever 754 may face up from the hinge 755. Then, after the wedge 752 opens the top bag 730 and / or broadens the opening of the top bag 730, the retaining lever 754 may rotate about the hinge 755 and face down from the hinge 755 to hold the edge of the top bag 730.

[0057] Referring to FIG. 8A, the bag loading system 620 may pull out and deploy the one or more bags 730 along the travel path of the tote 112 from the first level 101 to the second level 102 before the tote 112 reaches the bag loading position. For example, as shown in FIG. 8 A, when the mobile robot 110 with the tote 112 is at the third level 103 located below the first level 101, the bag loading system 620 may pull out one or more bags 730 from the bag feeder 621, and the pulled-out bags 730 may be ready to be inserted / loaded into the tote 112 before the tote 112 reaches the pulled-out bags 730. Thus, as shown in FIG. 8B, the pulled-out bags 730 may be inserted / loaded into the tote 112 when the mobile robot 110 with the tote 112 arrives at the bag loading location while moving from the first level 101 to the second level 102 of the workstation 100, and then the inserted / loaded bags 730 may move together with the tote 112 (e.g., when the tote 112 is moved by the mobile robot 110 from the bag loading location to another location).

[0058] As discussed above, in some embodiments, a workstation of an automated storage and retrieval system includes a first level coupled to a pathway of an automated storage and retrieval system and configured to receive a mobile robot transporting a tote, the tote received at the first level being empty. The workstation further includes a second level located above the first level and configured to receive the mobile robot moving from the first level and to provide access to the tote when the mobile robot is at the second level. The workstation further includes a bag feeder disposed between the first level and the second level, the bag feeder comprising a pluralityof bags each configured to fit into at least a portion of the tote. One or more of the plurality of bags are configured to be loaded into the at least the portion of the tote as the mobile robot moves from the first level to the second level.

[0059] 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

CLAIMSWhat is claimed is:

1. A workstation of an automated storage and retrieval system, the workstation comprising: a first level coupled to a pathway of an automated storage and retrieval system and configured to receive a mobile robot transporting a tote, the tote received at the first level being empty; a second level located above the first level and configured to receive the mobile robot moving from the first level and to provide access to the tote when the mobile robot is at the second level; and a bag feeder disposed between the first level and the second level, the bag feeder comprising a plurality of bags each configured to fit into at least a portion of the tote; wherein one or more of the plurality of bags are configured to be loaded into the at least the portion of the tote as the mobile robot moves from the first level to the second level.

2. The workstation of claim 1, wherein the first level and the second level are interconnected by a rail or a track that permits the mobile robot to move from the first level to the second level.

3. The workstation of claim 1 further comprising a slider configured to pull out one or more bags from the bag feeder to deploy the one or more bags between the first level and the second level.

4. The workstation of claim 3, wherein the slider is configured to grip a leading bag of the plurality of bags before pulling out the one or more bags.

5. The workstation of claim 3, further comprising a slider guide rail that permits the slider to move along the slider guide rail.

6. The workstation of claim 5, wherein the slider guide rail is oriented in parallel to an edge of the tote when the tote is located in a bag loading position between the first level and the second level.

7. The workstation of claim 6, wherein the slider is configured to pull out the one or more bags before the tote arrives in the bag loading position.

8. The workstation of claim 5, wherein the slider comprises a handle that may be grasped to manually cause the slider to move along the slider guide rail.

9. The workstation of claim 8, wherein the handle comprises a button which, when pushed, causes the slider to grip an end of a leading bag of the plurality of bags, and, when released, causes the slider to release the end of the leading bag of the plurality of bags.

10. The workstation of claim 3, wherein the slider further comprises a wedge configured to between a first position and a second position, the wedge including an edge positioned to face an opening of a leading bag in a stack of the bags before the leading bag is pulled out from the bag feeder, the edge of the wedge configured to be inserted into the opening of the leading bag in response to movement of the wedge from the first position to the second position.

11. The workstation of claim 10, further comprising a retaining lever, wherein, after the wedge is moved into the second position and the edge of the wedge is inserted into the opening of the leading bag in the stack of bags, the retaining lever is configured to be rotated about a hinge to hold an edge of the leading bag while the leading bag is being pulled out from the bag feeder.

12. The workstation of claim 1 further comprising a presser configured to press one or more bags pulled out from the bag feeder into the tote to load the one or more bags into the at least the portion of the tote and to cause the bags to transition from a folded configuration to an unfolded configuration.

13. The workstation of claim 12, further comprising a presser guide rail that permits the presser to move along the presser guide rail to overlie a bag of the one or more bags pulled out from the bag feeder.

14. The workstation of claim 13, wherein the presser includes: a first moving unit coupled to the presser guide rail and configured to move in a direction parallel to the presser guide rail; and a second moving unit coupled to the first moving unit and configured to move in a direction parallel to the presser guide rail together with the first moving unit and in a direction perpendicular to the presser guide rail to press the one or more bags pulled out from the bag feeder into the tote.

15. The workstation of claim 12, wherein, when the presser presses the one or more bags pulled out from the bag feeder into the tote to load the one or more bags into the at least the portion of the tote, a top portion of the one or more bags remains in a fixed position at a top edge of the tote to permit the one or more bags to transition from the folded configuration to an unfolded configuration within the tote.

16. The workstation of claim 1, further comprising a cutter configured to release one or more bags pulled out from the bag feeder from one or more remaining bags in the bag feeder by cutting a weakened boundary line between adjacent ones of the bags pulled out from the bag feeder and the bags remaining in the bag feeder.

17. The workstation of claim 16, further comprising a cutter guide rail that permits the cutter to move along the cutter guide rail to cut the weakened boundary line between the adjacent ones of the bags pulled out from the bag feeder and the bags remaining in the bag feeder.

18. The workstation of claim 17, wherein the cutter comprises a handle that may be grasped to manually cause the cutter to move along the cutter guide rail.

19. The workstation of claim 1 , wherein the bag feeder comprises the plurality of bags in a form of a roll of the bags or a stack of the bags.

20. The workstation of claim 1, further comprising a third level located below the first level.