Structure verification system and method

Abstract

An automated storage and retrieval system with structure verification is provided. The system includes a structure with multiple sections designed for mobile robot traversal. It also features a control circuit that performs the following functions: receives data from the mobile robot's sensor system as it moves through a section of the structure, compares this data with a design map to identify any deviations, and updates a mapping file based on these deviations. The mobile robot then uses this updated mapping file for subsequent navigation within the structure.

Description

STRUCTURE VERIFICATION SYSTEM AND METHODRelated Application(s)

[0001] This application claims the benefit of U.S. Provisional Application No. 63 / 627,349, filed January 31, 2024, which is incorporated by reference in its entity herein.Technical Field

[0002] The present invention relates to automated storage and retrieval systems and specifically structure verification of such systems using mobile robots.Background

[0003] Automated storage and retrieval systems (ASRS) have earned a vital role in supply chain management. One example of their rising demand can be seen in the grocery industry where order fulfillment centers are operated to efficiently fulfill customer orders. These facilities typically comprise storage sections located in conjunction with access portions to allow retrieval and storage of items, as needed. These items may be stored in temperature-controlled areas within the storage section. Typically, totes or containers are used to store items at desired locations. An example order fulfillment center includes a multilevel structure with horizontal rows accessing various storage sections. Mobile robots can travel these horizontal rows to retrieve or store totes as required and assist fulfilling a customer order.Brief Description of the Drawings

[0004] Disclosed herein are embodiments of apparatuses, systems, and methods for structure verification with mobile robots. This description includes drawings, wherein:

[0005] FIG. 1 A and FIG. IB are illustrations of a robotic storage and retrieval system in accordance with several embodiments.

[0006] FIG. 2 is a block diagram of a structure verification system in accordance with several embodiments;

[0007] FIG. 3 is a flow diagram of a method for structure verification in accordance with several embodiments;

[0008] FIG. 4 is a flow diagram of a process for system initialization in accordance with several embodiments;

[0009] FIG. 5 is a flow diagram of a process for ongoing system verification in accordance with several embodiments; and

[0010] FIG. 6 is an illustration of a mobile robot in accordance with several embodiments.

[0011] FIG.7 is a flow diagram of a method for structure verification in accordance with several embodiments;

[0012] 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 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 various embodiments of the present invention. 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 technical field as set forth above except where different specific meanings have otherwise been set forth herein.Detailed Description

[0013] Generally speaking, pursuant to various embodiments, systems, apparatuses and methods are provided herein for structure verification with a mobile robot. In some aspects, the techniques described herein relate to a structure verification system that includes a structure having a plurality of sections configured to allow a mobile robot to traverse the structure, and a control circuit configured to receive data from a sensor system of the mobile robot captured while the mobile robot is traversing a section of the structure, compare the data captured by the sensor system with a design map of the structure to detect a deviation associated with the section, update a mapping file based on the deviation, and wherein themobile robot is configured to subsequently travel on the structure based at least on the mapping file.

[0014] 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.

[0015] Referring now to FIGS. 1 A and IB, an example of a type of structure that may be verified by some embodiments of the systems and methods described herein is shown. In some embodiments, the systems and methods described herein may verify differently configured storage structures and / or other types of structures. FIG. 1 A shows a partial view of an embodiment of an order fulfillment facility 100 having a storage structure 102 including a number of bays 104 of storage locations 106.

[0016] In some embodiments, the storage structure 102 may be formed of a number of storage modules 110. The bays 104 defined by the storage modules 110 each include a y-z array of storage locations 106 in horizontal rows and level changing towers along the rows which in embodiments may be vertical towers. Mobile robots 148 may travel between storage levels in the z-direction within the level changing towers. The storage modules 110 form pairs of bays 104 that are arranged to face each other, separated by aisles 108. An aisle 108 may have a width such that a mobile robot 148 traveling within an aisle 108 may transfer containers to the bays 104 on either side of the aisle 108. The mobile robots 148 may also carry totes containing goods to and from portals for storage and retrieval of items from the storage structure 102.

[0017] The order fulfillment facility 100 may further include decks 112 spaced apart at different horizontal levels of the storage structure 102. The decks 112 may extend between the aisles so that mobile robots 148 can maneuver in the x-y plane of each deck to travelbetween different aisles. At least one of the decks 112 may also extend into the respective aisles to allow technicians to walk into an aisle 108 to service components within the aisle.

[0018] FIGS. 1A also shows examples of integrated turning decks 115. The turning decks 115 may be positioned at different vertical locations between the storage modules 110. The turning decks 115 may have a turning deck input / output 115-I / O that may align with the aisle 108 or another turning deck input / output 115-I / O. The turning deck 115 may enable the mobile robot 148 to efficiently change a direction of travel through the storage structure 102.

[0019] The order fulfillment facility 100 may further include a number of mobile robots 148 for transferring totes or other product or order containers to and from customer access portals and storage locations 106 in the bays 104. The mobile robots 148 may be self-guided and / or rail-guided so as to move horizontally and vertically within aisles 108 to transfer totes or other product containers between the mobile robots 148 and storage locations 106.

[0020] Referring now to FIG. IB, a portion of a track system 180 that may be part of a storage structure 102 according to some embodiments is shown. The storage structure 102 is a multilevel structure and the track system 180 includes horizontal rails 181 affixed at different vertical levels. The horizontal rails 181 provide access to storage shelves on either side of an aisle 108 in the x-direction on a given level. In some embodiments, the ends of one or more horizontal rails 181 are coupled to decks 112 or turning decks 115. In some embodiments, the storage structure 102 further includes vertical level changing towers 182 with vertical tracks within which the mobile robots may travel vertically in the z-direction between levels of storage locations 106. In some embodiments, the structure 102 may further include diagonal ramps that allow the mobile robots to move between levels via an incline. The storage structure 102 may also include other support elements such as a diagonal brace 187 or vertical poles 186.

[0021] In some embodiments, the storage structure 102, the horizontal rails 181, the vertical level changing towers 182, the turning decks 115, the diagonal brace 187, and / or the vertical poles 186 may include various features used by the mobile robot 148 for positioning and navigation within the storage structure 102. For example, structural features may include component connections (e.g., between horizontal rail 181 and deck 112, between horizontal rails 181 and vertical level changing towers 182), track gaps (e.g., between segments of thehorizontal rails 181), support elements (e.g., brace 187), fasteners (e.g., screws or clamps that connect one or more components of the structure), and / or electrical elements (e.g., charging rail or pad). In some embodiments, features may include markers 185 encoding location identifiers that provide navigation guidance. The markers 185 may be optical, electromagnetic, and / or physical markers. In some embodiments, the markers 185 may each include a unique 3D coordinate value corresponding to the marker’s location in the structure. In some embodiments, the mobile robot 148 may store a map file of the storage structure 102 including locations of one or more markers 185. Upon receiving a destination, the mobile robot 148 may determine its location within the structure 102 and / or control its movement and operations based on its location relative to one or more sensed markers 185. In some embodiments, the mobile robots 148 may be used to measure the dimensions and / or other characteristics of components of the storage structure 102 via the features. Further details of the embodiments of structure verification process are described in more detail with reference to FIGS. 2-6 herein.

[0022] Further details of the storage structure and mobile robots which may be used are described for example in the following U.S. patents and patent applications: U.S. Pat. No. 9,139,363, entitled “AUTOMATED SYSTEM FOR TRANSPORTING PAYLOADS,” issued Sep. 22, 2015; U.S. Pat. No. 10,435,241, entitled, “STORAGE AND RETRIEVAL SYSTEM,” issued Oct. 8, 2019; U.S. Pat. No. 11,142,398, entitled, “ORDER FULFILLMENT SYSTEM,” issued Oct. 12, 2021; U.S. Pat. No. 10,984,375, entitled “PICKING WORKSTATION WITH MOBILE ROBOTS & MACHINE VISION VERIFICATION OF EACH TRANSFERS PERFORMED BY HUMAN OPERATORS,” issued Apr. 20, 2021; U.S. Pat. No. 10,952,533, entitled “MODULAR STRUCTURE FOR AN AUTOMATED STORAGE AND RETRIEVAL SYSTEM,” issued Mar. 23, 2021; U.S. Pat. No. 11,267,651, entitled, “SYSTEM HAVING WORKSTATION WITH TOTE RETENTION AND RELEASE MECHANISM,” issued Mar. 8, 2022; and U.S. Patent Application No. 63 / 127,762, entitled, “MICRO-FULFILLMENT CENTER WITH AUTOMATED DISPENSE AND RETURN USING MOBILE ROBOTS AND METHOD OF OPERATING SAME,” fded on Dec. 18, 2020. Each of these patents and applications are incorporated by reference herein in their entirety.

[0023] Next referring to FIG. 2, a block diagram of a system for pickup order fulfillment is shown. The system includes one or more mobile robots 210 and a central computer system 220.

[0024] The central computer system 200 includes a control circuit 221, a memory 223, and a network interface device 227. The central computer system 200 may include one or more of a server, a central computing system, a cloud-based compute engine, a desktop computer system, a personal computer, a portable device, and the like. The control circuit 221 may include a processor, a microprocessor, a central processing unit (CPU), a graphics processing unit (GPU), an application-specific integrated circuit (ASIC), and the like and may be configured to execute computer-readable instructions stored on a computer-readable storage memory 223. The computer-readable storage memory 223 may include volatile and / or non-volatile memory and have stored upon it, a set of computer-readable instructions which, when executed by the control circuit 221, causes the central computer system 220 to perform structure verification via the one or more mobile robots 210 and send instructions for execution by the one or more mobile robots 210. In some embodiments, the computerexecutable instructions may cause the control circuit 221 of the central computer system 220 and / or the one or more mobile robots 210 to perform one or more functions described herein, such as steps described with reference to FIGS. 3-5. In some embodiments, the memory 223 may further store a design map, such as a computer aided design (CAD) model, of the structure that the mobile robot 210 travels on. For example, the memory 223 may store a design map of the storage structure 102 described with reference to FIGS. 1A and IB herein. In some embodiments, the design map may correspond to the as-designed configuration of the structure and may include dimensions and feature locations from a design model based on which the structure was originally assembled. In some embodiments, the memory 223 may further store mapping files including the design map configured to be used by the robot for navigation and a delta file determined based on sensor data gathered based on a sensor system of one or more mobile robots. In some embodiments, the delta file indicates the differences between the as-design and the as-built configuration of the structure.

[0025] The network interface device 227 may include a data port, a wired or wireless network adapter, and the like. In some embodiments, the central computer system 220 maycommunicate with the mobile robot 210 over one or more networks such as a local network, a private network, a cloud computing network, or the Internet. In some embodiments, the central computer system 220 may further communicate with other systems and devices such as an order database, an inventory database, associate user interface devices, customer user interface devices, etc.

[0026] The mobile robot 210 is a motorized unit configured to travel on a structure. In some embodiments, the mobile robot 210 may be configured to travel on a storage structure to retrieve and / or store items and / or totes. In some embodiments, the mobile robot 210 may be the mobile robot 148 described with reference to FIG. IB. The mobile robot 210 includes a control circuit 211, a memory 213, a network interface 217, a sensor system 215, and a drive system 219.

[0027] The control circuit 211 may include a processor, a microprocessor, a central processing unit (CPU), a graphics processing unit (GPU), an application-specific integrated circuit (ASIC), and the like and may be configured to execute computer-readable instructions stored on a computer-readable storage memory 213 The computer-readable storage memory 213 may include volatile and / or non-volatile memory and have stored upon it, a set of computer-readable instructions which, when executed by the control circuit 211, causes the mobile robot 210 to autonomously or semi-autonomously travel on a structure via the drive system 219 and gather data via the sensor system 215. In some embodiments, the computerexecutable instructions may cause the control circuit 211 of the mobile robot 210 to perform one or more functions described herein, such as steps described with reference to FIGS. 3-5. In some embodiments, the memory 213 may further store a copy of a mapping file, such as a 3D navigation map based on a computer-aided design (CAD) model of the structure that the mobile robot 210 travels on. In some embodiments, the mapping file may further include a delta file determined based on sensor data gathered based on a sensor system of one or more mobile robots as described in further detail herein.

[0028] The sensor system 215 may include one or more sensors for providing data for autonomous navigation and / or storage and retrieval functions. In some embodiments, the sensor system 215 may include one or more of an optical sensor, a radio frequency identification (RFID) sensor, a vibration sensor, a sound sensor, a tachometer, an odometer, apressure sensor, a voltmeter, an accelerometer, a gyroscope, a magnetometer, a temperature sensor, a humidity sensor, and / or an inertial measurement unit (IMU). In some embodiments, the sensor system 215 is configured to detect features on the structure such as optical markers, RFID markers, structural features, track connections, track gaps, fastening elements (e g., bolts, clamps), support elements (e.g., poles, braces), and / or electrical elements (charging rails or pads).

[0029] The drive system 219 may include a system for providing and controlling the movement of the mobile robot 210 on the structure. In some embodiments, the drive system 219 may include motor, wheels, gears, etc.

[0030] An example of mobile robot 210 is shown in FIG. 6. The mobile robot 210 includes an item / tote carrying portion 610, front drive wheels 630, vertical climbing gear 635, power storage 620, rear trailer wheels 648, and charging contacts 640. In some embodiments, sensors of the sensor system 215 may be coupled to any portion of the mobile robot 210. For example, optical sensors may be coupled to the front, sides, and / or back of the mobile robot 210. In some embodiments, the sensor system 215 may be configured to sense features via measuring vibration, acceleration, speed, etc. via one or more of the drive wheels r630, the trailer wheels 648, and the vertical climbing gear 635. In some embodiments, the sensor system 215 may be configured to detect the presence of charging rails or pads via the contacts 640.

[0031] Next referring to FIG. 3, a method for verifying a structure is shown. In some embodiments, one or more steps of FIG. 3 may be executed by a processor-based device executing computer-readable instructions stored on a memory device. In some embodiments, one or more steps of FIG. 3 may be performed by the central computer system 200 and / or the mobile robot 210 described with reference to FIG. 2 herein or other similar devices. In some embodiments, the process shown in FIG. 3 may be carried out during the initial setup of the system, as part of periodic maintenance and inspection, and / or while the mobile robots are performing tasks on the structure as ongoing monitoring / scanning

[0032] In step 310, a task is sent to a mobile robot for execution. In some embodiments, the task may be defined by a central computer system. In some embodiments, the task may be a structure verification task. For example, the mobile robot may be configured to travel ata normal speed for item storage and retrieval, and travel at a slower speed (e.g., 80%, 50%, etc.) for structure verification. In some embodiments, the task may be a storage and / or retrieval task, and the robot may capture data on the way to or from a storage location. In some embodiments, the mobile robot may be one of a plurality of mobile robots configured to perform storage and retrieval tasks on the structure. In some embodiments, the mobile robot may be a unit specialized for structure verification, for example, a unit equipped with additional sensors. In some embodiments, the task may specify one or more destination locations in the structure in sequence. In some embodiments, the task may further specify one or more actions to be performed at one or more destination locations. For example, the task instruction may specify a storage location for retrieving or returning a tote. In some embodiments, a mapping file may be sent to the mobile robot’s onboard memory such as the memory 213 of the mobile robot 210.

[0033] In step 320, the mobile robot travels on the structure and captures data. In some embodiments, the mobile robot may be configured to travel between locations indicated by the central computer system via a mapping file 390 of the structure indicating routes and features on the structure, and sensing for features on the actual structure. In some embodiments, the robot may travel based on a design map of the structure. In some embodiments, the design map may be a CAD model based on which the structure was initially constructed / assembled. In some embodiments, for the initial structure calibration / verification, the mapping file may only include the design map. In some embodiments, the robot may travel further based on a mapping file that includes delta values indicating differences between the actual structure and the design map and / or including a model of the actual structure determined based on measured data from one or more mobile robots.

[0034] In some embodiments, the mobile robot may determine a route to an indicated destination based on the map and times movements such as starts, stops, turns, and / or tote transfer actions based on detecting features / markers on the structure along the route. For example, upon receiving a task to retrieve a tote at location A, the robot may determine that it needs to travel down horizontal track A x cm past feature A to climb up vertical track A or it needs to travel down horizontal track B y cm past feature B and stop to retrieve a tote. Themobile robot may determine when to slow down to switch track, when to begin climbing, and when to stop to retrieve the tote based on detecting features such as markers on the structure.

[0035] The mobile robot captures data along the route via a sensor system such as the sensor system 215. In some embodiments, the sensor system includes an optical sensor, a radio frequency identification (RFID) sensor, a vibration sensor, a sound sensor, a tachometer, an odometer, a pressure sensor, a voltmeter, an accelerometer, a gyroscope, a magnetometer, a temperature sensor, a humidity sensor, and / or an inertial measurement unit (IMU). In some embodiments, the mobile robot may sense features such as an optical marker, an RFID marker, a structural feature, a track connection, a track gap, a fastening element, a support element, and / or an electrical element. In some embodiments, the robot may measure distances between features, detect acoustic or vibration properties of the track, measure track angles (e.g., incline or decline), measure electrical connection at charging contacts, measure the torque of the wheels or gears, etc.

[0036] In some embodiments, the data captured may include one or more detected features each associated with a capture location. In some embodiments, the capture location may be determined based on the distance traveled by a drive system of the mobile robot from a reference point (e.g., another feature) in the structure. In some embodiments, the captured data includes unique 3D coordinate values from markers, the coordinate values corresponding to the marker’s location in the structure. In some embodiments, the data may correspond to data the robot captures for navigation purposes. In some embodiments, the mobile robot, while in a verification mode, may use additional sensors and / or collect data not normally collected for navigation.

[0037] In step 330, the sensor data collected in step 320 is compared to a design map of the structure to detect differences. In some embodiments, step 320 may be performed by the central computer and / or the mobile robot. In some embodiments, the robot may determine the expected feature locations based on the design map and record instances where there is a mismatch between the expected feature locations and the actual detected location. For example, when a robot travels from mark A to mark B, if mark B is encountered earlier or later than expected based on the design map, the deviation may be identified and stored. In some embodiments, the recorded sensor data may be sent to the central computer system foranalytics. In some embodiments, the central computer system may compare the collected data with the design model or a system map that includes more information as compared to the mapping file stored on the mobile robot. In some embodiments, the IMU or tachometer data may be used to determine whether components are sufficiently level or angled as designed. In some embodiments, the data may be compared to determine whether the system has the expected acoustic, vibration, thermal, and / or texture profile. For example, acceptable acoustic, vibration, thermal, and / or texture ranges may be defined for one or more sections of the structure as designed, and measurements that exceed the acceptable ranges by be marked as a deviation. In some embodiments, the central computer system and / or the mobile robot may simulate sensor data of the mobile robot along the section based on the design map, wherein the deviation is detected based on comparing the data captured by the sensor system and the simulated sensor data.

[0038] If deviation is not detected, the mobile robot may continue to traverse the structure and perform tasks based on the mapping file. If a deviation is detected in step 340, the system may determine whether the deviation exceeds a correction threshold and / or is of a type that requires correction action for correct or efficient operation of the system. If the deviation is major (e.g., above the threshold or is of a type that requires corrective action), an alert may be generated in step 360 to notify the operators. For example, if the distance between two features deviates from the design map by more than 30%, an associate may be notified to perform repairs or adjustments of the structure. In some embodiments, major deviations may also cause the system maps used by the central storage system and / or central robot control system to be updated. The alert may identify the location and measurements associated with the detected defect.

[0039] If the deviation is minor (e.g., below the threshold or corrective action not required), in step 350, the mapping file may be updated. For example, a delta file may be added to the mapping files 390 to reflect the detected deviation. In some embodiments, the mapping file may be updated. For example, the delta file may indicate that marker A is 0.2cm further from marker B as compared to the design map. In some embodiments, the system may set a threshold difference (e.g., ,05cm) for updating the mapping file. In some embodiments, the mapping file may be determined based on data captured by a plurality ofrobots. For example, the delta value may be an average value of the difference detected by the last three mobile robots that travel over the same area. In some embodiments, the mapping file 390 may include delta values associated with different features in different sections of the structure determined based on data from different mobile robots. In some embodiments, the updated mapping file 390 may be loaded onto the local memory devices of each mobile robot that travels on the structure. The mobile robots may then traverse the structure based on the updated mapping file, including the delta file, to have a more accurate map layout of the as-built structure. For example, the mobile robot may determine when to slow down, stop, or turn based on distances determined based on feature locations indicated in the delta file in addition to the design amp.

[0040] Next referring to FIG. 4, a process for initializing a system is shown. In some embodiments, one or more steps in FIG. 4 may be performed by a processor-based device executing computer-readable instructions stored on a memory device, a human operator, and / or a combination thereof. In some embodiments, one or more steps of FIG. 4 may be performed by the central computer system 200 and / or the mobile robot 210 described with reference to FIG. 2 herein or other similar devices.

[0041] In step 401, the system configuration is initially defined. In some embodiments, the design model may be generated in step 410 which may include a 2D, 3D, or 4D (e.g., 3D over time) building information computer model, such as a Revit model. In step 405, a system map corresponding to the initial system configuration (e.g., 3D design model) is determined and stored. In step 407, a robot control system (RCS) map may also be stored for use by the robot control system. In some embodiments, the RCS may be less detailed and require less accuracy as compared to the mapping file used by the mobile robots. In step 409, an initial mapping file is determined based on the system design configuration. The mapping file may include a map of the structure using coordinate codes (e.g., universal coordinate code (UCC)) and a structural local library (SLL) that indicates the dimensions and feature locations of structures, components, and markers of the structure. In some embodiments, the markers may each encode the UCC corresponding to its location within the structure. In some embodiments, the design model in step 401, the system map in step 405, and the initialmapping file in step 409 may individually or collectively be referred to as the design map as they correspond to the as-design configuration of the structure.

[0042] In step 402, the bills of material (“BOM”) for the system and one or more mobile robots are generated to drive manufacturing. In step 410, the system is manufactured. For example, tracks, fasteners, support elements, markers, etc. may be manufactured at one or more facilities based on the BOM. In step 411, the system is installed. In some embodiments, the system may be installed in a fulfillment facility for storage of totes containing items for order fulfillment. In some embodiments, the installation of the system includes the assembly of structural components and markers such as flags and RFID tags according to the system design model.

[0043] In step 420, the mobile robots are manufactured. For example, the drive system, the cab, the wheels, etc. of the mobile robot are formed and assembled. The robots may also be “fingerprinted” for the system by loading data onto the local memory of the mobile robot. The data may include discrete data such as travel limits and trace data (e.g., as current traces during a move). In step 421, the mobile robots are configured. In some embodiments, the configuration process includes loading an as-design mapping file from step 409 onto the robot to allow the mobile robot to automatically or semi-autonomously traverse the structure and / or perform tasks. In step 422, the mobile robots are inducted into the system by, for example, physically placing the robot on the assembled structure and establishing a communication channel by the central computer system and the mobile robot. In step 412, the mobile robots and the structure go through an initial system-level fingerprinting after installation. For example, the robot may travel the structure and register trace data such as the current trace of a climbing tower or a vibration signature of a gap.

[0044] In step 430, an initial system scanning is performed. In some embodiments, the mobile robots may be sent to different destinations in the structure to capture data from different parts of the structure. In some embodiments, a mobile robot may be configured to enter a verification mode in which it travels at a reduced speed to collect data at high fidelity. In step 431, the design map corresponding to the as-designed configuration of the structure is compared to the data captured in step 430. In step 432, if the design map and the captured data match, or all deviations are within a predetermined tolerance, the mapping file isconfirmed and unchanged. If a mismatch is identified in step 432, in step 434, the degree of inconsistency is determined. If the inconsistency is greater than a correction threshold (e.g., threshold distance or percentage), an alert for a systemic issue may be generated in step 436. For a systemic issue, the system map and / or the robot system control (RSC) map be modified. In some embodiments, adjustment of the structure and / or system may be performed in response to the detection of a systematic issue. If the inconsistency is under a correction threshold in step 435, delta files indicating differences may be created and stored as system data as-configured in step 440. In some embodiments, the as-configured system data may be used to update or supplement the mapping file used by the mobile robots for navigation.

[0045] Next referring to FIG. 5, a process for ongoing verification of a structure is shown. In some embodiments, one or more steps in FIG. 5 may be performed by a processorbased device executing computer-readable instructions stored on a memory device, a human operator, and / or a combination thereof. In some embodiments, one or more steps of FIG. 5 may be performed by the central computer system 200 and / or the mobile robot 210 described with reference to FIG. 2 herein or other similar devices.

[0046] In step 501, data is collected by the mobile robot and / or the system as the robot mobiles travel on the structure to perform tasks. In some embodiments, data may be collected by multiple components of the system such as the RSC, multiple mobile robots, a workstation, etc. during normal operations of these components. In some embodiments, the generated data may include alarms, warnings, alerts, and discrete and trace data 510. In some embodiments, the stored data may include equipment discrete and trace data, failure data, and / or utilization data. In step 520, the collected data may be used for bot-level analytics. Differences detected via the bot-level analytics may generate bot-level alarm / warnings / alerts in step 521. In some embodiments, workstations may also perform workstation-level analytics. In step 530, the collected data may also be used for system-level analytics at a server such as a cloud-based server. Differences detected via the system-level analytics may generate system-level alarms / warnings / alerts in step 531. In step 540, bot or system level alarms / wamings / alerts may lead to correction and / or preventive actions. In someembodiments, the correction and / or preventive actions may include adjustments to the system and / or updates of mapping files such as to the delta files.

[0047] Fig. 7 is a flowchart of an example method for mapping a storage retrieval system. In step 710, data is captured with a sensor system of a mobile robot while the mobile robot is traversing a section of a structure. In some embodiments, the mobile robot may be the mobile robot 210 or a similar device. In some embodiments, step 710 may correspond to step 320.

[0048] In step 720, the data captured by the sensor system is compared with a design map of the structure to detect a deviation associated with the section. In some embodiments, step 720 may be performed by the control circuit of the central computer system 220 and / or the mobile robot 210. In some embodiments, step 720 may correspond to steps 330 and 340.

[0049] In step 730, a mapping file is updated based on the deviation. In some embodiments, step 720 may be performed by the control circuit of the central computer system 220 and / or the mobile robot 210. In some embodiments, 720 may correspond to step 350.

[0050] In some embodiments, in the systems and methods described, a structure is assembled based on a design model. In some embodiments, dimensions and locations (e.g., via UCC and SLL) may be determined based on the design model data to form an “as- designed” map. However, the assembled system may not be identical to the original design model due to various factors such as part tolerances, site inaccuracies, and installation inaccuracies.

[0051] Manually adjusting the map used by robots to match the system as-built can be tedious and time-consuming. Automating dimension and location marker checks and corrections with scans performed by mobile robots can save time and labor and reduce errors. In some embodiments, bots and systems may be fingerprinted to establish an operational baseline from which to compare with future events. In some embodiments, local monitoring of operational data with respect to original fingerprints provides a data source for analytics that leads to predictive maintenance and reduced downtime. In some embodiments, enterprise-level monitoring of operational data across sites also provides a data source foranalytics that leads to predictive maintenance and reduced downtime across a mobile robot fleet.

[0052] In some aspects, the techniques described herein relate to a dispenser apparatus, including: a cart compartment sized to receive a shopping cart and accessible from a fulfillment side and a pickup side; a temperature-controlled compartment positioned above the cart compartment and accessible from the fulfillment side and the pickup side; an access door on the pickup side; and an access controller configured to control access to the cart compartment and the temperature-controlled compartment via the access door.

[0053] In some aspects, the techniques described herein relate to an item dispensing system including: a plurality of dispenser apparatuses each including: a cart compartment; a temperature-controlled compartment; and an access door for controlling access to the cart compartment and the temperature-controlled compartment from a pickup side; and a central computer system including a control circuit configured: track statuses of the plurality of dispenser apparatuses based on communications with access controllers and / or sensor systems of each of the plurality of dispenser apparatuses; and provide fulfillment instructions based on the statuses of the plurality of dispenser apparatuses.

[0054] In some aspects, the techniques described herein relate to a method of dispensing items including: receiving, at a central computer system, an order; associating, in an order database, an item dispenser with the order, the item dispenser includes: a cart compartment sized to receive a shopping cart and accessible from a fulfillment side and a pickup side; a temperature-controlled compartment positioned above the cart compartment and accessible from the fulfillment side and a pickup side; and an access controller configured to control access to the cart compartment and the temperature-controlled compartment via an access door on the pickup side; and unlocking, via the access controller, the access door in response to receiving an unlock request.

[0055] 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 structure verification system comprising: a structure having a plurality of sections configured to allow a mobile robot to traverse the structure; and a control circuit configured to: receive data from a sensor system of the mobile robot captured while the mobile robot is traversing a section of the structure; compare the data captured by the sensor system with a design map of the structure to detect a deviation associated with the section; and update a mapping file based on the deviation; and wherein the mobile robot is configured to subsequently travel on the structure based at least on the mapping file.

2. The system of claim 1, wherein the sensor system comprises: an optical sensor, a radio frequency identification (RFID) sensor, a vibration sensor, a sound sensor, a tachometer, an odometer, a pressure sensor, a voltmeter, an accelerometer, a gyroscope, a magnetometer, a temperature sensor, a humidity sensor, and / or an inertial measurement unit (IMU).

3. The system of claim 1, wherein the data comprises one or more detected features each associated with a capture location.

4. The system of claim 3, wherein the capture location is determined based on a distance traveled by a drive system of the mobile robot from a reference feature in the structure.

5. The system of claim 1, wherein the design map comprises locations of one or more features of the structure, the one or more features comprising: an optical marker, an RFID marker, a structural feature, a track connection, a track gap, a fastening element, a support element, and / or an electrical element.

6. The system of claim 1, wherein deviations are detected based on detecting for markers of the structure each encoding a unique 3D coordinate value corresponding to the marker’s location in the structure.

7. The system of claim 1, wherein the design map comprises dimension and feature location information from a computer aided design (CAD) model according to which the structure is assembled.

8. The system of claim 1, wherein the mapping file comprises delta values indicating changes relative to the design map, and wherein the mobile robot is configured to control its movement based on the delta values and the design map.

9. The system of claim 1, wherein the control circuit is further configured to simulate sensor data of the mobile robot along the section based on the design map, wherein the deviation is detected based on comparing the data captured by the sensor system and the simulated sensor data.

10. The system of claim 1, wherein the control circuit is further configured to: receive additional data captured by a second sensor system of a second mobile robot while the second mobile robot is traversing the section of the structure based on the mapping file; compare the data captured by the second sensor system with the design map of the structure to detect additional deviation associated with the section; and update the mapping file based on the additional deviation.

11. The system of claim 1, wherein the mobile robot is configured to store a copy of the mapping file on a local memory storage device.

12. The system of claim 1, wherein the data is captured while the mobile robot is traveling to a storage location of the structure to retrieve or store a storage tote.

13. The system of claim 1, wherein the mobile robot is configured to travel at a transport speed to retrieve and return storage totes and a scanning speed that is slower than the transport speed, and wherein the data from the sensor system are captured while the mobile robot is traveling at the scanning speed.

14. The system of claim 1, wherein the structure comprises a multilevel structure and the section comprises a horizontal section, a vertical section, and / or a ramp.

15. The system of claim 1, wherein the mobile robot is configured to receive a destination identifier from a central computer system and autonomously traverse the structure towards a location associated with the destination identifier based on features and / or markers of the structure.

16. The system of claim 1, wherein the control circuit comprises an on-board processor of the mobile robot.

17. The system of claim 1, wherein the control circuit comprises a central computer system configured to send instructions to the mobile robot and update the mapping file stored on the mobile robot.

18. The system of claim 1, wherein the control circuit is further configured to determine whether the deviation exceeds a predetermined threshold and generate an alert in response to the deviation exceeding the predetermined threshold.

19. The system of claim 1, the mapping file is updated based on sensor data from a plurality of mobile robots.

20. A method for mapping a storage retrieval system comprising: capturing data with a sensor system of a mobile robot while the mobile robot is traversing a section of a structure;comparing, with a control circuit, the data captured by the sensor system with a design map of the structure to detect a deviation associated with the section; and updating, with the control circuit, a mapping file based on the deviation.