Manufacturing system with interconnected storage structure and manufacturing cells sharing common robots

Abstract

A manufacturing system is provided, comprising: an automated storage system (ASRS) structure having a three-dimensional array of storage locations distributed throughout a two-dimensional footprint of the ASRS structure at multiple storage levels; workpieces stored within the storage locations of the ASRS structure; a robotic storage / retrieval vehicle that can navigate in three dimensions within the ASRS structure to access the storage locations; and a plurality of manufacturing cells located outside the ASRS structure. The manufacturing system includes a track structure connected to the ASRS structure, the track structure defining one or more travel paths that RSRVs can travel from the ASRS structure. The same fleet of RSRVs that can navigate within the ASRS structure is operable to transfer workpieces to the manufacturing cells. One or more manufacturing cells are positioned along the track structure to obtain convenient access to workpieces and associated tooling and workpiece holders to manufacture items.

Description

[0001] This application claims priority to and the benefit of a provisional patent application entitled “Manufacturing Facility with Interconnected Storage Structure and Manufacturing Cells Sharing a Common Robotic Fleet” filed with the United States Patent and Trademark Office (USPTO) on June 11, 2019, with application number 62 / 860,024. The specification of the above-referenced patent application is incorporated herein by reference in its entirety. Technical Field

[0002] In general, embodiments herein relate to manufacturing. More specifically, embodiments herein relate to a manufacturing system having interconnected automated storage systems (ASRS) and manufacturing cells that share a fleet of common robotic storage / retrieval vehicles (RSRVs) that navigate within the ASRS structure and deliver components from the ASRS structure to the various manufacturing cells of the manufacturing system. Background Art

[0003] Automation in manufacturing generally refers to the implementation of systems that perform mechanical operations such as machining, assembly, material handling, etc. in a fully automated manner. Automated manufacturing includes the automated steps of the manufacturing process, and in addition to the automated steps, the manufacturing process also involves the transfer of specific components such as workpieces, workpiece holders, tooling, etc. required in various manufacturing cells of the manufacturing facility according to the specific manufacturing process performed in each manufacturing cell. As automation technology continues to develop, most operations in manufacturing facilities are usually performed using automated machines and robots with minimal human intervention. In some automated manufacturing facilities, the order of processing operations is determined by the configuration of the manufacturing equipment and cannot be changed from one order to another. In other automated manufacturing facilities that implement programmable automation, reprogramming and changing over the manufacturing equipment for each order is time-consuming and causes long periods of downtime, thereby reducing manufacturing speed. Given that reprogramming and changing over of manufacturing equipment is time-intensive, other automated manufacturing facilities significantly limit the number and variety of items manufactured, further reducing manufacturing speed.

[0004] Traditionally, manufacturing follows a linear workflow where each manufacturing step is performed in a sequence defined by a typical unidirectional flow of a conveyor system or transport path. Once the workflow is designed and the conveyors are fixed on the factory floor, the manufacturing workflow is essentially difficult to modify as demand changes. With customer expectations for customized products increasing rapidly, manufacturers aim to stand out by focusing on the customer experience. Therefore, automation and manufacturing systems with the ability to easily and flexibly adapt to changing conditions are needed.

[0005] Traditional manufacturing facilities include dispersed manufacturing areas divided into two or more, and mostly separate or separate lines, in which manufacturing units are interconnected by large-scale remote conveyor systems and transportation paths. The layout of traditional manufacturing facilities usually relies on large-scale remote conveyor systems, numerous channels between shelves, and widely spaced and discontinuous manufacturing areas, so it is space-intensive, operation-intensive and equipment-intensive. The traditional system divides each manufacturing process into independent functions, which are managed by independent entities connected by fixed conveyor belts or ground transportation. The manufacturing process usually includes receiving, preparing materials, setting up sub-assemblies and final assembly, which are usually independent processes operated by independent manufacturing equipment connected by linear conveyors or ground transportation. According to the assembly process, the manufacturing unit is usually configured for a single sub-assembly and requires many transportation paths to complete the final assembly. All manufacturing processes need to be completed by a single automated material handling system, which does not require remote conveyors or ground transportation, and the manufacturing unit can be software configured and programmed as needed.

[0006] The automated storage system (ASRS) used in some manufacturing facilities is usually not connected to the manufacturing unit, making it difficult to access the components stored in the ASRS and required for the manufacturing process to be performed in the manufacturing unit. In addition, the ASRS equipment relies on downstream sorting solutions to deliver items to the work area at the right time and in the right order. It is necessary to integrate an ASRS capable of handling a large amount of inventory into a manufacturing environment by connecting an expandable manufacturing unit to the ASRS to provide convenient access to a large number of components, thereby optimizing the manufacture of items, such as workpieces and workpiece kits and related tool parts and workpiece holders. In addition, it is necessary to configure manufacturing units in real time for a variety of on-demand manufacturing processes, and to transport items between all manufacturing units in any order, thereby allowing any number of processes to be completed multiple times in any order. In addition, it is necessary to deliver workpieces, tool parts and workpiece holders to the manufacturing unit on time at any stage of the manufacturing process to manufacture sub-assemblies on time.

[0007] Another difficulty with traditional manufacturing methods is that they rely on one-way conveyors and line flow paths between processes, which require buffer storage if the line flow rates are different. Without buffer storage, if the upstream process is processing items faster than the downstream process at any given time, materials will quickly accumulate and paralyze the system. Due to the complexity and expense of buffer storage for each process, traditional automation solutions attempt to solve the problem through strict front-end equipment and workflow design, as well as meticulous management during operation to ensure acceptable flow between processes. As a result, workflows cannot be flexibly changed once established, and manufacturers remain vulnerable to unexpected disruptions.

[0008] In addition, in the traditional method, the components such as workpieces must be physically transferred from one manufacturing unit to another. In addition, each manufacturing unit receives the components and identifies the components, such as by barcode scanning, radio frequency identification (RFID) scanning, etc., to complete the logical transfer of custody between entities, which is another disadvantage of traditional logistics. In addition, because traditional automation solutions rely on miles of fixed conveyors or travel paths on the ground, and most of the vertical space above the conveyor system and workstations is not used, the footprint of the entire operation is relatively large.

[0009] Therefore, there has long been a need for a manufacturing system with interconnected ASRS and manufacturing cells, wherein the ASRS and manufacturing cells share a fleet of common robotic storage / retrieval vehicles (RSRVs), wherein the RSRV navigates within the ASRS structure and transfers components from the ASRS structure to various manufacturing cells of the manufacturing system to manufacture items in a time-efficient, space-efficient and operationally efficient manner, while solving the above-mentioned problems associated with the prior art. Summary of the invention

[0010] This summary is provided to introduce various concepts that are further disclosed in the detailed description in a simplified form. This summary is not intended to limit the scope of the claimed subject matter.

[0011] Embodiments of the present invention address the needs of the above-mentioned manufacturing system, which has an interconnected automated storage system (ASRS) and manufacturing cells, wherein the ASRS and manufacturing cells share a team of common robotic storage / retrieval vehicles (RSRVs), wherein the RSRV navigates within the ASRS structure and transfers components from the ASRS structure to the various manufacturing cells of the manufacturing system to manufacture items in a time-efficient, space-efficient, and operationally efficient manner. The manufacturing system disclosed herein can easily and flexibly adapt to changing conditions. Embodiments of the present invention allow all manufacturing processes to be completed through a single automated manufacturing system, which does not require remote conveyors or ground transportation, and the manufacturing cells can be software-configured as needed. Embodiments of the present invention integrate an ASRS capable of handling a large amount of inventory into a manufacturing environment by connecting an expandable manufacturing cell to the ASRS to provide convenient access to multiple components, thereby optimizing item manufacturing, such as workpieces and workpiece kits and related tooling and workpiece holders.

[0012] In the manufacturing system disclosed herein, manufacturing cells can be configured instantly for a variety of on-demand manufacturing processes. In addition, the manufacturing system allows components and items to be transported in any order and sequence between all manufacturing cells, rather than being transported linearly by conveyors, thereby allowing any number of processes to be completed multiple times in any order. In addition, the manufacturing system disclosed herein delivers components to manufacturing cells on time at any stage of the manufacturing process to manufacture sub-assemblies on time. In addition, the manufacturing system disclosed herein allows components and finished products in the ASRS structure to be buffered between processes performed by the manufacturing cells. In addition, the continuity between each ASRS structure and the manufacturing cells outside the ASRS structure allows components and finished products to be directly physically transferred without the need to identify or scan components and finished products.

[0013] The manufacturing system disclosed herein includes a storage configuration, the storage configuration including an ASRS structure, a batch of workpieces and a team of RSRVs. The ASRS structure includes a three-dimensional array of storage locations, the storage locations are distributed throughout the two-dimensional footprint of the ASRS structure of multiple storage layers within the ASRS structure. The batch of workpieces is stored in the storage location of the ASRS structure for manufacturing items from the workpieces. Each RSRV in the team of RSRVs can navigate along three dimensions within the ASRS structure to enter the storage location in the 3D array. In one embodiment, the ASRS structure includes at least one track assembly layer, the track assembly layer including a 2D grid track layout. The team of RSRVs can navigate along at least two dimensions on the 2D grid track layout within the ASRS structure. The manufacturing system disclosed herein further includes a plurality of manufacturing units located outside the ASRS structure. In one embodiment, the manufacturing system disclosed herein further includes a track structure connected to the ASRS structure, the track structure extending beyond the 2D footprint of the ASRS structure to define the extension of the ASRS structure. In one embodiment, the track structure is an extension of the 2D grid track layout of the track assembly layer of the ASRS structure. The track structure is configured to define one or more travel paths on which the RSRV can navigate and along which the manufacturing units are distributed. The same team of RSRVs that can navigate in three dimensions within the ASRS structure can be operated to transfer workpieces to the manufacturing units. In one embodiment, the workpieces can be transported between each manufacturing unit in any order. In another embodiment, the first manufacturing unit in the manufacturing unit receives the workpiece to perform one or more of the multiple processing steps of the manufacturing process, then stores the workpiece in a storage location of the ASRS structure, and then retrieves the workpiece from the storage location of the ASRS structure to transfer the workpiece to a second manufacturing unit in the manufacturing unit. In another embodiment, each manufacturing unit is configured to receive the workpiece multiple times to perform one or more processing steps of the manufacturing process.

[0014] In one embodiment, the storage configuration of the manufacturing system disclosed herein further includes a batch of tool pieces for manufacturing items. The tool pieces are stored in the same ASRS structure as the workpieces. The tool pieces can be taken out from the same ASRS structure by the same team of RSRVs and transferred to the manufacturing unit.

[0015] In one embodiment, the storage configuration of the manufacturing system disclosed herein further includes a batch of storage units of compatible size and shape for storage in the storage location of the ASRS structure. The storage unit is configured to be carried by the RSRV to transfer the storage unit to and from the storage location, and to and from the manufacturing unit. In one embodiment, the storage unit includes a workpiece storage unit or a tool storage unit or any combination thereof. Each workpiece storage unit is configured to accommodate one or more workpieces. Each tool storage unit is configured to accommodate one or more tools. In one embodiment, the manufacturing units are configured to be arranged in a continuous arrangement outside the ASRS structure. In one embodiment, due to the continuous arrangement of the manufacturing units, the storage units are configured to be transferred to and from the storage location of the ASRS structure, and to and from the manufacturing units without the need to identify the storage unit.

[0016] In one embodiment, the workpiece storage unit includes an inventory storage unit and a kit storage unit. Each inventory storage unit is configured to include a collection of inventory workpieces. Each kit storage unit is configured to include a kit of mixed workpieces, wherein the mixed workpieces are picked up from one or more inventory storage units according to the manufacturing process that will be performed on the mixed workpieces once they are transferred to a manufacturing unit. In another embodiment, the manufacturing system disclosed herein further includes at least one stock preparation workstation, which is configured to receive inventory storage units transferred from the ASRS structure by the RSRV to allow inventory workpieces to be picked up from the inventory storage units at the stock preparation workstation. In one embodiment, the stock preparation workstation is configured to receive the unloading of workpiece storage units by the same team of RSRVs, and / or the travel of workpiece storage units through the stock preparation workstation.

[0017] In one embodiment, the storage configuration of the manufacturing system disclosed herein further includes a batch of workpiece holders. Each workpiece holder is configured to accommodate one or more workpieces in a predetermined position during the manufacture of the item. The workpiece holder is stored in the same ASRS structure as the workpiece. The workpiece holder can be taken out from the same ASRS structure by the same team of RSRVs and transferred to the manufacturing unit. In one embodiment, each workpiece holder has a universal footprint with standardized size and shape, and the size and shape of the universal footprint are the same as the compatible size and shape of each of the batch of storage units, and is configured to fit in the storage position of the ASRS structure. Each workpiece holder includes a base, and the base has a standardized shape and size, which is configured to fit in the storage position of the ASRS structure. In one embodiment, each workpiece holder and each storage unit are configured to have a matching layout with interface features, and the RSRV interacts with the workpiece holder and the storage unit through the matching layout to allow the workpiece holder and the storage unit to be loaded into and unloaded from the RSRV.

[0018] In one embodiment, in addition to the batch of workpieces stored in the storage location of the ASRS structure, the storage configuration also includes a batch of tool pieces or a batch of workpiece holders stored in the ASRS structure. Each tool piece is useful for performing one or more processing steps of a manufacturing process on one or more workpieces during the manufacture of an item. Each workpiece holder is configured to accommodate one or more workpieces in a predetermined position during the manufacture of an item. In this embodiment, the team of RSRVs is operable to extract at least one of the tool piece and the workpiece holder and the workpiece from the storage location. The same team of RSRVs that can navigate along three dimensions within the ASRS structure is operable to transfer materials or components, such as workpieces and tool pieces and / or workpiece holders, between manufacturing units. In one embodiment, the components can be transported between each manufacturing unit in any order. In another embodiment, each manufacturing unit is configured to receive the components multiple times to perform one or more processing steps of a manufacturing process.

[0019] In one embodiment, each manufacturing unit includes at least one workpiece receiving area, and the workpiece receiving area is configured to receive a workpiece to be processed in the corresponding manufacturing unit. The workpiece receiving area is configured to receive a workpiece storage unit placed thereon. In one embodiment, the workpiece receiving area includes two workpiece receiving areas. Each of the two workpiece receiving areas is configured to receive a set of workpieces required by the corresponding manufacturing unit.

[0020] In one embodiment, at least a subset of the manufacturing cells are located on the track structure or in a region of the track structure. In one embodiment, the track structure is a grid track structure including a plurality of sets of intersecting tracks on which the RSRV can navigate in two dimensions. In one embodiment, the width of the workpiece receiving area in each of the two dimensions is generally equal to an integer multiple of the distance between two adjacent parallel tracks of the grid track structure. In another embodiment, the width of the workpiece receiving area in each of the two dimensions does not exceed the distance between two adjacent parallel tracks of the grid track structure.

[0021] In one embodiment, the grid track structure includes square blocks. Each square block is defined by a first pair of parallel tracks in a first direction and a second pair of parallel tracks in a second direction, wherein the second direction is perpendicular to the first direction. Each manufacturing unit occupies a unit space, and the area of ​​the unit space is equal to the area of ​​a predetermined number of square blocks. In one embodiment, at least one unit space is a square space, and the area of ​​the square space can be divided into nine square subspaces. The area of ​​each of the nine square subspaces is equal to the area of ​​one square block of the grid track structure. Four corner subspaces of the nine square subspaces are configured as a receiving area, and the receiving area is used to receive materials required by the corresponding manufacturing unit. In one embodiment, a first pair of intermediate surrounding subspaces between the four corner subspaces on the first pair of opposite surrounding sides of the unit space are occupied by robot workers. In one embodiment, a central subspace between the robot workers is configured as a working area, and a workpiece is transferred to the working area, and the workpiece is processed by the robot worker in the working area. In one embodiment, a second pair of intermediate surrounding subspaces between the four corner subspaces on the second pair of opposite surrounding sides of the unit space are adjacent to the working area. In one embodiment, at least one of the second pair of intermediate peripheral subspaces is an unoccupied open area through which the RSRV is configured to enter and exit the work area. In another embodiment, each of the second pair of intermediate peripheral subspaces is an unoccupied open area, whereby the RSRV is configured to completely travel through the corresponding manufacturing unit.

[0022] In one embodiment, each manufacturing unit includes at least one robotic picker operable to pick up workpieces from the workpiece receiving area. In another embodiment, each manufacturing unit further includes a working area, and the picked workpieces are transferred from the workpiece receiving area to the working area by the robotic picker.

[0023] In one embodiment, each manufacturing unit in the subset includes at least one tool receiving area, the tool receiving area being configured to receive the tooling required in the corresponding manufacturing unit. In one embodiment, the width of the tool receiving area in each of two dimensions is generally equal to the distance between two adjacent parallel tracks of the grid track structure. In another embodiment, the width of the tool receiving area in each of the two dimensions does not exceed the distance between two adjacent parallel tracks of the grid track structure. In one embodiment, each manufacturing unit in the subset includes at least one robotic worker, the robotic worker being mounted on top of a mounting base, the mounting base being mounted on or in the grid track structure. In one embodiment, the width of the mounting base in each of the two dimensions is generally equal to an integer multiple of the distance between two adjacent parallel tracks of the grid track structure. In another embodiment, the width of the mounting base in each of the two dimensions does not exceed the distance between two adjacent parallel tracks of the grid track structure.

[0024] In one embodiment, the manufacturing unit of the manufacturing system disclosed herein is configured as a multi-layer structure, and the multi-layer structure includes multi-layer manufacturing units. In one embodiment, the multi-layer structure includes: a grid track structure, located at each of the multiple layers; and an upright frame member. The grid track structure includes multiple sets of cross tracks, and the RSRV can navigate along two dimensions on the cross tracks. The upright frame members interconnect the cross tracks of the multiple layers. In one embodiment, one or more upright frame members are configured to enable the RSRV to travel in an ascending direction and / or a descending direction on the upright frame members to transfer between the multiple layers. In one embodiment, the grid track structure of one layer in the multiple layers of the multi-layer structure is connected to a corresponding layer in the storage layer in the ASRS structure, and the RSRV is configured at the corresponding layer to transfer between the ASRS structure and the multi-layer structure.

[0025] In one embodiment, the manufacturing unit includes a fully automated manufacturing unit and one or more manually-attended manufacturing units configured relative to the grid track structure. The fully automated manufacturing unit is located in a distributed position in the main inner area of ​​the entire grid track structure. The manually-attended manufacturing unit is located in the peripheral area of ​​the grid track structure.

[0026] In one embodiment, the manufacturing system disclosed herein further includes a computer control system (CCS), which is operable to communicate with the team of RSRVs. The CCS includes: a network interface, connected to a communication network; at least one processor, connected to the network interface; and a non-transitory computer-readable storage medium, communicatively connected to the processor. The non-transitory computer-readable storage medium, such as a memory unit, is configured to store computer program instructions, which, when executed by the processor, cause the processor to start one or more RSRVs to perform one or more of the following: (a) navigate within the ASRS structure and / or navigate through the manufacturing unit; (b) retrieve one or more workpieces contained in one or more storage units from a storage location of the ASRS structure; (c) transfer one or more workpieces contained in one or more storage units to at least one material preparation workstation to package and prepare the workpieces into one or more kit storage units; (d) pick up one or more kit storage units from the material preparation workstation; (e) transfer one or more kit storage units to the ASRS structure; (f) transfer one or more workpieces contained in one or more storage units to the ASRS structure; (g) transfer one or more workpieces contained in one or more storage units to the ASRS structure; (h) transfer one or more workpieces contained in one or more storage units to the ASRS structure; (h) transfer one or more workpieces contained in one or more storage units to the ASRS structure; (i) transfer one or more workpieces contained in one or more storage units to the ASRS structure; (j ... (f) taking out from the same ASRS structure: one or more kit storage units and at least one of the one or more workpieces contained in another one or more storage units, one or more tool parts contained in another one or more storage units, and one or more workpiece holders; (g) transferring the one or more kit storage units and at least one of the one or more workpieces contained in another one or more storage units, one or more tool parts contained in another one or more storage units, and one or more workpiece holders to a manufacturing unit to manufacture the items; and (h) introducing the items on the final workpiece holders into the ASRS structure.

[0027] A method for executing a workflow in a manufacturing system is also disclosed herein. In the method disclosed herein, workpieces and workpiece holders are stored in corresponding storage locations of an ASRS structure. Workpieces are stored in workpiece storage units of storage locations. In one embodiment, each workpiece storage unit is filled with a kit of different workpieces according to the requirements of the manufacturing process. In one embodiment, each workpiece storage unit is filled at a material preparation workstation connected to the ASRS structure. At the material preparation workstation, the team of RSRVs is configured to convey inventory storage units taken out from corresponding storage locations in the ASRS structure, the inventory storage units including inventory workpieces; pick up different workpieces of the kit from the inventory workpieces in the inventory storage unit and compile them into the workpiece storage unit; and each workpiece storage unit is transported away from the material preparation workstation by an RSRV and stored in a corresponding storage location in the ASRS structure for subsequent removal from the ASRS structure.

[0028] In one embodiment, tool storage units configured to hold tool pieces used in a manufacturing process are stored in an ASRS structure. Using the fleet of RSRVs that can navigate within the ASRS structure, one or more workpiece storage units and selected workpiece holders are extracted from the ASRS structure and transferred to the manufacturing cell respectively according to the requirements of the manufacturing process to be performed in the manufacturing cell outside the ASRS structure. In one embodiment, the same type of RSRV is configured to perform the extraction and transfer of the workpiece storage unit and the selected workpiece holder from the ASRS structure to the manufacturing cell separately. At the manufacturing cell, the selected workpiece holder is positioned at a work position accessible to one or more workers of the manufacturing cell. At the manufacturing cell, with the selected workpiece holder fixed in the work position, (i) one or more workpieces are transferred from the workpiece storage unit to the selected workpiece holder; and (ii) the processing steps of the manufacturing process are performed on the workpieces fixed to the selected workpiece holder. In one embodiment, before performing the processing steps of the manufacturing process, a subset of the tool storage units are extracted from the ASRS structure using one RSRV and transferred to the manufacturing cell. In one embodiment, before executing a processing step of the manufacturing process, a tool selected from a subset of the tool storage unit is attached to the robotic worker of the manufacturing cell according to the requirements of the manufacturing process to be performed by the robotic worker on the workpiece.

[0029] In one embodiment, the workpiece storage unit includes two workpiece storage units. In one embodiment, the two workpiece storage units are transferred to two corresponding receiving areas of the manufacturing unit. The two workpieces are transferred from the two workpiece storage units placed in the two corresponding receiving areas to the selected workpiece holders.

[0030] In one embodiment, after the workpieces are transferred from the workpiece storage unit to the selected workpiece holder, the unneeded or empty workpiece storage unit is removed from the manufacturing unit, wherein the selected workpiece has been removed and there are no more workpieces required for the manufacturing process of the manufacturing unit. In this embodiment, an RSRV is used to transfer additional workpiece storage units to the manufacturing unit, and the additional workpiece storage unit includes one or more additional workpieces required for the manufacturing unit. In one embodiment, the additional workpieces are used for different manufacturing processes to be performed in the same manufacturing unit. In one embodiment, the unneeded or empty workpiece storage unit is removed using a different RSRV than the RSRV that transfers the additional workpiece storage unit to the manufacturing unit. In one embodiment, the different RSRV is configured to remove the unneeded or empty workpiece storage unit after the different workpiece storage unit has been unloaded at the different manufacturing unit to supply the contents of the different workpiece storage unit to the different manufacturing unit. After performing a processing step of a manufacturing process on a workpiece secured to a selected workpiece holder, removing the selected workpiece holder and the workpiece thereon from the manufacturing cell; transferring another workpiece holder to the manufacturing cell using an RSRV for use in a different manufacturing process; supporting the workpiece holder in a working position; transferring additional workpieces from an additional workpiece storage unit to the workpiece holder; and performing one or more processing steps of the different manufacturing process on the additional workpieces.

[0031] In the method disclosed herein, after the finished product is completed by processing the workpieces in one or more manufacturing cells, the finished product is introduced into the ASRS structure on the one RSRV. In one embodiment, one or more final processing steps are performed on the final workpiece support to complete the finished product, and the finished product on the final support is introduced into the ASRS structure. In one embodiment, the final workpiece support is the same as the selected workpiece support to which the workpiece is transferred.

[0032] The manufacturing system and method disclosed herein integrates an ASRS structure with multiple manufacturing cells in a manner to perform various manufacturing processes on the multiple manufacturing cells. In the manufacturing system and method disclosed herein, a grid track structure connected to the lower 2D grid of the ASRS structure allows the same team of RSRVs to continuously provide operations to all manufacturing cells, wherein the same team of RSRVs can navigate to and from the ASRS structure, and to and from each manufacturing cell.

[0033] In one or more embodiments, the related system includes circuits and / or programming for performing the methods disclosed herein. Circuits and / or programming are any combination of hardware, software, and / or firmware configured to perform the methods disclosed herein according to the design choices of the system designer. In one embodiment, various structural elements are used depending on the design choices of the system designer. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] The foregoing summary of the invention and the following detailed description will be better understood when read in conjunction with the accompanying drawings. To illustrate the embodiments herein, illustrative structures of the embodiments are shown in the accompanying drawings. However, the embodiments herein are not limited to the specific structures, components and methods disclosed herein. The description of the structure, component or method step represented by the figure mark in the accompanying drawings is applicable to the description of the structure, component or method step represented by the same figure mark in any subsequent drawings herein.

[0035] Figure 1 is a top plan view of a manufacturing system according to an embodiment of the present invention, the manufacturing system including an automated storage and retrieval system (ASRS) structure adjacent to a material preparation area and a manufacturing center.

[0036] Figure 2 According to one embodiment of this invention, Figure 1 A side perspective view of the manufacturing system shown in FIG.

[0037] Figure 3 is a top isometric view of a three-dimensional grid storage structure defining an ASRS structure of a manufacturing system according to one embodiment of the present invention.

[0038] Figure 4A A robotic storage / retrieval vehicle (RSRV) and compatible storage units employed in an ASRS configuration of a manufacturing system according to an embodiment of the present invention.

[0039] Figure 4B An embodiment according to this invention is shown Figure 4A An RSRV and a compatible storage unit are shown showing the turntable arm of the RSRV extended to engage the storage unit to push or pull the storage unit onto the RSRV.

[0040] Figure 4C According to one embodiment of this invention, Figure 4A A bottom plan view of a storage unit is shown.

[0041] Figure 4D According to one embodiment of this invention, Figure 4A A partial cross-sectional view of a memory cell shown in FIG. 1, showing interface features on the bottom side of the memory cell configured to interface with FIG. 4A to FIG. 4B The RSRV shown is compatible.

[0042] Figure 5A FIG. 1 is a top perspective view of a workpiece support that can be stored in an ASRS structure according to an embodiment of the present invention.

[0043] Figure 5B According to one embodiment of this invention, Figure 5A A top plan view of the workpiece support is shown in FIG.

[0044] Figure 5C According to one embodiment of this invention, Figure 5A A side view of the workpiece support is shown in FIG.

[0045] Fig. 6A For Figure 5A 0026] FIG1 is a top perspective view of a workpiece holder shown in FIG1 , showing a workpiece accommodated in the workpiece holder.

[0046] Figure 6B FIG. 1 is a top plan view of a workpiece support according to an embodiment of the present invention, wherein a workpiece is accommodated in the workpiece support.

[0047] Figure 7 According to one embodiment of this invention, Figure 1 to Figure 2 A top plan view of a material preparation area of ​​a manufacturing system is shown in FIG.

[0048] FIG. 8A to FIG. 8D According to different embodiments of this invention, Figure 1 to Figure 2 A partial top plan view of a manufacturing center of a manufacturing system shown in FIG. 1 shows a fully automatic manufacturing unit and an adjacent manually-attended manufacturing unit, wherein different storage units are used in the manufacturing workflow.

[0049] Fig. 9A According to one embodiment of this invention, Figure 1 to Figure 2 A perspective view of a fully automated manufacturing cell of a manufacturing center is shown in , showing a robotic picker loading a first workpiece of a first type from a first workpiece storage unit onto a workpiece support carried by a RSRV.

[0050] Fig. 9B A stereoscopic view of a manufacturing cell according to an embodiment of the present invention, showing a robotic picker loading a second workpiece of a second type from a second workpiece storage unit onto a workpiece holder carried by an RSRV for attachment to a first workpiece of a first type on the workpiece holder carried by the RSRV by a robotic handler, and the RSRV removing the first workpiece storage unit including the remaining workpieces of the first type to prepare the manufacturing cell for subsequent different manufacturing processes.

[0051] Fig. 9CA stereoscopic view of a manufacturing cell according to one embodiment of the present invention, showing that while a robotic processing worker is picking up automatically selected tool parts from a tool part storage unit to join a second workpiece to a first workpiece on a workpiece holder carried by the RSRV, the RSRV transfers a third workpiece storage unit containing a third type of workpieces to the manufacturing cell to replace the removed workpiece storage unit.

[0052] Fig.9D A perspective view of a manufacturing cell according to an embodiment of the present invention, showing: a completed subassembly of a first workpiece and a second workpiece that have been joined, the completed subassembly leaving the manufacturing cell on a workpiece support carried by an RSRV; and a new workpiece support carrying a fourth type of workpiece, the new workpiece support being transferred on another RSRV to be assembled with a third type of workpiece during a subsequent manufacturing process.

[0053] Fig.9E A stereoscopic view of a manufacturing cell according to one embodiment of the present invention, showing that while a robotic picker is loading a third workpiece of a third type from a third workpiece storage unit onto a new workpiece holder carried by an RSRV, a robotic processing worker is picking up automatically selected tool parts from a tool part storage unit to join the third workpiece to a fourth workpiece on a new workpiece holder carried by an RSRV.

[0054] Fig.9F is a perspective view of a manufacturing cell according to an embodiment herein, showing the collaboration between a robotic picker and a robotic handler to join a third workpiece to a fourth workpiece on a new workpiece holder carried by an RSRV.

[0055] Fig.10 According to one embodiment of this invention, Figure 1 and Figure 2 , which shows an example of an RSRV traveling on a multi-station path to move a workpiece support through multiple manufacturing stages of various manufacturing cells in the manufacturing center.

[0056] Fig.11 According to one embodiment of this invention, Figure 1 and Figure 2 , which shows an example of a pair of RSRVs traveling on a multi-station path to transport workpieces and tooling pieces between ASRS structures and manufacturing cells in the manufacturing center.

[0057] Fig. 12A It is a side perspective view of a manufacturing system according to an embodiment of the present invention, which shows that a manufacturing center includes a plurality of manufacturing units, and the manufacturing units are configured in a multi-layer structure.

[0058] Fig. 12B According to one embodiment of this invention, Fig. 12A A partial enlarged stereoscopic view of the manufacturing center is shown in FIG.

[0059] Fig.13 The present invention is a flowchart of a method for executing a workflow in a manufacturing system according to an embodiment of the present invention.

[0060] Fig.14 The present invention is a flowchart of a method for performing a material preparation operation of a workflow in a manufacturing system according to an embodiment of the present invention.

[0061] FIG. 15A to FIG. 15C The present invention is a flowchart of a method for performing manufacturing operations to complete a work order using a workpiece storage unit in a manufacturing system according to an embodiment of the present invention.

[0062] FIG. 16A to FIG. 16C The present invention is a flowchart of a method for performing manufacturing operations to complete a work order using a kit storage unit in a manufacturing system according to an embodiment of the present invention.

[0063] Fig.17 The present invention is a flowchart of a method for manufacturing a product in a manufacturing system according to an embodiment of the present invention.

[0064] Fig.18 FIG. 1 is an architectural block diagram of a manufacturing system according to an embodiment of the present invention, which illustrates the communication between a computer control system and components of the manufacturing system. DETAILED DESCRIPTION

[0065] Various aspects of the present disclosure may be implemented as a system of components and / or structures, methods, and / or non-transitory computer-readable storage media having one or more computer-readable program codes stored thereon. Thus, various embodiments of the present disclosure may take the form of a combination of hardware and software embodiments, including, for example, mechanical structures and electronic components, computing components, circuits, microcode, firmware, software, etc.

[0066] Figure 1 FIG. 1 is a top plan view of a manufacturing system 100 according to an embodiment of the present invention, wherein the manufacturing system 100 includes an automated storage and retrieval system (ASRS) structure 101 adjacent to a material preparation area 102 and a manufacturing center 105. The material preparation area 102 is adjacent to the ASRS structure 101 at a periphery 101a of the ASRS structure 101. The material preparation area 102 includes one or more material preparation workstations, such as Figure 7 The manual operation, manual assistance or manual participation material preparation workstation 103 and the robot material preparation workstation 104 disclosed in the detailed description of the ASRS 101 are also adjacent to the ASRS structure 101 at the periphery 101a of the ASRS structure 101. Figure 2 According to one embodiment of this invention, Figure 1A side perspective view of a manufacturing system 100 is shown in FIG. Figure 2 One side of the ASRS structure 101 where the material preparation area 102 and the manufacturing center 105 are located is shown. For illustration, Figure 1 to Figure 2 A preparation area 102 and a manufacturing center 105 are shown, both of which are adjacent to the ASRS structure 101 on the same peripheral side 101a of the ASRS structure 101; however, the scope of the manufacturing system 100 disclosed herein is not limited to the configuration in which the preparation area 102 and the manufacturing center 105 are located on the same peripheral side 101a of the ASRS structure 101, but can be expanded to any configuration in which one or both of the preparation area 102 and the manufacturing center 105 are located on any one or more peripheral sides of the ASRS structure 101.

[0067] like Figure 3 and FIG. 4A to FIG. 4B As shown, the manufacturing system 100 disclosed herein includes a storage configuration including an ASRS structure 101 and a fleet of robotic storage / retrieval vehicles (RSRVs) 306. The ASRS structure 101 includes a three-dimensional (3D) array of storage locations distributed throughout a two-dimensional (2D) footprint of the ASRS structure 101 in multiple storage layers within the ASRS structure 101. Figure 3 As shown, in one embodiment, the ASRS structure 101 is configured as a 3D grid storage structure 300. Each RSRV 306 in the fleet of RSRVs 306 can navigate along three dimensions within the ASRS structure 101 to access storage locations in the 3D array. As described below, the RSRVs 306 can be operated to deposit storage units, such as boxes, pallets, boxes, pallets, etc., in storage locations of the ASRS structure 101 and retrieve storage units from the storage locations. Figure 3 As shown, in one embodiment, the ASRS structure 101 includes at least one track assembly layer, and the track assembly layer includes a 2D grid track layout 302. Figure 3 As shown, the fleet of RSRVs 306 may navigate along at least two dimensions on the 2D grid track layout 302 within the ASRS structure 101 .

[0068] The manufacturing system 100 disclosed herein further includes a plurality of manufacturing cells 106 and 107 located outside the ASRS structure 101. The manufacturing cells 106 and 107 constitute the manufacturing center 105 of the manufacturing system 100. The manufacturing cells 106 and 107 are classified, standardized, and modularly constructed for different manufacturing processes. In one embodiment, the manufacturing system 100 disclosed herein further includes a track structure 108, which is connected to the ASRS structure 101 and extends beyond the 2D footprint of the ASRS structure 101 to define an extension of the ASRS structure 101. In one embodiment, the track structure 108 is an extension of the 2D grid track layout 302 of the track assembly layer of the ASRS structure 101. The manufacturing cell 106 is configured relative to the track structure 108. The track structure 108 is configured to define one or more travel paths, the RSRV 306 can navigate on the travel path, and the manufacturing cell 106 is distributed along the travel path. The same fleet of RSRVs 306, which can navigate along three dimensions within the ASRS structure 101, can be operated to transfer components to the manufacturing cells 106 and 107, such as workpieces and / or tooling pieces in storage units, workpiece holders, etc. In one embodiment, the components can be transported between each of the manufacturing cells 106 and 107 in any order. In another embodiment, each of the manufacturing cells 106 and 107 is configured to receive the components multiple times to perform one or more processing steps of the manufacturing process. In one embodiment, each of the manufacturing cells 106 and 107 is equipped with product-neutral equipment and is configured to achieve a specific basic function of the product. In another embodiment, each manufacturing cell 106 can be individually expanded with process-specific equipment. The manufacturing cells 106 are configured to perform multiple manufacturing processes, such as welding, gluing, stamping, brazing, riveting, etc. During the execution of the previous process of uninterrupted manufacturing, components for subsequent processing steps of the manufacturing process are routed to each manufacturing cell 106 in real time. In one embodiment, at least a subset of the fabrication cells 106 are located within the track structure 108 or within an area of ​​the track structure 108. In one embodiment, the track structure 108 is a grid track structure including a plurality of sets of intersecting tracks on which the RSRV 306 can navigate in two dimensions.

[0069] The manufacturing center 105 includes a plurality of fully automated manufacturing cells 106 or robotic manufacturing cells 106 that are distributed in a spaced-apart manner over a 2D area of ​​a track structure 108 that is connected to a 2D grid track layout 302 of the ASRS structure 101. The grid track structure 108 of the manufacturing center 105 forms a coplanar extension of the grid lower track layout 302 of the ASRS structure 101 to allow the same fleet of RSRVs 306 navigating the ASRS structure 101 to deposit and retrieve storage units to and from the ASRS structure 101, transfer retrieved storage units to the manufacturing cells 106 and 107, and return retrieved storage units to the ASRS structure 101 when no longer needed by the manufacturing center 105. Figure 1 to Figure 2 In the illustrated embodiment, the manufacturing units 106 are arranged, for example, in a rectangular array such that each manufacturing unit 106 is aligned with other manufacturing units 106 located in a corresponding row and a corresponding column of the rectangular array. In other embodiments, the manufacturing units 106 are arranged in arrays of different configurations. Similarly, although Figure 1 to Figure 2 The illustrated embodiment shows sixteen fabrication units 106, but the number of fabrication units 106 may vary and need not be a square number, whether the fabrication units 106 are arranged in a rectangular array, another uniformly distributed pattern or array, or in any other pattern, uniform or otherwise.

[0070] like Figure 1 to Figure 2 As shown, the fully automated manufacturing cells 106 are distributed over the main interior area of ​​the grid track structure 108. That is, the fully automated manufacturing cells 106 are located at distributed positions throughout the main interior area of ​​the grid track structure 108. In one embodiment, each fully automated manufacturing cell 106 includes at least one robotic picker 109, which is operable to pick up components, such as workpieces, tool parts, etc., from a receiving area configured in the corresponding manufacturing cell 106. Figure 1 to Figure 2 In the illustrated embodiment, the manufacturing center 105 further includes one or more manually operated, manually assisted or manually participated manufacturing units 107, which are, for example, located in the peripheral area 108a of the grid track structure 108. In one embodiment, the manually participated manufacturing unit 107 is specifically located on the side of the grid track structure 108 farthest from the ASRS structure 101; however, in other embodiments, the manually participated manufacturing unit 107 is additionally or alternatively located on either of the two lateral sides 108b and 108c of the grid track structure 108 extending outward from the peripheral side 101a of the ASRS structure 101. In addition, for illustration, Figure 1 to Figure 2An ASRS structure 101 is shown adjacent to a single manufacturing center 105, wherein the entire grid track structure 108 and all of the manufacturing cells 106, 107 are located on a single side 101a of the ASRS structure 101. In another embodiment, the manufacturing system 100 disclosed herein is configured such that the grid track structure 108 of a single manufacturing center 105 occupies more than one side of the ASRS structure 101. In another embodiment, multiple manufacturing centers include respective grid track structures adjacent to respective different sides of the ASRS structure 101, such that navigation of the RSRV 306 is performed between the grid track structures of separate manufacturing centers via the grid lower track layout 302 of the ASRS structure 101.

[0071] like Fig.18 As shown, in one embodiment, the manufacturing system 100 disclosed herein further includes a computer control system (CCS) 131, and the CCS 131 is in operative communication with the team of RSRVs 306. At various stages of the workflow executed by the manufacturing system 100, the CCS 131 activates one or more RSRVs 306 to perform one or more of the following: (a) navigating within the ASRS structure 101 and / or navigating through the manufacturing cells 106, 107; (b) taking out one or more workpieces contained in one or more storage cells from the storage location of the ASRS structure 101; (c) transferring one or more workpieces contained in one or more storage cells to at least one material preparation workstation 103, 104 to package the workpieces into one or more kit storage cells; (d) picking up one or more kit storage cells from the material preparation workstation 103, 104; (e) returning and storing one or more kit storage cells to the storage location of the ASRS structure 101. (f) taking out from the same ASRS structure 101: one or more kit storage units and at least one of the one or more workpieces contained in another one or more storage units, one or more tool pieces contained in yet another one or more storage units, and one or more workpiece holders; (g) transferring the above one or more kit storage units and at least one of the one or more workpieces contained in another one or more storage units, one or more tool pieces contained in yet another one or more storage units, and one or more workpiece holders to manufacturing units 106, 107 to manufacture items; and (h) introducing the finished product on the final workpiece holder into the ASRS structure 101. When the product changes, the manufacturing units 106, 107 are automatically upgraded to be used for the new task. In one embodiment, the CCS 131 automatically upgrades the manufacturing units 106, 107 to be used for the new task. When workers perform testing and maintenance on a specific manufacturing unit, the tasks can be transferred to other manufacturing units to achieve uninterrupted manufacturing. In the case of any manufacturing unit 106, 107 performing an uninterrupted manufacturing process, the manufacturing units 106, 107 are configured on the fly as needed.

[0072] Consider an example workflow of the manufacturing system 100 disclosed herein. Materials such as workpieces are introduced into storage units and stored in the ASRS structure 101. Similarly, materials such as tool pieces are introduced into storage units and stored in the ASRS structure 101. In addition, workpiece holders such as fixtures are introduced and stored in the ASRS structure 101. The CCS 131 receives a digital production plan with specified materials or workpiece kits / tool ​​kits and related process instructions. Digital instructions for software configure the manufacturing unit 106 to manufacture an item or product. The production plan includes details of all processes required to manufacture the item. The details include, for example: a list of all procedures involved in manufacturing the item, where each process is assigned to one or more manufacturing units 106; a list of materials required to complete each process; a list of tool pieces required to complete each process; and a list of steps / specifications required for a robot worker to complete each process, etc. Kit storage units including, for example, workpiece kit boxes and tool kit boxes are established at material preparation workstations 103, 104 and stored in the ASRS structure 101. The workpiece kit box including the workpieces is circulated through the pick-up access port of the stock preparation station 103 or 104 to allow a human worker or a robot worker to pick up all the workpieces required for each manufacturing process. The tool kit box including the tool pieces is circulated through the pick-up access port of the stock preparation station 103 or 104 to allow a human worker or a robot worker to pick up all the tool pieces required for each manufacturing process. In one embodiment, the workpiece kit box and / or the tool kit box include inserts, such as foam materials, inserts, etc., to arrange the workpieces and / or tool pieces according to whether the robot worker can handle the workpiece or tool piece. After assembly, the workpiece kit box and the tool kit box are stored back in the ASRS structure 101.

[0073] The CCS 131 receives production or work orders and assigns one or more manufacturing cells 106 and 107 to the manufacturing process using order priorities. The RSRV 306 routes and removes and delivers one or more workpiece kit boxes and tool kit boxes to a receiving station in a designated manufacturing cell 106. The RSRV 306 routes and removes and delivers workpiece holders or fixtures to a fixture channel in a designated manufacturing cell 106. The first robotic worker is, for example, a robotic picker in a designated manufacturing cell 106, which removes a workpiece from a workpiece kit box and places the removed workpiece in a workpiece holder or precisely positions the workpiece to assemble the workpiece to another workpiece already positioned on the workpiece holder. The second robotic worker is, for example, a robotic processing worker in a designated manufacturing cell, which processes the workpiece. The robotic worker repeats the action for all workpieces in the workpiece kit box to create assemblies and / or sub-assemblies. If another process is required, the RSRV 306 is configured to transport the workpiece support including the partially completed subassembly to another pre-configured manual manufacturing cell 106 or robotic manufacturing cell 107; and / or, if there is no manufacturing capacity, return the workpiece support including the partially completed subassembly to the ASRS structure 101 for later processing. If completed, the RSRV 306 is configured to return the workpiece support including the completed assembly / subassembly to the ASRS structure 101.

[0074] In one embodiment, the RSRVs 306 travel through the manufacturing system 100 as follows: One RSRV 306 takes a desired workpiece kit box from the ASRS structure 101. The RSRV 306 delivers the desired workpiece kit box to a designated empty storage location located in one manufacturing cell 106. The RSRV 306 travels to the designated manufacturing cell 106 and picks up an unneeded workpiece kit box and delivers the unneeded workpiece kit box to the ASRS structure 101 for storage. Another RSRV 306 delivers a desired tool piece kit box to a designated empty storage location located in the manufacturing cell 106. The other RSRV 306 travels to the designated manufacturing cell 106 and picks up an unneeded tool piece kit box and delivers the unneeded tool piece kit box to the ASRS structure 101 for storage. In another embodiment, the same RSRV 306 that delivers the desired workpiece kit box to the designated manufacturing cell 106 removes the unneeded workpiece kit box from the designated manufacturing cell 106. Similarly, the same RSRV 306 that delivers the required tool kit boxes to the designated manufacturing cell 106 removes the unneeded tool kit boxes from the designated manufacturing cell 106 .

[0075] Figure 3 is a top isometric view of a three-dimensional (3D) grid storage structure 300 according to one embodiment of the present invention. The 3D grid storage structure 300 defines Figure 1 to Figure 2 An automated storage system (ASRS) structure 101 of a manufacturing system 100 is shown. In one embodiment, the 3D grid storage structure 300 of the manufacturing system 100 defining the ASRS structure 101 and the associated robotic storage / retrieval vehicles (RSRVs) 306 and storage cells 303 are of the type disclosed by applicant in U.S. patent application Ser. Nos. 15 / 568,646, 16 / 374,123, 16 / 374,143, and 16 / 354,539, each of which is incorporated herein by reference in its entirety. Figure 3 A small scale example of a 3D grid storage structure 300 is shown in FIG. Figure 3 As shown in , the grid storage structure 300 includes two-dimensional (2D) grid track layouts 301 and 302, and the 2D grid track layouts 301 and 302 are respectively located at the highest level or top layer and the lowest level or bottom layer of the assembly track. That is, the grid storage structure 300 includes a grid upper track layout 301 and a grid lower track layout 302, wherein the grid upper track layout 301 is located in a higher horizontal plane, and the grid lower track layout 302 is located in a lower horizontal plane closer to the ground, and the grid upper track layout 301 is located above the matching and aligned grid lower track layout 302. Between these aligned grid upper track layouts 301 and grid lower track layouts 302 is a 3D array of storage locations occupying multiple intermediate storage layers between the highest top layer and the lowest bottom layer. Each storage location in the 3D array can accommodate a corresponding storage unit 303 therein. In one embodiment, the storage unit 303 is Figure 3 302. The storage locations 303 are arranged in vertical storage columns 304, wherein storage locations having equal square footprints are aligned with each other. Each of the vertical storage columns 304 is adjacent to a vertical upright axis 305 through which a storage location in the vertical storage column 304 is accessible. A fleet of RSRVs 306 is configured to travel horizontally in two dimensions in each of the grid track arrangements 301, 302, and to travel vertically in a third dimension between the two grid track arrangements 301, 302 through the open upright axis 305.

[0076] Each of the grid track layouts 301, 302 includes: a set of X-direction tracks 307 located in the X-direction of the corresponding horizontal plane; and a set of Y-direction tracks 308 located in the Y-direction of the same horizontal plane and perpendicularly intersecting the X-direction tracks 307. The intersecting X-direction tracks 307 and Y-direction tracks 308 define a horizontal reference grid of the 3D grid storage structure 300, each horizontal grid row of the horizontal reference grid is defined between a pair of adjacent X-direction tracks 307, and each horizontal grid column of the horizontal reference grid is defined between a pair of adjacent Y-direction tracks 308. Each intersection point between one of the horizontal grid columns and one of the horizontal grid rows indicates the position of a corresponding vertical storage column 304 or a corresponding vertical axis 305. That is, each vertical storage column 304 and each vertical axis 305 is located at a corresponding rectangular coordinate point of the horizontal reference grid of the corresponding area defined between two X-direction tracks 307 and two Y-direction tracks 308. Each such region defined between the four tracks 307 and 308 in the grid track layout 301 or 302 is also referred to herein as a corresponding “block” of the grid track layout 301 or 302. The 3D addressing of each storage location in the 3D grid storage structure 300 is accomplished by a given vertical storage column layer within the corresponding vertical storage column 304 where the given storage location is located. That is, the 3D address of each storage location is defined by the horizontal grid row, horizontal grid column, and vertical storage column layer of the storage location in the 3D grid storage structure 300.

[0077] At each intersection between the X-direction rails 307 and the Y-direction rails 308, a corresponding upright frame member 309 vertically spans between the grid upper rail layout 301 and the grid lower rail layout 302, thereby cooperating with the rails 307 and 308 to define a frame of the 3D grid storage structure 300, which is used to accommodate and organize the 3D array of storage units 303 within the frame. Therefore, each upright axis 305 of the 3D grid storage structure 300 includes four vertical frame members 309, and the four vertical frame members 309 span the entire height of the upright axis 305 at the four corners of the upright axis 305. Each frame member 309 includes groups of rack teeth on both sides of the vertical frame member 309, and the rack teeth are arranged in series along the vertical Z direction of the 3D grid storage structure 300. Therefore, each upright axis 305 includes a total of eight groups of rack teeth, wherein each corner of the upright axis 305 has two groups of rack teeth, and the eight groups of rack teeth are connected to each other. FIG. 4A to FIG. 4B The eight pinions 311a, 311b shown on each RSRV 306 cooperate to enable the RSRV 306 to travel in an ascending direction and a descending direction through the vertical shaft 305 of the 3D grid storage structure 300 between the grid upper track layout 301 and the grid lower track layout 302.

[0078] Figure 4A According to one embodiment of this invention, Figure 1 to Figure 2 The robotic storage / retrieval vehicles (RSRVs) 306 and compatible storage units 303 employed in the automated storage system (ASRS) structure 101 of the manufacturing system 100 are shown. Each RSRV 306 includes a wheeled frame or chassis 310, which includes a circular transfer wheel 311a and a toothed pinion 311b. The transfer wheel 311a is configured to transport the RSRV 306 on the grid upper track layout 301 and the grid lower track layout 302 in the track travel mode. The toothed pinion 311b is located on the inner side of the transfer wheel 311a to enable the RSRV 306 to pass through the axis travel mode. Figure 3 The three-dimensional (3D) grid storage structure 300 is shown traveling on a geared vertical shaft 305. Each toothed pinion 311b and the corresponding transfer wheel 311a are part of a combined single wheel unit, which wheel unit as a whole or at least the transfer wheel 311a can be horizontally extended in an outboard direction from the RSRV 306 to use the transfer wheel 311a in a track travel mode on the grid track layout 301 or 302, and which wheel unit as a whole or at least the transfer wheel 311a can be horizontally retracted in an inboard direction from the RSRV 306 to use the toothed pinion 311b in an axle travel mode with the toothed pinion 311b engaged with the rack teeth of the vertical frame member 309 of the vertical shaft 305.

[0079] A set of four X-direction wheel units are configured in pairs on two opposite sides of the RSRV 306 to drive the RSRV 306 on the X-direction track 307 of the grid track layout 301 or 302 of the 3D grid storage structure 300. A set of four Y-direction wheel units are configured in pairs on the other two opposite sides of the RSRV 306 to drive the RSRV 306 on the Y-direction track 308 of the grid track layout 301 or 302. One set of wheel units can be raised / lowered relative to the other set of wheel units to switch the RSRV 306 between the X-direction travel mode and the Y-direction travel mode. When the raised set of wheel units is located at the outer position on the grid upper track layout 301, it is also possible to operate to lower the other set of wheel units so that the other set of wheel units engage with the rack teeth of the vertical shaft 305, and then the raised wheel units are also moved inwardly to fit in the vertical shaft 305, thereby completing the conversion of the RSRV 306 from the track travel mode to the shaft travel mode, so as to allow the RSRV 306 to be lowered through the vertical shaft 305 through the driving operation of the toothed pinion 311b. Similarly, when the lowered set of wheel units is located at the outer position on the grid lower track layout 302, it is also possible to operate to raise the other set of wheel units so that the other set of wheel units engage with the rack teeth of the vertical shaft 305, and then the lowered wheel units are also moved inwardly to complete the conversion of the RSRV 306 from the track travel mode to the shaft travel mode, so as to allow the RSRV 306 to be raised through the vertical shaft 305 through the driving operation of the toothed pinion 311b. In one embodiment, an external lifting device (not shown) located in the grid lower track layout 302 is additionally or alternatively used to assist or perform lifting of the RSRV 306 from the grid lower track layout 302 into the upper vertical shaft 305.

[0080] Each RSRV 306 includes an upper support platform 312 on which any storage unit 303 may be received for carriage by the RSRV 306. The upper support platform 312 includes a rotatable turret 313 surrounded by a fixed outer deck surface 314. The rotatable turret 313 includes an extendable / retractable arm 315, referred to herein as a "turret arm," mounted in a diametric slot of the rotatable turret 313 and movably supported in the diametric slot for linear movement into and out of a deployed position extending outwardly from the outer circumference of the rotatable turret 313.

[0081] Figure 4B An embodiment according to this invention is shown Figure 4A306 and a compatible storage unit 303, which shows a turntable arm 315 of the RSRV 306 extended to engage with the storage unit 303 to push or pull the storage unit 303 onto the RSRV 306. The turntable arm 315 carries a snap member 316 thereon, for example, on a shuttle that moves back and forth along the turntable arm 315, to engage with a matching snap feature on the underside of the storage unit 303. The turntable arm 315 with the snap member 316, together with the rotatable function of the turntable 313, allows the storage unit 303 to be pulled onto the upper support platform 312 on all four sides of the RSRV 306, as well as the storage unit 303 to be pushed off the upper support platform 312, thereby allowing each RSRV 306 to be moved between the upper support platform 312 and the lower support platform 312. Figure 3 The storage units 303 are accessed from any side of any vertical axis 305 in the illustrated three-dimensional (3D) grid storage structure 300, which includes fully enclosed vertical axes 305, each of which is surrounded by vertical storage columns 304 on all four sides of the vertical axis 305 to maximize the storage density in the 3D grid storage structure 300. That is, each RSRV 306 can be operated in four different working positions within any vertical axis 305 to access any storage location on any of the four different sides of the vertical axis 305 to deposit or retrieve the corresponding storage unit 303 from the selected storage location. In one embodiment, an alternative mechanism is used to replace the turntable and arm combination, which enables four-sided loading and unloading of the storage units 303 in the four different working positions.

[0082] In one embodiment, the framework of the 3D grid storage structure 300 includes a set of rack supports at each storage location to cooperatively form a rack for the storage units 303 currently stored at the storage location, whereby any given storage unit 303 can be removed from its storage location by one RSRV 306 without affecting the storage units 303 above and below the given storage unit 303 in the same storage column 304. Similarly, at any storage layer in the 3D array of storage locations in the 3D grid storage structure 300, the rack defined by the set of rack supports allows the storage unit 303 to be returned to a designated storage location. Thus, each RSRV 306 can access any vertical axis 305 through two-dimensional horizontal navigation of the grid track layout 301, 302, and can vertically travel in an ascending direction or a descending direction along the third dimension to access any storage location and deposit or remove a storage unit 303 into or from the storage location. In one embodiment, as Figure 2As shown, the 3D grid storage structure 300 is externally enclosed about its periphery, wherein selected portions of the grid lower track layout 302 of the 3D grid storage structure 300 are visible through the unenclosed inlet / outlet, such as 9A to 9F 127 and 128, RSRV 306 passes through the inlet / outlet at Figure 1 to Figure 2 Transferring between the grid track structure 108 of the manufacturing center 105 and the grid lower track layout 302 of the 3D grid storage structure 300 is shown.

[0083] Figure 4C According to one embodiment of this invention, Figure 4A A bottom plan view of the storage unit 303 is shown in FIG. Figure 4C As shown, the main snap groove 317 is located at the bottom side of the box-type storage unit 303. The main snap groove 317 is an annular bottom opening groove, which follows Figure 4D A 360 degree annular path is shown around the center point 318 of the bottom plate 321 of the storage unit 303, the annular path being located at an intermediate radial distance between the center point 318 and the periphery of the bottom plate 321. Figure 4D According to one embodiment of this invention, Figure 4A FIG. 3 is a partial cross-sectional view of a storage unit 303 shown in FIG. 304 , which shows interface features on the bottom side of the storage unit 303, the interface features being configured to interface with the storage unit 303. FIG. 4A to FIG. 4B The illustrated robotic storage / retrieval vehicle (RSRV) 306 is compatible with Figure 4D As shown, the main engaging groove 317 is recessed upward from the lowest plane of the storage unit 303 to form a continuous annular narrow groove. FIG. 4A to FIG. 4B The snap members 316 of the illustrated turret arms 315 of the RSRV 306 may be received in the annular slots to allow the storage unit 303 to be loaded and unloaded from the RSRV 306. Just inside the periphery of each of the four sides of the bottom plate 321, the bottom side of the storage unit 303 includes a respective secondary snap recess 319 that is recessed upward from the lowest plane of the storage unit 303, for selective engagement of the secondary snap recess 319 by the snap members 316 of the turret arms 315 of the RSRV 306, such as during an attempt to engage the storage unit 303 by the extended turret arms 315 of the RSRV 306, when the snap members 316 of the turret arms 315 fail to engage the primary snap grooves 317. Each of the secondary snap recesses 319 is a relatively small rectangular slot or cavity that is located midway along the respective peripheral side of the bottom plate 321 of the storage unit 303. Therefore, just inside the periphery of the storage unit 303 , four secondary engaging grooves 319 are arranged at ninety degree intervals from each other around the center point 318 of the bottom plate 321 of the storage unit 303 .

[0084] like FIG. 4A to FIG. 4B As shown, the rotatable turntable 313 of the upper support platform 312 of the RSRV 306 and the surrounding outer deck surface 314 together define a square landing area, and when the storage units 303 are carried on the upper support platform 312 of the RSRV 306, the storage units 303 are located on top of the square landing area. The size and shape of this landing area are equal or nearly equal to the size and shape of the bottom surface of each storage unit 303. Therefore, in the position where the storage units 303 are fully and properly placed on the upper support platform 312 of the RSRV 306, the storage units 303 occupy all or nearly all of the landing area without protruding from the periphery of the upper support platform 312 of the RSRV 306. Therefore, in the position where the storage units 303 are properly placed on the landing area, the entire occupied area of ​​the storage units 303 is located within the periphery of the upper support platform 312 of the RSRV 306 or the landing area.

[0085] To ensure that the storage unit 303 is fully accommodated and properly aligned on the landing area of ​​the RSRV 306, as shown in FIG. FIG. 4A to FIG. 4B As shown, in one embodiment, the upper support platform 312 includes a set of load state sensors 401, which are located proximate to the periphery of the upper support platform 312 at locations spaced apart along the periphery of the upper support platform 312. In the example shown, the load state sensors 401 are optical sensors that are recessed into the outer deck surface 314 of the landing area and are provided in a number of four. Each load state sensor 401 is located near a corresponding one of the four outer corners of the landing area. As part of the loading routine, the storage unit 303 is removed from the storage unit 303 using the retraction of the turntable arm 315. Figure 3The storage locations in the illustrated three-dimensional (3D) grid storage structure 300 are pulled onto the RSRV 306, and a computer processor, such as a local processor on the RSRV 306, is communicatively coupled to the load state sensors 401, and checks the status of the four load state sensors 401 to detect the presence of the bottom side of the storage unit 303 above the load state sensors 401. Thus, the positive detection signals from the four load state sensors 401 confirm the presence of the storage units 303 at the four corners of the landing area, thereby confirming that the storage units 303 are fully received on the landing area and properly squarely aligned on the landing area. This confirmation confirms that the primary snap grooves 317 in the storage unit 303 are properly engaged by the snap members 316 of the RSRV 306. Failure to obtain positive detection signals from all four load status sensors 401 indicates a failure of engagement of the primary engagement groove 317, resulting in a failure to properly load the storage unit 303 onto the RSRV 306, in response to which the turntable arm 315 of the RSRV 306 re-extends to push the failed or improperly loaded storage unit 303 back to its corresponding storage position before retrying to extract the storage unit 303. When the storage unit 303 is properly loaded onto the RSRV 306, the primary engagement groove 317 allows the rotatable turntable 313 to rotate relative to the storage unit 303 beneath the storage unit 303 while the storage unit 303 is stationarily disposed on the upper support platform 312 of the RSRV 306. In one embodiment, this relative rotation allows the storage unit 303 to be later unloaded to a different side of the RSRV 306 than when the storage unit 303 was loaded onto the RSRV 306, depending on the target destination to which the storage unit 303 is to be unloaded from the RSRV 306.

[0086] In one embodiment, a reflective optical sensor is used in the RSRV 306 for load status detection, wherein when a storage unit 303 is present above the reflective optical sensor, light energy emitted by the light beam emitter of the reflective optical sensor is reflected from the bottom side of the storage unit 303 back to the light receiver of the reflective optical sensor, thereby successfully determining the presence of the storage unit 303. In one embodiment, the time of flight calculation, i.e., the time difference between the emission of the light pulse and the detection of the reflected light pulse, is used to distinguish between the reflection from the bottom side of the storage unit 303 on the landing area of ​​the RSRV 306 and the reflection from another surface farther away from the reflective optical sensor. In other embodiments, different types of sensors other than optical sensors are used for load status detection. For example, a limit switch or a magnetic sensor is used for load status detection, wherein the limit switch is mechanically actuated by contacting the bottom side of the storage unit 303 or the magnetic sensor is actuated due to the presence of a cooperating magnetic element that emits a detectable magnetic field on the bottom side of the storage unit 303. The use of an optical sensor eliminates the need for moving parts or magnetic integration or other special configurations of the storage unit 303.

[0087] In addition to the primary snap-fit ​​groove 317 and the secondary snap-fit ​​groove 319, Figure 4C The bottom side of the illustrated storage unit 303 also includes four protruding elements or bosses 320 disposed within the periphery of the bottom plate 321 at the four corners of the bottom plate 321. Due to the perforated skeleton or mesh structure of the bottom plate 321, the bottom ends of the bosses 320 form an enlarged solid surface area at the lowest plane of the storage unit 303, which is otherwise primarily unoccupied open space. These enlarged solid surface areas at the bottom ends of the bosses 320 are positioned to align with and be detected by the load state sensors 401 at the corners of the upper support platform 312 of the RSRV 306 when the storage unit 303 is properly loaded into an aligned position on the RSRV 306. In the embodiment where the bottom plate 321 is a solid or less perforated structure, the bottom side of the bottom plate 321, except for the annular primary snap groove 317 and the four secondary snap grooves 319, is a continuous solid surface that spans from the primary snap groove 317 to the outer corners of the bottom plate 321 without interruption, so that there is no need for Figure 4C The bottom plate 321 is shown with a skeleton or mesh structure of bosses 320 .

[0088] Figure 1 to Figure 2 The storage configuration of the manufacturing system 100 shown further includes a batch of workpieces stored in Figure 3 The storage unit 303 is used in the 3D grid storage structure 300 to store the storage location of the 3D grid storage structure 300. Figure 1 to Figure 2The manufacturing system 100 shown includes workpieces such as raw materials, prefabricated components, preassembled sub-assemblies, etc. required for various manufacturing processes performed by the manufacturing units 106 and 107. In one embodiment, a storage unit 303 is also used in the 3D grid storage structure 300 to store tool pieces required for various manufacturing processes performed by robot workers or human workers in the manufacturing units 106 and 107. A storage unit including workpieces is referred to herein as a "workpiece storage unit", while a storage unit including tool pieces is referred to herein as a "tool piece storage unit". In one embodiment, the workpiece storage unit and the tool piece storage unit are the same as each other. In another embodiment, the workpiece storage unit and the tool piece storage unit are different from each other, but share some or all of the same interface features, such as FIG. 4C to FIG. 4D The primary snap grooves 317, secondary snap grooves 319, and / or sensor-detectable boss surfaces 320 are shown, and the storage unit 303 has a function compatible with the RSRV 306 due to the interface features to load and unload the storage unit 303 to and from the RSRV 306. In another embodiment, the 3D grid storage structure 300 also stores a batch of workpiece supports. FIG. 5A to FIG. 5C A workpiece support is shown in FIG.

[0089] Figure 5A is a top perspective view of a workpiece support 501 according to an embodiment of the present invention, and the workpiece support 501 can be stored in Figures 1 to 3 1 and 2, in an automated storage and retrieval system (ASRS) structure 101 including a three-dimensional (3D) grid storage structure 300. Workpiece holders 501 are configured to provide repeatability, accuracy, and interchangeability during the manufacturing process of an article or product. Each workpiece holder 501 is a fixture or fixture configured to hold one or more workpieces thereon, the workpieces being Figure 1 to Figure 2 Workpieces are shown being processed during a manufacturing process in one or more manufacturing cells 106 of a manufacturing center 105. Each workpiece support 501 is configured to receive and hold one or more workpieces in a specific predetermined or fixed position to allow one or more processing steps of a manufacturing process to be performed on the workpieces. Each workpiece support 501 is configured to guide a tool piece during a manufacturing process. Figure 5B According to one embodiment of this invention, Figure 5A A top plan view of a workpiece support 501 is shown in FIG. Figure 5C According to one embodiment of this invention, Figure 5A 1. Similar to the storage unit 303, the workpiece support 501 is stored on the rack rails of the ASRS structure 101 and therefore has the same bottom interface as the storage unit 303.

[0090] exist FIG. 5A to FIG. 5CIn the illustrated embodiment, each workpiece support 501 includes a standardized base plate 502, the structure of the base plate 502 is the same for all workpiece supports, and has the same FIG. 4C to FIG. 4D The bottom plate 321 of the storage unit 303 is shown to have a matching footprint and a matching or similar bottom side configuration. Each workpiece holder 501 shares a matching footprint with the storage unit 303 to allow each workpiece holder 501 and storage unit 303 to be stored in any storage location of the ASRS structure 101. Therefore, the bottom side of the base plate 502 of each workpiece holder 501 includes a main snap-in groove around the center point of the base plate 502, which is similar to the bottom side of the base plate 502 of the ASRS structure 101. FIG. 4C to FIG. 4D The main snap groove 317 on the bottom side of the storage unit 303 is shown. In another embodiment, the bottom side of the base plate 502 of each workpiece support 501 further includes a secondary snap groove near the periphery of the base plate 502, which is similar to the secondary snap groove 317 on the bottom side of the storage unit 303. FIG. 4C to FIG. 4D The secondary snap-in groove 319 on the bottom side of the storage unit 303 is shown. In another embodiment, the bottom side of the base plate 502 of each workpiece holder 501 further includes a sensor detectable surface near the corner of the base plate 502, which is similar to the sensor detectable surface on the bottom side of the base plate 502. FIG. 4C to FIG. 4D The bottom end of the boss 320 of the skeleton structure on the bottom side of the bottom plate 321 shown or its smooth continuous bottom surface area is formed by FIG. 4A to FIG. 4B The load state sensor 401 of the illustrated robotic storage / retrieval vehicle (RSRV) 306 reads these surfaces. The footprint of the base plate 502 of the workpiece support 501 has the same or substantially similar area and shape as the storage unit 303 and is configured to fit within each storage location on the rack of the ASRS structure 101 and similarly fit within the storage unit 303. FIG. 4A to FIG. 4B The top of the upper support platform 312 is shown within the designated landing zone of each RSRV 306. The interface features on the bottom side of the workpiece holder 501 are similar to the interface features on the bottom side of the storage unit 303 and allow the workpiece holder 501 to be compatible with the RSRV 306. Because each workpiece holder 501 shares the same RSRV interface features with the storage unit 303, each workpiece holder 501 is also configured to be loaded into and unloaded from each RSRV 306 in the same manner as the storage unit 303. It should be understood that the base plate 502 of the workpiece holder 501 and each storage unit 303 share the use of matching RSRV interface features, which allows the workpiece holder 501 and the storage unit 303 to be stored in and retrieved from the same 3D grid storage structure 300 using the same RSRV 306, whether the RSRV interface features are the features specifically disclosed herein for the turntable-based RSRV 306, or some other configuration compatible with variations of the RSRV 306.

[0091] Fig. 6A For Figure 5A FIG. 5 is a top perspective view of a workpiece support 501 shown in FIG. 5 , which shows a workpiece 601 accommodated in the workpiece support 501. Figure 1 to Figure 2 The workpieces 601 required for the various manufacturing processes performed by the manufacturing units 106 , 107 of the illustrated manufacturing system 100 include, for example, prefabricated components, preassembled subassemblies, and the like. Figure 6B FIG. 5 is a top plan view of a workpiece support 501 according to an embodiment of the present invention, wherein a workpiece 601 is accommodated in the workpiece support 501 .

[0092] Figure 7 According to one embodiment of this invention, Figure 1 to Figure 2 1 is a top plan view of a staging area 102 of a manufacturing system 100 shown in FIG. New workpieces arriving at the manufacturing facility in full bin quantities can be unloaded and introduced into the Figure 3 The three-dimensional (3D) grid storage structure 300 defining the automated storage and retrieval system (ASRS) structure 101 is shown as a general inventory, wherein a plurality of workpieces 701 of the same type are transferred to a shared workpiece storage unit, which is referred to herein as an "inventory storage unit", and then, according to the Figure 1 to Figure 2 In accordance with the requirements of the manufacturing process performed at one of the manufacturing units 106, 107 of the manufacturing center 105 shown, a smaller number of workpieces are pulled out from the inventory storage unit to compile a storage unit 303b including a single type of workpiece or a kit of different workpieces. The kit collection of different workpieces compiled from different inventory storage units 303a is placed in another storage unit, which is referred to herein as a "kit storage unit" to distinguish this storage unit 303c from the inventory storage unit 303a including the general inventory workpiece 701 and the workpiece storage unit 303b containing a single type of workpiece. The material preparation process of transferring the general inventory workpiece 701 from multiple inventory storage units 303a to the workpiece storage unit 303b or the kit storage unit 303c is performed in the material preparation area 102 equipped with one or more material preparation workstations 103, 104. The number of material preparation workstations 103, 104 can be changed in various embodiments. In one embodiment, these material preparation workstations 103, 104 are the same or similar to the type of picking workstations disclosed by the applicant in PCT patent application No. PCT / IB2020 / 054380, which is incorporated herein by reference in its entirety.

[0093] exist Figure 7In the illustrated embodiment, each of the material preparation workstations 103 and 104 is configured with an L-shaped structure, the L-shaped structure including a first side 103a, 104a and a second side 103b, 104b, wherein the first side 103a, 104a protrudes outward from the surrounding side 101a of the ASRS structure 101, and the second side 103b, 104b extends parallel to the surrounding side 101a of the ASRS structure 101. The interior of each material preparation workstation 103, 104 is closed, and therefore, each material preparation workstation 103, 104 includes a vertical outer wall, such as Figure 2 As shown, the corresponding material preparation workstations 103, 104 are closed by the outer wall at their sides, except for the inner side thereof which is open to the 3D grid storage structure 300 at the grid lower track layout 302. Each material preparation workstation 103, 104 further includes a top cover plate 110, the bottom side of which defines the inner ceiling of each material preparation workstation 103, 104, and the opposite top side of which defines the working surface of the outer workbench.

[0094] Inside the first side 103a, 104a is the lower track of the corresponding material preparation workstation 103, 104. The lower track of each material preparation workstation 103, 104 is an extension of the grid lower track layout 302 of the 3D grid storage structure 300. In one embodiment, the lower track of the material preparation workstation 103, 104 is a bidirectional track that is two blocks wide of the 3D grid storage structure 300 and extends perpendicular to the surrounding side of the 3D grid storage structure 300. Similar to the grid lower track layout 302 of the 3D grid storage structure 300, the lower track of each material preparation workstation 103, 104 includes vertical cross tracks that define square blocks of the lower track. The first column of blocks extending along the outside of the first sides 103a, 104a, i.e., along the opposite side of the second sides 103b, 104b, defines the outbound half of the bidirectional lower track of the first sides 103a, 104a, on which the robotic storage / retrieval vehicle (RSRV) 306 leaves the 3D grid storage structure 300 in the grid lower track layout 302 and travels away from the 3D grid storage structure 300 within the first sides 103a, 104a of the corresponding material preparation workstations 103, 104. The second column of blocks extending along the opposite inner side of the first sides 103a, 104a defines the inbound half of the bidirectional lower track of the first sides 103a, 104a, on which the RSRV 306 can travel back to the 3D grid storage structure 300 on the grid lower track layout 302. The RSRV 306 leaves the 3D grid storage structure 300, passes through the first sides 103a, 104a of the corresponding material preparation workstations 103, 104, and returns to the 3D grid storage structure 300. Figure 7 Indicated by arrow 702 in FIG.

[0095] Above the access block on the storage half of the lower track, a pick-up access port 111 opens from the work surface of its workbench through the top cover plate 110 into the interior space of the first side 103a, 104a of the corresponding material preparation workstation 103, 104. Therefore, when the RSRV 306 traveling through the first side 103a, 104a of the corresponding material preparation workstation 103, 104 stops at the access block of the storage half it travels through, the human worker 703 or the robot worker 704 of the corresponding material preparation workstation 103, 104 standing or installed near the corner of the L-shaped workstation 103, 104 can interact with the inventory storage unit 303a carried on the top of the RSRV 306 to pick up one or more inventory workpieces 701 therefrom. The inventory storage unit 303a then moves forward from the access block of the lower track of the corresponding material preparation workstation 103, 104, back into the 3D grid storage structure 300 on the grid lower track layout 302.

[0096] The second side 103b, 104b of the corresponding material preparation workstation 103, 104 similarly includes a placement access port 112, which passes through the top cover plate 110 of the corresponding material preparation workstation 103, 104 from the working surface of its workbench at a position above another access block that receives an initially empty workpiece storage unit or an initially empty kit storage unit. Therefore, this placement access port 112 allows access to an empty workpiece storage unit or an empty kit storage unit to place the inventory workpiece 701 picked up from one or more inventory storage units 303a circulating through the pick-up access port 111 in the empty storage unit. Long-term static parking of RSRV 306 at the placement access port 112 may be considered a waste of resources, preventing the specific RSRV 306 from being assigned to other tasks during this period, so in one embodiment, the second side 103b, 104b of the corresponding material preparation workstation 103, 104 does not include a vehicle track for allowing storage units to be carried by vehicles through the second side 103b, 104b of the corresponding material preparation workstation 103, 104. Instead of the vehicle track, the second side 103b, 104b includes an internal conveyor 114a, which runs along the second side 103b, 104b from the far end farthest from the first side 103a, 104a to the access block located below the placement access port 112. Around the grid lower track layout 302 of the 3D grid storage structure 300, the RSRV 306 unloads the empty workpiece storage unit or the empty kit storage unit from the unloading / picking block 113 onto the internal conveyor 114a, and the internal conveyor 114a of the preparation workstations 103, 104 pushes the empty workpiece storage unit or the empty kit storage unit to the placement access port 112, where the inventory workpiece 701 picked up from the inventory storage unit 303a is placed in the workpiece storage unit 303b or the kit storage unit 303c. Once the workpiece storage unit 303b or the kit storage unit 303c is compiled, the filled workpiece storage unit 303b or the filled kit storage unit 303c is moved out of the material preparation workstation 103, 104 onto a return conveyor 114b, which runs in the opposite direction of the internal conveyor 114a of the material preparation workstation 103, 104 to transfer the filled workpiece storage unit 303b or the filled kit storage unit 303c back to the unloading / picking block 113, so that it can be picked up by another RSRV 306 in the unloading / picking block 113. Then, this RSRV 306 carries the filled workpiece storage unit 303b or the filled kit storage unit 303c into the 3D grid storage structure 300 and places the filled kit storage unit 303c in an available storage location for subsequent storage in the 3D grid storage structure 300. Figure 1 to Figure 2 The production unit 106 or 107 shown is retrieved from the available storage location as required.

[0097] Therefore, each material preparation workstation 103, 104 includes two travel paths, on which the inventory storage unit 303a and the workpiece storage unit 303b or the kit storage unit 303c can be transferred through the material preparation workstations 103, 104 through the corresponding access ports 111, 112, and the storage units 303a, 303b, 303c can be entered at the access ports 111, 112 to pick up the workpiece 701 from the corresponding storage units 303a, 303b, 303c transferred through the material preparation workstations 103, 104 and place the workpiece 701 into the corresponding storage units 303a, 303b, 303c. One travel path through the material preparation workstations 103, 104 involves the on-board travel of the corresponding storage units 303a, 303b, 303c on the extended track of the 3D grid storage structure 300, while the other travel path is a conveyor-based short path, on which the unloading and picking of the corresponding storage units 303a, 303b, 303c are also performed by the team of RSRVs 306.

[0098] FIG. 8A to FIG. 8D According to different embodiments of this invention, Figure 1 to Figure 2 A partial top plan view of a manufacturing center 105 of the manufacturing system 100 is shown, which shows a fully automated manufacturing unit 106 and an adjacent manually attended manufacturing unit 107, wherein different storage units 303b, 303c and 303d are used in the manufacturing workflow. Fig. 8A and Figure 8C A workpiece storage unit 303b and a tool storage unit 303d are shown as being employed in a manufacturing workflow. Figure 8B and Fig.8D A kit storage unit 303c and a tool storage unit 303d are shown as being employed in a manufacturing workflow.

[0099] like FIG. 8A to FIG. 8D As shown, the grid track structure 108 of the manufacturing center 105 includes multiple sets of cross tracks. Figure 3 and FIG. 4A to FIG. 4B The RSRV 306 shown can navigate along two dimensions on the cross-tracks. Figures 1 to 3 The ASRS structure 101 is shown as an extension of the corresponding tracks of the grid lower track layout 302 of the three-dimensional (3D) grid storage structure 300. FIG. 8A to FIG. 8DIn the illustrated embodiment, the extension track 115 extends in the X direction of a two-dimensional (2D) reference plane shared by the grid lower track layout 302 of the 3D grid storage structure 300 and the grid track structure 108 of the manufacturing center 105, so that the extension track 115 is connected to the X direction track 307 of the grid lower track layout 302 of the 3D grid storage structure 300 in a straight line. The extension track 115 of the grid track structure 108 intersects the transverse track 116 perpendicularly, and in the illustrated example, the transverse track 116 extends in the Y direction of the shared 2D reference plane. Therefore, at a position spaced outward from the periphery of the 3D grid storage structure 300, the transverse track 116 is parallel to the Y direction track 308 of the grid lower track layout 302 of the 3D grid storage structure 300. The grid track structure 108 includes square blocks 117, each of which is defined between a pair of adjacent parallel extension tracks 115 and a pair of adjacent transverse tracks 116.

[0100] exist FIG. 8A to FIG. 8B In the illustrated embodiment, the blocks 117 in the grid track structure 108 are all square. FIG. 8C to FIG. 8D In another illustrated embodiment, the blocks 117 in the grid track structure 108 are not all square because not every X-direction track 307 in the grid lower track layout 302 of the 3D grid storage structure 300 has a corresponding extension track 115 connected thereto. In this embodiment, although the lateral tracks 116 are positioned at regular, consistent intervals, the extension tracks 115 are omitted at some locations where the extension tracks 115 would otherwise pass through the automated manufacturing unit 106. Therefore, in this embodiment, the term column is used to represent a strip-like area across the grid track structure 108 in the X-direction, the inner width of which is sized between two adjacent extension tracks 115, and the grid track structure 108 includes: wider columns, which are occupied by the automated manufacturing units 106 and are composed of wider rectangular blocks 119; and narrower columns, which are arranged in pairs and are adjacent to the wider columns on opposite sides of each wider column. As shown in FIG. FIG. 8A to FIG. 8D As shown, the term row is used to represent a strip-like area across the grid track structure 108 in the Y direction, the inner width of which is sized to span two adjacent transverse tracks 116, and the grid track structure 108 includes rows of uniform equal width.

[0101] exist FIG. 8A to FIG. 8BIn the illustrated embodiment, the grid track structure 108 includes a full set of extended tracks 115 positioned at regular, uniform intervals throughout the grid track structure 108, wherein all blocks in the grid track structure 108 are configured in a square configuration, and all columns and rows have uniform, equal widths. Each square block 117 represents a reference unit of the grid track structure 108, and the dimensions of the manufacturing unit 106 and its modular components are measured from the reference unit. FIG. 8A to FIG. 8D As shown illustratively, each automated manufacturing unit 106 occupies a square unit space, and the area of ​​the square unit space is equal to the area of ​​nine square blocks 117 of the grid track structure 108. Therefore, in one embodiment, the square unit space is divided into a set of nine square subspaces. The area of ​​each of the nine square subspaces is equal to the area of ​​one square block 117 of the grid track structure 108.

[0102] like FIG. 8A to FIG. 8D As shown in an exemplary embodiment, each automated manufacturing cell 106 includes: four modular receiving stations 118a, 118b, 118c, and 118d; a first robot worker module 120a; and a second robot worker module 120b. The four modular receiving stations 118a, 118b, 118c, and 118d occupy four corner subspaces of the manufacturing cell 106. The first robot worker module 120a occupies a first intermediate surrounding subspace, which is located between two corner subspaces on a first side of the square around the manufacturing cell 106. The second robot worker module 120b occupies a second intermediate surrounding subspace, which is located between two other corner subspaces on the opposite second side of the square around the manufacturing cell 106. In one embodiment, each of the receiving station modules 118a to 118d and the robot worker modules 120a, 120b is a square footprint module, and the footprint of the square footprint module is generally equal to the footprint of a single square subspace of the manufacturing cell 106. Therefore, the width of each of the receiving station modules 118a to 118d and the robot worker modules 120a, 120b in the X direction and the Y direction does not exceed the width of the square block 117 in the same directions, the dimensions of the width in the same directions being between the two parallel tracks on opposite sides of the square block 117. FIG. 8A to FIG. 8DIn the illustrated embodiment, each of the receiving station modules 118a to 118d and the robotic worker modules 120a, 120b is a single-unit 1×1 module that occupies only a single base unit or a square block 117 of the grid track structure 108. In other embodiments, multi-unit or multi-block modules are additionally or alternatively employed, wherein each of the multi-unit or multi-block modules occupies a corresponding number of entire units or blocks in the grid track structure 108. For example, a dual-unit 2x 1 module is two units wide in one dimension and one unit wide in another dimension and occupies two units of the grid track structure 108. In any case, the width of each of the receiving station modules 118a to 118d and the robotic worker modules 120a, 120b in either direction is generally equal to an integer multiple of the width of any square block 117, the width of which is also referred to herein as a “unit width”. For illustration, FIG. 8A to FIG. 8D A 3×3 square block is shown, wherein two robot workers 123a and 123b constitute a single manufacturing unit 106; however, the scope of the manufacturing center 105 disclosed herein is not limited to each manufacturing unit 106 including a 3×3 square block with two robot workers 123a and 123b, but can be expanded to include an expandable manufacturing unit with additional square blocks and robot workers in the X direction or the Y direction. For example, the manufacturing center 105 is configured with expandable manufacturing units 106, each of which includes a 3×5 square block with four robot workers and six storage units.

[0103] In one embodiment, each of the modular receiving stations 118a, 118b, 118c, 118d is a shelf assembly sized to accommodate one of the storage units 303b, 303c, and 303d thereon. Fig. 9A As shown, the rack assembly includes a pair of parallel rack rails 129 supported by a set of four structural brackets or upright posts 121. Each upright post 121 is mounted at the intersection of two perpendicular rails 115, 116 of the grid track structure 108 at a corresponding corner of the square subspace of the manufacturing unit 106. Each rack rail 129 extends along a corresponding side of the square subspace, and the distance between the two rack rails 129 is less than the width of each of the square-bottomed storage units 303b, 303c or 303d. The open space between the two rack rails 129 allows the storage units 303b, 303c or 303d to be stored in the storage units 303b, 303c or 303d. FIG. 4A to FIG. 4BThe turntable arm 315 of the RSRV 306 is shown inserted between two rack rails 129 to push the storage unit 303b, 303c, or 303d from the RSRV 306 onto the rack rails 129 during unloading of the storage unit 303b, 303c, or 303d to the manufacturing cell 106. Similarly, once the storage unit 303b, 303c, or 303d is placed on the rack rails 129 and is lowered FIG. 4A to FIG. 4B The upper support platform 312 of the RSRV 306 is shown to lower the turntable arm 315 of the RSRV 306 downwardly out of engagement with the bottom side of the storage unit 303b, 303c, or 303d, and the space between the rack rails 129 allows the turntable arm 315 of the RSRV 306 to retract, thereby placing the storage unit 303b, 303c, or 303d in the manufacturing unit 106 and allowing the RSRV 306 to move away to freely perform other retrieval and transfer tasks for other manufacturing units 106. A reverse process is performed during a later pick-up of a storage unit 303b, 303c, or 303d, the reverse process comprising: extending the turntable arm 315 of the RSRV 306 between the rack rails 129; raising the upper support platform 312 of the RSRV 306 to raise the extended turntable arm 315 so that it engages with the bottom side of the storage unit 303b, 303c, or 303d; and then retracting the turntable arm 315 to pull the storage unit 303b, 303c, or 303d onto the upper support platform 312 of the RSRV 306. Since the spacing of the rack supports in the vertical storage column 304 of the 3D grid storage structure 300 is equal to the spacing of the rack rails 129 of the receiving stations 118a to 118d, the unloading and picking of the storage units 303b, 303c and 303d at the receiving stations 118a to 118d are the same as the storage and retrieval of the storage units 303b, 303c and 303d at the storage locations equipped with racks in the 3D grid storage structure 300.

[0104] exist Fig. 8A and Figure 8C In the exemplary embodiment shown in FIG. 1 , two modular receiving stations 118a and 118b on opposite sides of the first robot worker module 120a are designated as a first workpiece receiving area and a second workpiece receiving area, and the workpiece storage unit 303b is transferred to the first workpiece receiving area and the second workpiece receiving area by the RSRV 306 to provide the manufacturing unit 106 with two types of workpieces 701a and 701b required for the manufacturing process of the manufacturing unit 106. Figure 8B and Fig.8DIn another embodiment exemplarily shown in FIG. 1 , two modular receiving stations 118a and 118b on opposite sides of the first robot worker module 120a are designated as the first workpiece receiving area and the second workpiece receiving area, and the kit storage unit 303c is transferred by the RSRV 306 to the first workpiece receiving area and the second workpiece receiving area to provide the manufacturing unit 106 with a specific combination of two types of workpieces required for the manufacturing process of the manufacturing unit 106. Another two modular receiving stations 118c and 118d on opposite sides of the second robot worker module 120b are designated as the first tool receiving area and the second tool receiving area, and the tool storage unit 303d is transferred by the RSRV 306 to the first tool receiving area and the second tool receiving area to provide the manufacturing unit 106 with a specific group of tool pieces 801 required for the manufacturing process of the manufacturing unit 106. The first workpiece accommodating area and the first tool accommodating area are designated as a first group of paired accommodating areas for supplying the workpieces 701a, 701b and the tool part 801 to a first manufacturing process to be performed in the manufacturing unit 106, while the second workpiece accommodating area and the second tool accommodating area are designated as a second group of paired accommodating areas for supplying the workpieces 701a, 701b and the tool part 801 to a different second manufacturing process to be performed in the manufacturing unit 106.

[0105] Each of the robot worker modules 120a, 120b includes a square or rectangular mounting base 122 that defines a single-block or multi-block footprint of the corresponding robot worker module 120a, 120b, which footprint does not exceed the boundaries of the designated subspace of the manufacturing cell 106 in which the corresponding robot worker module 120a, 120b is installed. In one embodiment, the mounting base 122 is suspended between a set of four upright posts 121 at the four corners of the designated subspace or subspaces. FIG. 8A to FIG. 8DIn the illustrated embodiment, each of the robot worker modules 120a, 120b is adjacent to two receiving stations 118a, 118b or two receiving stations 118c, 118d at an immediately adjacent subspace of the manufacturing cell 106, and each of the robot worker modules 120a, 120b shares two upright posts 121 with each of the two adjacent receiving stations 118a, 118b or each of the two adjacent receiving stations 118c, 118d. Robot workers 123a, 123b in the form of multi-axis articulated robotic arms, for example, are located on top of a mounting base 122. In one embodiment, the robot worker 123a of the first robot worker module 120a is used as a robot picker to pick up workpieces 701a, 701b from the receiving stations 118a, 118b located in two workpiece receiving areas adjacent to the robot worker module 120a. The robot worker 123b of the second robot worker module 120b is used as a robot processing worker to perform manufacturing process steps on the workpieces 701a, 701b picked up by the robot picker 123a. The robot processing worker 123b is a type whose tool holder includes an automatic tool exchange interface, which can be selectively coupled with different tool pieces 801 to allow different manufacturing process steps to be performed using different tool pieces 801. Therefore, the robot processing worker 123b can select and attach the necessary tool pieces 801 from any of the two groups of tool pieces 801 accommodated in the tool piece storage unit 303d, which is placed on top of the modular receiving stations 118c, 118d of the two tool receiving areas adjacent to the robot worker module 120b.

[0106] like FIG. 8A to FIG. 8DAs shown, the receiving stations 118a to 118d and the robot worker modules 120a and 120b occupy six of the nine subspaces of the manufacturing cell 106 on opposite sides of the manufacturing cell 106. The remaining three subspaces between the two groups of occupied subspaces remain unoccupied. Among the three unoccupied subspaces, the central subspace between the two robot worker modules 120a and 120b defines the working area of ​​the manufacturing cell 106, and the RSRV 306 carrying the workpiece support 501 can be parked in the working area to place the workpiece support 501 in the working position between the two robot workers 123a, 123b for the robot workers 123a, 123b to enter. This working position of the workpiece support 501 allows one or more workpieces 701a, 701b from any workpiece receiving area to be placed on the workpiece support 501 in a specified position and orientation according to one or more manufacturing process steps by the robot picker 123a, and then the one or more manufacturing process steps are performed on the workpiece on the support by the robot processing worker 123b using a suitable tool piece 801, wherein the suitable tool piece 801 is automatically selected and attached by the robot processing worker 123b from a plurality of sets of tool pieces received in the tool receiving stations 118c, 118d. The other two unoccupied subspaces of the manufacturing unit 106 are the middle surrounding subspaces 124a, 124b, each of which remains open between a workpiece receiving area and a tool receiving area on the respective sides of the manufacturing unit 106. The three unoccupied subspaces form a through path through which the RSRV 306 carrying the workpiece holder 501 travels from one side of the manufacturing unit 106 to the other side, pausing in the central subspace to place and process the workpieces 701a, 701b on the workpiece holder 501. According to one embodiment of the present invention, Fig. 8A and Figure 8C The manufacturing unit 106 is shown when two workpiece storage units 303b including two types of workpieces 701a and 701b are used in the manufacturing process. In this embodiment, a plurality of workpiece storage units 303b are stored, retrieved, and transferred to the manufacturing unit 106. In addition, in the manufacturing unit 106, for each workpiece storage unit 303b, there is a tool storage unit 303d. The workpiece storage unit 303b is retrieved from the 3D grid storage structure 300, transferred, and used in a series of assembly steps in the manufacturing unit 106. According to an embodiment of the present invention, Figure 8B and Fig.8D The manufacturing unit 106 is shown when two kit storage units 303c including a specific combination of different types of workpieces are used in the manufacturing process. In one example, Figure 8B and Fig.8DThe kit storage unit 303c on the right side shown is a storage unit currently being used for assembly, while the kit storage unit 303c on the left side is a storage unit used in a subsequent manufacturing process.

[0107] Fig. 9A According to one embodiment of this invention, Figure 1 to Figure 2 1 is a perspective view of a fully automated manufacturing cell 106 of a manufacturing center 105, which shows a robot picker 123a loading a first workpiece 701a of a first type from a first workpiece storage unit 303b onto a workpiece support 501 carried by a RSRV. Fig. 9A As shown, the RSRV 306 carrying the workpiece holder 501 can leave the ASRS structure 101 including the three-dimensional (3D) grid storage structure 300 at the unenclosed exit 127, and the RSRV 306 travels from the grid lower track layout 302 of the 3D grid storage structure 300 to the grid track structure 108 of the manufacturing center 105 through the exit 127, and then can travel along the grid track structure 108 to the destination manufacturing cell 106 of the workpiece holder 501. The RSRV 306 enters the through-path of the manufacturing cell 106 at the middle surrounding subspace 124a on one side of the manufacturing cell 106, stops at the central subspace of the manufacturing cell 106 until the workpieces 701a, 701b have been placed and processed on the workpiece holder 501, and then leaves the manufacturing cell 106 through the middle surrounding subspace 124b on the opposite side of the manufacturing cell 106. RSRV306 transports the workpiece holder 501 and the processed workpiece thereon back to the 3D grid storage structure 300 through the unenclosed return entrance 128 for storage in its 3D storage location, wherein the RSRV 306 travels from the grid track structure 108 of the manufacturing center 105 to the grid lower track layout 302 of the storage structure 300 at the return entrance 128.

[0108] exist Fig.10 In the illustrated embodiment, upon exiting from the current manufacturing cell 106, the RSRV 306 may proceed forward to another manufacturing cell 106, where additional workpieces may be added to the workpiece holder 501 and the previously processed workpieces thereon. In one embodiment, this routing of the RSRV 306 through the plurality of manufacturing cells 106 is repeated through a series of manufacturing processes performed in the plurality of manufacturing cells 106 until a finished product, such as a finished product or a finished subassembly, is manufactured, at which point the finished product or finished subassembly is returned to the 3D grid storage structure 300 and stored in a corresponding storage location therein.

[0109] The specific dimensions of the manufacturing unit 106 disclosed herein and 9A to 9FThe number, type, and layout of the modular components and unoccupied spaces therein shown are provided as examples and may vary. The modularity of the components of the manufacturing cells 106 relative to the grid track structure 108 of the square cells allows a great degree of flexibility to customize and reorganize any manufacturing cell 106 according to new or changed needs of the manufacturing facility. In one embodiment, as disclosed in the following exemplary manufacturing scenario, two workpiece receiving areas are provided in each manufacturing cell 106 to minimize non-productive time in the manufacturing cell 106.

[0110] like Fig. 9A As shown, the first workpiece receiving station 118a receives a plurality of workpieces 701a of a first type, such as type A, and the second workpiece receiving station 118b receives a plurality of workpieces 701b of a different second type, such as type B. Fig. 9A As shown, the robot picker 123a has placed a workpiece 701a of type A and a workpiece 701b of type B from the corresponding workpiece storage unit 303b onto the workpiece support 501 carried by the RSRV parked in the central subspace of the manufacturing cell 106, and another workpiece 701a of type A from the first group is shown to be placed onto the workpiece support 501. Fig. 9A In the example shown, the workpiece holder 501 is configured to accommodate a plurality of workpieces 701a of type A along a specified orientation suitable for joining a workpiece 701b of type B to a corresponding workpiece 701a of type A. Fig. 9B As shown, once the required number of type A workpieces 701a are placed on the workpiece holder 501, the empty RSRV 306 can travel from the 3D grid storage structure 300 to the manufacturing unit 106 through the exit 127, pick up the currently unneeded workpiece storage unit 303b from the first receiving station 118a, and return the workpiece storage unit 303b to the 3D grid storage structure 300 through the return entrance 128.

[0111] Fig. 9B1 is a perspective view of a manufacturing unit 106 according to an embodiment of the present invention, which shows that a robot picker 123a loads a second workpiece 701b of type B from a second workpiece storage unit 303b onto a workpiece holder 501 carried by an RSRV, so that the second workpiece 701b of type B is attached to a first workpiece 701a of type A by a robot handler 123b on the workpiece holder 501 carried by the RSRV, and the RSRV 306 removes the first workpiece storage unit 303b including the remaining workpiece 701a of type A to prepare the manufacturing unit 106 for subsequent different manufacturing processes. During the picking up of the currently unnecessary workpiece storage unit 303b from the first workpiece receiving station 118a, the robot picker 123a picks up the workpiece 701b of type B from the second workpiece receiving station 118b, transfers the workpiece 701b of type B to the workpiece support 501 placed in the central subspace of the manufacturing cell 106, and places or receives the workpiece 701b of type B on a placed workpiece 701a of type A at a designated position and orientation for joining. At the same time, the robot processing worker 123b selects and self-attaches a designated tool 801 from a tool storage unit 303d placed on a tool receiving station 118d in a tool receiving area.

[0112] Fig. 9C 1 is a perspective view of a manufacturing cell 106 according to an embodiment of the present invention, which shows that while a robot handling worker 123b is picking up an automatically selected tool piece 801 from a tool piece storage unit 303d to join a second work piece 701b of type B to a first work piece 701a of type A on a work piece holder 501 carried by an RSRV, an RSRV 306 delivers a third work piece storage unit 303b containing a work piece 701c of a third type, such as type C, to the manufacturing cell 106 to replace the removed work piece storage unit 303b. The robot handling worker 123b uses the attached tool piece 801 to join a work piece 701b of type B held by the robot picker 123a to a work piece 701a of type A previously placed on the work piece holder 501, while another RSRV 306 delivers a third work piece storage unit 303b containing a work piece 701c of type C to a first work piece receiving station 118a previously occupied by a work piece storage unit 303b but now having removed the work piece storage unit 303b. In one embodiment, the kit storage unit is Figure 1 to Figure 2 and Figure 7 The staging area 102 of the manufacturing system 100 is shown assembled through staging operations and configured to contain a specific combination of various types of workpieces required for a specific manufacturing process to avoid the operation of taking out and transferring multiple workpiece storage units 303b to the manufacturing unit 106 for a single manufacturing process.

[0113] Fig.9D1 is a perspective view of a manufacturing unit 106 according to an embodiment of the present invention, showing: a completed subassembly of a first workpiece 701a and a second workpiece 701b that have been joined, the completed subassembly leaving the manufacturing unit 106 on a workpiece holder 501 carried by an RSRV; and a new workpiece holder 501 carrying a fourth type of workpiece 701d, such as type D, which is transferred on another RSRV 306 to assemble the type D workpiece 701d with the type C workpiece 701c during a subsequent manufacturing process. Fig.9D A workpiece holder 501 is shown currently containing subassemblies, each of which includes a workpiece 701b of type B that has been joined to a corresponding workpiece 701a of type A by the cooperation of the two robot workers 123a, 123b disclosed above. The workpiece holder 501 and the subassemblies thereon are sent away from the manufacturing cell 106 by the RSRV 306 carrying the workpiece holder 501 thereon, while another RSRV 306 carrying a plurality of workpieces 701d of type D from the 3D grid storage structure 300 arrives at the manufacturing cell 106 from which the subassemblies have left. In one embodiment, the workpiece holder 501 and the subassemblies thereon that have left are carried by the RSRV 306 to the 3D grid storage structure 300 for storage. In another embodiment, the workpiece holder 501 and the subassemblies thereon that have left are carried by the RSRV 306 to another manufacturing cell 106 for further processing. Then, the workpiece 701c of type C from the third workpiece storage unit 303b is placed at the first workpiece receiving station 118a, and the workpiece 701c of type C is appropriately placed or received relative to the workpiece 701d of type D by the robot picker 123a. At the same time, the robot processing worker 123b replaces the tool part at the tool part receiving station 118d when necessary, and then performs a joining process to join the workpiece 701d of type D to the workpiece 701c of type C.

[0114] Fig.9E 1 is a perspective view of a manufacturing unit 106 according to an embodiment of the present invention, showing that while the robotic picker 123a is loading a third workpiece 701c of type C from a third workpiece storage unit 303b onto a new workpiece holder 501 carried by an RSRV, a robotic processing worker 123b is picking up an automatically selected tool part 801 from a tool part storage unit 303d to join the third workpiece 701c of type C to a fourth workpiece 701d of type D on the new workpiece holder 501 carried by an RSRV.

[0115] Fig.9F1 is a perspective view of a manufacturing cell 106 according to an embodiment of the present invention, which shows the cooperation between a robot picker 123a and a robot handler 123b to join a third workpiece 701c of type C to a fourth workpiece 701d of type D on a new workpiece holder 501 carried by an RSRV. The robot picker 123a accommodates the third workpiece 701c and the fourth workpiece 701d on the workpiece holder 501 in a predetermined direction, and at the same time, the robot handler 123b joins the third workpiece 701c to the fourth workpiece 701d using a selected tool 801.

[0116] The foregoing examples illustrate how a workpiece storage unit 303b in one of the two workpiece storage areas can be swapped out while the manufacturing cell 106 is placing and processing workpieces from one of the other workpiece storage areas, whether in preparing the manufacturing cell 106 for a different manufacturing process as contemplated in the foregoing examples, or in replacing an empty workpiece storage unit 303b with a full storage unit 303b or 303c with workpieces of the same type or set to replenish the manufacturing cell 106 for repeating the same manufacturing process. Similarly, the foregoing examples illustrate how the RSRV 306 carrying the second workpiece holder 501 is queued at the manufacturing cell 106 prior to completing the manufacturing process on the workpiece contents of the first workpiece holder 501. In this manner, once the first workpiece holder 501 leaves the manufacturing cell 106 on its RSRV 306, the second workpiece holder 501 advances to a working position between the robot workers 123a, 123b in the center of the manufacturing cell 106. The foregoing examples also illustrate how the workpiece holder 501 delivered to the manufacturing unit 106 can be an empty workpiece holder or an occupied workpiece holder, regardless of whether such pre-processing or assembly was earlier performed in the same manufacturing unit 106 or in a different manufacturing unit, wherein the occupied workpiece holder refers to a workpiece holder on which a processed workpiece or an assembled subassembly has been pre-processed or assembled. In the case where the arriving workpiece holder 501 is an occupied workpiece holder, the workpiece holder 501 can arrive directly from another manufacturing unit, or from a storage location in the 3D grid storage structure 300 where the workpiece holder 501 is temporarily stored or temporarily buffered between manufacturing processes.

[0117] Fig.10 According to one embodiment of this invention, Figure 1 to Figure 2 FIG. 1 is a top plan view of a manufacturing center 105, which shows an RSRV 306 traveling on a multi-stop path to transfer FIG. 9A to FIG. 9BAn example of a workpiece support 501 moving through multiple manufacturing stages of various manufacturing cells 106 in a manufacturing center 105 is shown. In one embodiment, multiple manufacturing cells 106 are connected together in a daisy-chain manner to sequentially perform several manufacturing processes using any manufacturing cell sequence on the grid track structure 108. In another embodiment, individual manufacturing processes are assigned to each manufacturing cell 106 and completed as availability permits. For example, the manufacturing cells 106 may be performed in any combination, depending on their priority and availability. Fig.10 Steps 1, 2, 3 and 4 are shown. Fig.10 As shown, before returning the completed subassembly to the ASRS structure 101, the RSRV 306 carrying the workpiece holder 501 with the workpiece thereon travels on a path having a plurality of stations, for example, four stations in four different manufacturing cells 106. The workpiece on the workpiece holder 501 undergoes one or more process steps of the manufacturing process at each manufacturing cell 106 to produce a finished product, such as a finished product or a finished subassembly. The same RSRV 306 then delivers the finished product to the ASRS structure 101 for storage therein.

[0118] In one embodiment, a computer control system (CCS) 131 randomly assigns a receiving station of each manufacturing cell 106 to accommodate a storage cell. For example, the CCS 131 assigns one receiving station to a workpiece kit box of a current process, another receiving station to a tool kit box of a current process, yet another receiving station to a workpiece kit box of a subsequent process, and yet another receiving station to a tool kit box of a subsequent process. The CCS 131 further assigns other blocks in the manufacturing cell 106 as follows: blocks configured as channels for workpiece holders 501 carried by RSRVs; and blocks for accommodating robotic workers, such as robotic pickers for grabbing workpieces to be processed on the workpiece holders 501, and robotic processing workers for processing workpieces on the workpiece holders 501 using tool pieces. If the manufacturing process is too complex for robotic processing, or if the workpieces processed by the process are larger than the storage cell, a human-involved manufacturing cell 107 is used. At the human-involved manufacturing cell 107, the workpiece kit boxes and tool kit boxes are transferred to human workers. The CCS 131 displays the instructions on a human machine interface (HMI) located at the human-attended manufacturing unit 107. The instructions displayed according to the type of storage unit are presented at the port of the human-attended manufacturing unit 107.

[0119] Fig.11 According to one embodiment of this invention, Figure 1 to Figure 2, which shows an example of a pair of RSRVs 306 traveling on a multi-station path to transport workpieces and tooling pieces between the ASRS structure 101 and the manufacturing cells 106 of the manufacturing center 105. 9A to 9F Exchanging one tool storage unit 303d for another at one of the two tool receiving stations 118c, 118d shown, while using one or more tool parts from the other tool receiving station in the manufacturing unit 106, is useful for switching the manufacturing unit 106 from one manufacturing process to another without losing production time. Fig.11The use of two workpiece storage areas and two tool storage areas is shown, wherein an RSRV 306 sent out from a 3D grid storage structure 300 transfers a workpiece storage unit 303b or a kit storage unit 303c to a workpiece storage area of ​​one manufacturing unit 106, and the RSRV 306 can be used to pick up an empty or unnecessary workpiece storage unit 303b from another manufacturing unit 106, or pick up an empty or unnecessary kit storage unit 303c, and then return the empty or unnecessary workpiece storage unit 303b or the empty or unnecessary kit storage unit 303c to the 3D grid storage structure 300 for storage therein. Similarly, the RSRV 306 sent from the 3D grid storage structure 300 transfers the tool storage unit 303d to the tool receiving area of ​​one manufacturing unit 106, and the RSRV 306 can be used to pick up an empty or unneeded tool storage unit 303d from another manufacturing unit 106 and then return the empty or unneeded tool storage unit 303d to the 3D grid storage structure 300 for storage therein. At the same time, in the case where each manufacturing unit 106 has two workpiece receiving areas and two tool receiving areas, non-productive time in the manufacturing unit 106 can be avoided by continuing manufacturing in the receiving area that is still occupied while emptying and replenishing the other receiving area. In one embodiment, the same RSRV 306 is configured to pick up an empty or unneeded tool storage unit 303d after unloading the required workpiece storage unit 303b, and vice versa. That is, the same RSRV 306 used to unload a desired workpiece storage unit 303b or kit storage unit 303c to the manufacturing unit 106 may be configured to pick up an empty or unneeded tool storage unit 303d from the manufacturing unit 106. Similarly, the same RSRV 306 used to unload a desired tool storage unit 303d to the manufacturing unit 106 may be configured to pick up an empty or unneeded workpiece storage unit 303b or kit storage unit 303c from the manufacturing unit 106. A single mission route of the RSRV 306 may also be employed when dual mission assignment, i.e., a single trip of the RSRV 306 out of the 3D grid storage structure 300 to unload a desired storage unit and pick up an empty or unneeded storage unit improves the efficiency of the manufacturing process.

[0120] The fully automated manufacturing cells 106 are distributed throughout the main interior area of ​​the grid track structure 108, and at least one row or column of the grid track structure 108 between any two adjacent manufacturing cells 106 remains open to allow the RSRV 306 to travel therebetween. Figure 10 to Figure 11In the exemplary embodiment shown, two rows or columns between each pair of adjacent fabrication cells 106 remain open to prevent the interaction of one RSRV 306 with one fabrication cell 106 from hindering the interaction of another RSRV 306 with an adjacent fabrication cell 106 .

[0121] In one embodiment, each of the manually-attended manufacturing cells 107 has the same structure as the workstations disclosed in applicant's U.S. patent applications Nos. 16 / 374,123 and 16 / 374,143, wherein each of the manually-attended manufacturing cells 107 includes a lower track on which the RSRV 306 can travel to transfer storage units to access blocks on the lower track, where human workers of the manually-attended manufacturing cells 107 can access the storage units through access openings 125 in workbenches 126 located on the lower track. Figure 1 to Figure 2 and Figures 10 to 12B In the illustrated embodiment, a plurality of manually attended manufacturing cells 107 are arranged in series with one another such that their lower tracks collectively occupy a single row or column of the grid track structure 108 of the manufacturing center 105 on respective sides adjacent to the periphery 108a of the grid track structure 108. In the illustrated example, four manually attended manufacturing cells 107 occupy the outermost rows of the grid track structure 108 on the far side of the manufacturing center 105. In an embodiment, the manually attended manufacturing cells 107 are additionally or alternatively located in respective columns of the grid track structure 108 on one or both of the lateral sides 108b and 108c of the grid track structure 108. The lower tracks of the manually attended manufacturing cells 107 occupy a row or column of the same grid track structure 108 where the fully automated manufacturing cells 106 are located, and are therefore part of the same extension of the grid lower track layout 302 of the 3D grid storage structure 300, wherein the fully automated manufacturing cells 106 are provided operation by the RSRV 306 through said portion. Thus, RSRV 306 is operable to transfer workpiece storage unit 303b or kit storage unit 303c to manually attended manufacturing cell 107, wherein the contents of workpiece storage unit 303b or kit storage unit 303c are transferred from the workpiece storage unit 303b or kit storage unit 303c to the manually attended manufacturing cell 107. Figure 1 to Figure 2 and Figure 7 The RSRV 306 is shown organized in the inventory storage unit 303a of the material preparation area 102. In one embodiment, the RSRV 306 also transmits the tool storage unit 303d, which includes the tool parts required at the manually-attended manufacturing cells 107 to perform the processing steps of the manufacturing process currently assigned to those manually-attended manufacturing cells 107, whether those tool parts are required and used by human workers, robotic workers, another automated manufacturing equipment such as a computer numerical control (CNC) machine, or any combination thereof at the manually-attended manufacturing cells 107.

[0122] Similar to the manually attended manufacturing cells 107 including CNC machines or other automated manufacturing equipment, in one embodiment, one or more fully automated manufacturing cells 106 include such equipment. For example, instead of a robotic picker placing a workpiece from one or more workpiece receiving areas of an automated manufacturing cell 106 onto a workpiece holder 501 carried by an RSRV, the robotic picker places the workpiece into a CNC machine such as a milling machine, a drill press, a lathe, a laser cutter, a plasma cutter, a water jet cutter, etc., or other automated manufacturing equipment for processing therein, and then the robotic picker optionally transfers the processed workpiece from the CNC machine or other automated manufacturing equipment back to the RSRV 306, such as into a workpiece storage unit carried on the RSRV 306 for return to the ASRS structure 101, or onto a workpiece holder 501 carried by the RSRV 306 for entry into the ASRS structure 101, or onward to another automated manufacturing cell 106. The RSRV 306 is used to provide access to one or more manufacturing cells 106 and 107 from the grid track structure 108 or other defined track extensions of the ASRS structure 101, regardless of the specific equipment and layout used in the manufacturing cells 106 and 107. Similarly, although the illustrated embodiment uses fully automated manufacturing cells 106 in the primary interior region of the grid structure 108, and positions human-attended manufacturing cells 107 in the peripheral region 108a of the grid track structure 108, in one embodiment, human-attended manufacturing cells 107 may alternatively be located within the interior region of the grid track structure 108, provided that safe access for humans to and from such human-attended manufacturing cells 107 is established in a manner that avoids potential collisions between human workers and RSRVs 306 traveling within the grid track structure 108.

[0123] Fig. 12A 1 is a side perspective view of a manufacturing system 100 according to an embodiment of the present invention, which shows that a manufacturing center 105 includes a plurality of manufacturing units 106, and the manufacturing units 106 are configured as a multi-layer structure. In the multi-layer structure, the manufacturing center 105 includes multiple layers of manufacturing units 106. That is, the manufacturing center 105 includes multiple track navigation manufacturing layers, for example, Fig. 12A and Fig. 12B Two track navigation fabrication layers 130a and 130b are shown. Fig. 12B According to one embodiment of this invention, Fig. 12A FIG. 1 is a partial enlarged perspective view of the manufacturing center 105 shown in FIG. Each of the track navigation manufacturing layers 130a and 130b includes FIG. 8A to FIG. 8C A two-dimensional (2D) grid track structure 108 of the type disclosed in the detailed description of FIG. FIG. 8A to FIG. 8CAs shown, the 2D grid track structure 108 includes a plurality of sets of cross tracks 115, 116, and the RSRV 306 can navigate along two dimensions on the cross tracks 115. The 2D grid track structure 108 of each of the track navigation manufacturing layers 130a and 130b includes a corresponding set of manufacturing units 106, and the manufacturing units 106 are installed on the grid track structure 108 of each layer of the manufacturing layers 130a and 130b. FIG. 12A to FIG. 12B As shown, the lowest grid track structure 108 of the track navigation manufacturing layer 130a in the two-layer example is different from the lowest grid track structure 108 of the track navigation manufacturing layer 130a in the two-layer example. FIG. 8A to FIG. 8C The ground level track structure is identical to that disclosed in the detailed description of Figure 3 The grid lower track layout 302 of the three-dimensional (3D) grid storage structure 300 defining the ASRS structure 101 is shown. Each higher level subsequently disposed above the ground level track structure, such as the second track navigation manufacturing level 130b, lacks a direct connection to the corresponding grid track layout 302 of the 3D grid storage structure 300.

[0124] In one embodiment, the multi-layer structure further includes upright frame members 309. The upright frame members 309 interconnect the cross rails 115, 116 of the plurality of layers 130a, 130b. In one embodiment, one or more upright frame members 309 are configured to allow the RSRV 306 to travel in an ascending direction and / or a descending direction on the upright frame members 309 to transfer between the plurality of layers 130a, 130b. In one embodiment, the 2D grid track structure 108 of one of the plurality of layers of the multi-layer structure is connected to a corresponding one of the storage layers in the ASRS structure 101, and the RSRV 306 is configured at the corresponding one of the storage layers to transfer between the ASRS structure 101 and the multi-layer structure. In order to allow the RSRV 306 to enter each subsequent higher layer track structure from the ground layer track structure, the RSRV 306 is connected to the ground layer track structure. Figure 3The same type of rack-tooth upright frame members 309 used in the illustrated 3D grid storage structure 300 are used to interconnect the tracks 115, 116 in the different levels to allow the RSRV 306 to travel up and down between the different levels in the same manner as the RSRV 306 travels up and down through the upright shafts 305 of the 3D grid storage structure 300. In one embodiment, the rack-tooth frame members 309 are used to allow the RSRV 306 to travel up and down at the four corners of any unoccupied square blocks in the grid track structure 108 that are not occupied by unit components, such as the holding stations of any manufacturing units, robotic workers, etc. In one embodiment, the rack-tooth frame members are used throughout the multi-level structure so that the vertical space between any unoccupied square block on one level and the matching unoccupied square block on the next level can be used as a vertical travel axis through which the RSRV 306 can be raised and lowered between the levels. This maintains flexibility to ensure that even if the manufacturing cell layout or equipment on one or more floors is reconfigured in a manner that obstructs previously available travel axes, other travel axes are still available for inter-floor travel of RSRV306. In another embodiment, the multi-story structure incorporates, in addition to the rack-tooth frame member 309, a lifting mechanism of the type disclosed in Applicant's co-pending PCT Application No. PCT / CA2019 / 050815 filed on June 10, 2019, or replaces the rack-tooth frame member 309 with the lifting mechanism, the PCT Application No. PCT / CA2019 / 050815 being incorporated herein by reference in its entirety. In one embodiment, at each grid track layout from which RSRV306 must climb up to a higher level in the multi-story structure, the lifting mechanism is located in the departure block of the grid track layout below the corresponding axis, wherein the corresponding axis is the axis through which RSRV306 ascends to the higher level above.

[0125] exist FIG. 12A to FIG. 12B In the exemplary embodiment, the multi-layer structure of the manufacturing center 105 is a two-layer structure with a height lower than that of the ASRS structure 101. Thus, the highest layer 130b of the multi-layer structure is at a lower height than that of the ASRS structure 101. Figure 3The grid upper track layout 301 of the 3D grid storage structure 300 defining the ASRS structure 101 is shown at a lower height. In other embodiments, the height of the multi-layer structure of the manufacturing center 105 is equal to or higher than the height of the ASRS structure 101, in which case the highest or middle layer of the multi-layer structure may have its grid track structure 108 connected to the grid upper track layout 301 of the 3D grid storage structure 300, in which case the RSRV 306 may be transferred between the ASRS structure 101 and the manufacturing center 105 at multiple layers of the ASRS structure 101 and the manufacturing center 105. In another embodiment, the 3D grid storage structure 300 is optionally equipped with an exit and return port at an intermediate layer between its grid upper track layout 301 and the grid lower track layout 302, which opens toward the grid track structure 108 at one or more corresponding layers of the multi-layer structure of the manufacturing center 105. Such an intermediate layer of the 3D grid storage structure 300 is equipped with a complete grid track layout, which is similar to the grid track layouts at the top and bottom of the 3D grid storage structure 300. In another embodiment, in order to avoid reducing the storage density, the 3D grid storage structure 300 is optionally equipped with an exit at the outer shaft of the 3D grid track structure 300 at the middle layer between the grid upper track layout 301 and the grid lower track layout 302, so that the RSRV 306 climbing or descending through the outer shaft can be transferred to the multi-layer structure of the manufacturing center 105. To this end, in one embodiment, the outer shaft includes a pair of transfer rails, which are suspended between the frame members 309 of the outer shaft and aligned with the corresponding pair of rails of the grid track structure 108 of the corresponding layer in the multi-layer structure of the manufacturing center 105. In this embodiment, the transfer between the 3D grid storage structure 300 and the manufacturing center 105 does not have to be performed at a layer of the 3D grid storage structure 300 that defines the grid track layout.

[0126] Additionally, in other embodiments, RSRVs 306 from the ASRS structure 101 are used to provide operations directly to one or more manufacturing cells 106, thereby avoiding the need for intermediate conveyors or other equipment between the ASRS structure 101 and the manufacturing cells 106, which is not necessarily achieved through a 2D grid track structure 108 connected to the ASRS structure 101. In one embodiment, a track network extending outward from the grid track layout of the ASRS structure 101 and returning is used to allow RSRVs 306 to exit the ASRS structure 101 and travel to one or more manufacturing cells 106 distributed along the track network. Figure 1 to Figure 2As shown, in one embodiment, the track network includes one or more 2D grid track structures 108, the 2D grid track structure 108 having an array of manufacturing units 106 distributed therein, but each such 2D grid track structure 108 is discretely located at a distance from the ASRS structure 101 and connected to the ASRS structure 101 through other tracks of the network. In one embodiment, the other tracks of the network include: at least one transfer track dedicated to the outbound travel of the RSRV 306 from the ASRS structure 101 to the grid track structure 108; and at least one return track dedicated to the inbound travel of the RSRV 306 from the grid track structure 108 back to the ASRS structure 101.

[0127] Although in the illustrated embodiment, the RSRV 306 exits the 3D grid storage structure 300 defining the ASRS structure 101 via an extension of the grid lower track layout 302, other embodiments may alternatively employ an extension of the upper grid track layout 301 of the 3D grid storage structure 300 to allow the RSRV 306 to exit from the 3D upper grid track layout 301 to an external manufacturing unit 106. In one embodiment, the rail network includes one or more elevated rails that are connected to the grid upper track layout 301 of the 3D grid storage structure 300, or to an intermediate layer of the 3D grid storage structure 300 between the grid upper track layout 301 and the grid lower track layout 302, and extend outward therefrom to one or more manufacturing units 106 located in other areas of the manufacturing facility at locations away from the 3D grid storage structure 300. In one embodiment, if the manufacturing unit 106 is located at ground level or at any height lower than the grid upper track layout 301 on the elevated track, the manufacturing unit 106 is provided with service by a descending shaft connected to the elevated track, wherein the descending shaft is composed of the same rack and tooth frame members 309 as the 3D grid storage structure 300 and is installed at appropriate intervals along the elevated track to allow the RSRV 306 to descend from the elevated track and unload the storage unit carried by the RSRV at the manufacturing unit 106. In one embodiment, each descending shaft provides service for a single manufacturing unit, or multiple manufacturing units distributed within the 2D grid track structure or distributed along a one-dimensional track at a lower height. The manufacturing capacity of the manufacturing center 105 can be increased by expanding the 2D grid track structure or adding more layers to the structure of the manufacturing center 105.

[0128] Fig.13 FIG. 1 is a flow chart of a method for executing a workflow in a manufacturing system according to an embodiment of the present invention. Figures 1 to 12BAs disclosed in the detailed description of the present invention, the manufacturing system disclosed herein includes: a storage configuration having an automated storage system (ASRS) structure and a team of robotic storage / retrieval vehicles (RSRVs); and a plurality of manufacturing cells located outside the ASRS structure. In one embodiment, the storage configuration includes a batch of workpieces. The batch of workpieces is stored in a storage location of the ASRS structure for manufacturing items from the workpieces. The same team of RSRVs that can navigate in three dimensions within the ASRS structure can be operated to transfer the workpieces to the manufacturing cells. In one embodiment, the workpieces can be transported between each manufacturing cell in any order. The manufacturing system disclosed herein allows the workpieces to be transported in any order and sequence between each manufacturing cell, rather than being transported linearly by a conveyor. In another embodiment, a first manufacturing cell in the manufacturing cell receives the workpiece to perform one or more of a plurality of processing steps of the manufacturing process, then stores the workpiece in a storage location of the ASRS structure, and then retrieves the workpiece from the storage location of the ASRS structure to transfer the workpiece to a second manufacturing cell in the manufacturing cell. In another embodiment, each manufacturing cell is configured to receive the workpiece multiple times to perform one or more processing steps of the manufacturing process.

[0129] In one embodiment, the storage configuration of the manufacturing system disclosed herein further includes a batch of tool pieces for manufacturing items. The tool pieces are stored in the same ASRS structure as the workpieces. The tool pieces can be taken out from the same ASRS structure by the same team of RSRVs and transferred to the manufacturing unit.

[0130] In one embodiment, the storage configuration of the manufacturing system disclosed herein further includes a batch of storage units of compatible size and shape for storage in the storage location of the ASRS structure. The storage unit is configured to be carried by the RSRV to transfer the storage unit to and from the storage location, and to transfer the storage unit to and from the manufacturing unit. The manufacturing system disclosed herein allows buffering of the storage unit in the ASRS structure between each process performed by different manufacturing units. In one embodiment, the storage unit includes a workpiece storage unit or a tool storage unit or any combination thereof. Each workpiece storage unit is configured to accommodate one or more workpieces. Each tool storage unit is configured to accommodate one or more tool pieces. In one embodiment, the manufacturing units are configured to be arranged continuously outside the ASRS structure. In one embodiment, due to the continuous arrangement of the manufacturing units, the storage unit is configured to be transferred to and from the storage location of the ASRS structure, and to and from the manufacturing units without identifying the storage unit. The continuity between the ASRS structure and each different manufacturing unit outside the ASRS structure allows the storage unit to be directly physically transferred without identifying or scanning the storage unit.

[0131] In one embodiment, the workpiece storage unit includes an inventory storage unit and a kit storage unit. Each inventory storage unit is configured to include a collection of inventory workpieces. Each kit storage unit is configured to include a kit of mixed workpieces, wherein the mixed workpieces are picked from one or more inventory storage units according to the manufacturing process to be performed on the mixed workpieces once they are transferred to a manufacturing unit. Figure 7 As disclosed in the detailed description of, in another embodiment, the manufacturing system disclosed herein further includes at least one stock preparation workstation, the stock preparation workstation being configured to receive the inventory storage unit transferred from the ASRS by the RSRV to allow the inventory workpiece to be picked up from the inventory storage unit at the stock preparation workstation. In one embodiment, the stock preparation workstation is configured to receive the unloading of the workpiece storage unit by the same team of RSRVs, and / or the travel of the workpiece storage unit through the stock preparation workstation.

[0132] like FIG. 5A to FIG. 5C and FIG. 6A to FIG. 6B As disclosed in the detailed description of, in one embodiment, the storage configuration of the manufacturing system disclosed herein further includes a batch of workpiece holders. Each workpiece holder is configured to accommodate one or more workpieces in a predetermined position during the manufacture of the item. The workpiece holder is stored in the same ASRS structure as the workpiece. The workpiece holder can be taken out from the same ASRS structure by the same team of RSRVs and transferred to the manufacturing unit. In one embodiment, each workpiece holder has a universal footprint with standardized size and shape, and the size and shape of the universal footprint are the same as the compatible size and shape of each of a batch of storage units, and is configured to fit in the storage position of the ASRS structure. Each workpiece holder includes a base, and the base has a standardized shape and size, which is configured to fit in the storage position of the ASRS structure. In one embodiment, each workpiece holder and each storage unit are configured with a matching layout with interface features, and the RSRV interacts with the workpiece holder and the storage unit through the matching layout to allow the workpiece holder and the storage unit to be loaded into and unloaded from the RSRV.

[0133] In one embodiment, in addition to the batch of workpieces stored in the storage location of the ASRS structure, the storage configuration also includes a batch of tool pieces or a batch of workpiece holders stored in the ASRS structure. Each tool piece is useful for performing one or more processing steps of a manufacturing process on one or more workpieces during the manufacture of an item. Each workpiece holder is configured to accommodate one or more workpieces in a predetermined position during the manufacture of an item. In this embodiment, the team of RSRVs is operable to extract at least one of the tool piece and the workpiece holder and the workpiece from the storage location. The same team of RSRVs that can navigate along three dimensions within the ASRS structure is operable to transfer materials or components, such as workpieces and tool pieces and / or workpiece holders, between manufacturing units. In one embodiment, the components can be transported between each manufacturing unit in any order. In another embodiment, each manufacturing unit is configured to receive the components multiple times to perform one or more processing steps of a manufacturing process.

[0134] In one embodiment, each manufacturing unit includes at least one workpiece receiving area, and the workpiece receiving area is configured to receive a workpiece to be processed in the corresponding manufacturing unit. The workpiece receiving area is configured to receive a workpiece storage unit placed thereon. In one embodiment, the workpiece receiving area includes two workpiece receiving areas. Each of the two workpiece receiving areas is configured to receive a set of workpieces required by the corresponding manufacturing unit.

[0135] In one embodiment, at least a subset of the manufacturing units are located on the track structure or in the area of ​​the track structure. FIG. 8A to FIG. 8C and 9A to 9F As disclosed in the detailed description of , in one embodiment, the track structure is a grid track structure including a plurality of sets of intersecting tracks, and the RSRV can navigate along two dimensions on the intersecting tracks. In one embodiment, the width of the workpiece receiving area in each of the two dimensions is generally equal to an integer multiple of the distance between two adjacent parallel tracks of the grid track structure. In another embodiment, the width of the workpiece receiving area in each of the two dimensions does not exceed the distance between two adjacent parallel tracks of the grid track structure.

[0136] In one embodiment, the grid track structure includes square blocks. Each square block is defined by a first pair of parallel tracks in a first direction and a second pair of parallel tracks in a second direction, wherein the second direction is perpendicular to the first direction. Each manufacturing unit occupies a unit space, and the area of ​​the unit space is equal to the area of ​​a predetermined number of square blocks. In one embodiment, at least one unit space is a square space, and the area of ​​the square space can be divided into nine square subspaces. The area of ​​each of the nine square subspaces is equal to the area of ​​one square block of the grid track structure. Four corner subspaces of the nine square subspaces are configured as a receiving area, and the receiving area is used to receive materials required by the corresponding manufacturing unit. In one embodiment, a first pair of intermediate surrounding subspaces between the four corner subspaces on the first pair of opposite surrounding sides of the unit space are occupied by robot workers. In one embodiment, a central subspace between the robot workers is configured as a working area, and a workpiece is transferred to the working area, and the workpiece is processed by the robot worker in the working area. In one embodiment, a second pair of intermediate surrounding subspaces between the four corner subspaces on the second pair of opposite surrounding sides of the unit space are adjacent to the working area. In one embodiment, at least one of the second pair of intermediate peripheral subspaces is an unoccupied open area through which the RSRV is configured to enter and exit the work area. In another embodiment, each of the second pair of intermediate peripheral subspaces is an unoccupied open area, whereby the RSRV is configured to completely travel through the corresponding manufacturing unit.

[0137] In one embodiment, each manufacturing unit includes at least one robotic picker operable to pick up workpieces from the workpiece receiving area. In another embodiment, each manufacturing unit further includes a working area, and the picked workpieces are transferred from the workpiece receiving area to the working area by the robotic picker.

[0138] In one embodiment, each manufacturing unit in the subset includes at least one tool receiving area, the tool receiving area being configured to receive the tooling required in the corresponding manufacturing unit. In one embodiment, the width of the tool receiving area in each of two dimensions is generally equal to the distance between two adjacent parallel tracks of the grid track structure. In another embodiment, the width of the tool receiving area in each of the two dimensions does not exceed the distance between two adjacent parallel tracks of the grid track structure. In one embodiment, each manufacturing unit in the subset includes at least one robotic worker, the robotic worker being mounted on top of a mounting base, the mounting base being mounted on or in the grid track structure. In one embodiment, the width of the mounting base in each of the two dimensions is generally equal to an integer multiple of the distance between two adjacent parallel tracks of the grid track structure. In another embodiment, the width of the mounting base in each of the two dimensions does not exceed the distance between two adjacent parallel tracks of the grid track structure.

[0139] exist Fig.13 In the method disclosed herein shown, workpieces and workpiece holders are stored 1301 in corresponding storage locations of an ASRS structure. Workpieces are stored in workpiece storage units of storage locations. In one embodiment, each workpiece storage unit is filled with a kit of different workpieces according to the requirements of the manufacturing process. In one embodiment, each workpiece storage unit is filled at a material preparation workstation connected to the ASRS structure. At the material preparation workstation, the team of RSRVs is configured to convey inventory storage units taken out from corresponding storage locations in the ASRS structure, the inventory storage units including inventory workpieces; pick up different workpieces of the kit from the inventory workpieces in the inventory storage unit and compile them into the workpiece storage unit; and each workpiece storage unit is transported away from the material preparation workstation by an RSRV and stored in a corresponding storage location in the ASRS structure for subsequent removal from the ASRS structure.

[0140] In one embodiment, tool storage units configured to hold tool pieces used in a manufacturing process are stored in an ASRS structure. In the method disclosed herein, one or more workpiece storage units and selected workpiece holders are extracted 1302 from the ASRS structure and transferred 1303 to the manufacturing cell, respectively, according to the requirements of the manufacturing process to be performed in the manufacturing cell outside the ASRS structure, using the fleet of RSRVs that can navigate within the ASRS structure. In one embodiment, the same type of RSRV is configured to perform the extraction and transfer of the workpiece storage unit and the selected workpiece holder from the ASRS structure to the manufacturing cell separately. At the manufacturing cell, the selected workpiece holder is positioned 1304 at a work position accessible to one or more workers of the manufacturing cell. At the manufacturing cell, with the selected workpiece holder fixed in the work position 1305, (i) one or more workpieces are transferred 1305a from the workpiece storage unit to the selected workpiece holder; and (ii) the processing steps of the manufacturing process are performed 1305b on the workpiece fixed on the selected workpiece holder. In one embodiment, before the processing step of the manufacturing process is performed, a subset of the tool storage units is extracted from the ASRS structure using an RSRV and transferred to the manufacturing cell. In one embodiment, before the processing step of the manufacturing process is performed, a tool selected from the subset of the tool storage units is attached to the robotic worker of the manufacturing cell according to the requirements of the manufacturing process to be performed by the robotic worker on the workpiece.

[0141] In one embodiment, the workpiece storage unit includes two workpiece storage units. In one embodiment, the two workpiece storage units are transferred to two corresponding receiving areas of the manufacturing unit. The two workpieces are transferred from the two workpiece storage units placed in the two corresponding receiving areas to the selected workpiece holders.

[0142] In one embodiment, after the workpieces are transferred from the workpiece storage unit to the selected workpiece holder, the unneeded or empty workpiece storage unit is removed from the manufacturing unit, wherein the selected workpiece has been removed and there are no more workpieces required for the manufacturing process of the manufacturing unit. In this embodiment, an RSRV is used to transfer additional workpiece storage units to the manufacturing unit, and the additional workpiece storage unit includes one or more additional workpieces required for the manufacturing unit. In one embodiment, the additional workpieces are used for different manufacturing processes to be performed in the same manufacturing unit. In one embodiment, the unneeded or empty workpiece storage unit is removed using a different RSRV than the RSRV that transfers the additional workpiece storage unit to the manufacturing unit. In one embodiment, the different RSRV is configured to remove the unneeded or empty workpiece storage unit after the different workpiece storage unit has been unloaded at the different manufacturing unit to supply the contents of the different workpiece storage unit to the different manufacturing unit. After performing a processing step of a manufacturing process on a workpiece secured to a selected workpiece holder, removing the selected workpiece holder and the workpiece thereon from the manufacturing cell; transferring another workpiece holder to the manufacturing cell using an RSRV for use in a different manufacturing process; supporting the workpiece holder in a working position; transferring an additional workpiece from an additional workpiece storage unit to the workpiece holder; and performing one or more processing steps of the different manufacturing process on the additional workpiece.

[0143] In the method disclosed herein, after the finished product is completed by processing the workpieces in one or more manufacturing cells, the finished product is introduced into the ASRS structure on the one RSRV. In one embodiment, one or more final processing steps are performed on the final workpiece support to complete the finished product, and the finished product on the final support is introduced into the ASRS structure. In one embodiment, the final workpiece support is the same as the selected workpiece support to which the workpiece is transferred.

[0144] Fig.14Flowchart of a method for performing a material preparation operation of a workflow in a manufacturing system according to an embodiment of the present invention. Consider an example in which a work order for a kit storage unit is received, which is referred to herein as a "kit box". At step 1401, the material preparation operation begins upon receiving the work order. At step 1402, a computer control system (CCS) of the manufacturing system receives a work order for a desired kit box. At step 1403, the CCS instructs a first robotic storage / retrieval vehicle (RSRV) to retrieve an empty storage unit, which is referred to herein as an "empty box". At step 1404, the first RSRV retrieves the empty box from an automated storage system (ASRS) structure and provides the empty box to a placement port or a placement access port of a material preparation workstation in a material preparation area of ​​the manufacturing system. At step 1405, the CCS instructs a second RSRV to retrieve a desired workpiece storage unit, such as a desired single stock keeping unit (SKU) box. At step 1406, the second RSRV retrieves a single SKU box from the ASRS structure and provides the single SKU box to a pick-up port or a pick-up access port of a material preparation workstation. In step 1407, a worker, either a human worker or a robot worker, picks up the required number of workpieces from the single SKU box and places the picked workpieces in an empty box that is being packaged and prepared at the placement port of the preparation workstation. In step 1408, the CCS instructs the second RSRV to store the single SKU box. In step 1409, the second RSRV stores the single SKU box in the ASRS structure. In step 1410, the CCS determines whether more workpieces are needed in the kit box based on the work order. If more workpieces are needed in the kit box, steps 1405 to 1409 of the method disclosed herein are repeated until no more workpieces are needed in the kit box. If no more workpieces are needed in the kit box, in step 1411, the CCS instructs the first RSRV to store the kit SKU box. In step 1412, the first RSRV stores the kit SKU box in the ASRS structure. When the kit SKU box has been processed and stored, the preparation operation ends 1413. In one embodiment, the above-mentioned stocking operation is also performed on the tooling to create a tooling kit box or a tooling kit storage unit.

[0145] FIG. 15A to FIG. 15CFlowchart of a method for performing manufacturing operations to complete work orders using workpiece storage units in a manufacturing system according to an embodiment of the present invention. In step 1501, a manufacturing operation begins when a manufacturing system receives a work order for assembly. In step 1502, a computer control system (CCS) of the manufacturing system receives a work order for a desired assembly with software instructions. In step 1503, upon executing the software instructions, the CCS instructs a first robotic storage / retrieval vehicle (RSRV) to retrieve a workpiece holder associated with the manufacturing operation to be performed. In step 1504, the first RSRV retrieves the associated workpiece holder from an automated storage system (ASRS) structure and provides the workpiece holder to a designated fully automated manufacturing cell or robotic manufacturing cell at a manufacturing center of the manufacturing system. In step 1505, the CCS instructs a second RSRV to retrieve the desired workpiece storage unit. In step 1506, the second RSRV retrieves the desired workpiece storage unit from the ASRS structure and places the workpiece storage box on a workpiece receiving station of a designated robotic manufacturing cell. In step 1507, the CCS instructs a third RSRV to retrieve the desired tool storage unit. At step 1508, the third RSRV retrieves the required tool storage unit from the ASRS structure and places the tool storage unit on the tool receiving station of the designated robotic manufacturing cell.

[0146] In step 1509, CCS instructs a robot worker to pick up a specified workpiece, wherein the robot worker is operably coupled to a robot picker at another mounting base of the specified robot manufacturing cell. In step 1510, the robot picker picks up the specified workpiece from the workpiece storage unit. In step 1511, CCS instructs the robot picker to place the specified workpiece in the work position. In step 1512, CCS determines whether to fasten the specified workpiece to the subassembly located on the workpiece support based on the work order. If fastening is not required, the manufacturing operation continues to step 1516 disclosed below. If the specified workpiece needs to be fastened to the subassembly located on the workpiece support, in step 1513, CCS instructs another robot worker to obtain or pick up the specified tool from the tool storage unit, wherein the other robot worker is operably coupled to a robot processing worker at the mounting base of the specified robot manufacturing cell. In step 1514, the robot processing worker obtains the specified tool from the tool storage unit. In step 1515, the CCS instructs the robot processing worker to fasten the workpiece to the subassembly using the acquired tool piece. In step 1516, the CCS determines whether more workpieces are needed in the subassembly. If more workpieces are needed in the subassembly, steps 1509 to 1515 of the method disclosed herein are repeated until no more workpieces are needed. If no more workpieces are needed in the subassembly, in step 1517, the CCS instructs the second RSRV or the fourth RSRV to store the workpiece storage unit. In one embodiment, the CCS instructs the same second RSRV that transfers the workpiece storage unit to the manufacturing unit to store the workpiece storage unit. In another embodiment, the CCS instructs another RSRV, i.e., the fourth RSRV, to store the workpiece storage unit. In step 1518, the second RSRV or the fourth RSRV stores the workpiece storage unit in the ASRS structure. In step 1519, the CCS instructs the third RSRV or the fifth RSRV to store the tool storage unit. In one embodiment, the CCS instructs the same third RSRV that transfers the tool storage unit to the manufacturing unit to store the tool storage unit. In another embodiment, the CCS instructs another RSRV, namely the fifth RSRV, to store the tool storage unit. In step 1520, the third RSRV or the fifth RSRV stores the tool storage unit in the ASRS structure. In step 1521, the CCS determines whether a different workpiece is required in the subassembly. If a different workpiece is required in the subassembly, steps 1505 to 1520 of the method disclosed herein are repeated until a different workpiece is no longer required in the subassembly. In step 1522, the CCS determines whether a workpiece holder is required in another manufacturing unit in the manufacturing center. If a workpiece holder is required in another manufacturing unit, in step 1523, the CCS instructs the first RSRV to transport the workpiece holder with the subassembly to the next manufacturing unit.At step 1524, the first RSRV transports the workpiece holder with the subassembly to the next manufacturing cell, where steps similar to steps 1505 to 1522 are performed. If the workpiece holder is not needed at another manufacturing cell, then at step 1525, the CCS instructs the first RSRV to store the workpiece holder with the completed subassembly. At step 1526, the first RSRV stores the workpiece holder with the completed subassembly for the work order in the ASRS structure. When the work order is completed, the manufacturing operation ends 1527.

[0147] FIG. 16A to FIG. 16C Flowchart of a method for performing manufacturing operations to complete work orders using kit storage units in a manufacturing system according to an embodiment of the present invention. In step 1601, a manufacturing operation begins when a manufacturing system receives a work order for an assembly. In step 1602, a computer control system (CCS) of the manufacturing system receives a work order for a desired assembly with software instructions. In step 1603, upon executing the software instructions, the CCS instructs a first robotic storage / retrieval vehicle (RSRV) to retrieve a workpiece holder associated with the manufacturing operation to be performed. In step 1604, the first RSRV retrieves the associated workpiece holder from an automated storage system (ASRS) structure and provides the workpiece holder to a designated fully automated manufacturing cell or robotic manufacturing cell at a manufacturing center of the manufacturing system. In step 1605, the CCS instructs a second RSRV to retrieve a desired workpiece kit storage unit, also referred to as a "workpiece kit box." In step 1606, the second RSRV retrieves the desired workpiece kit box from the ASRS structure and places the workpiece kit box on a workpiece receiving station of a designated robotic manufacturing cell. In step 1607, the CCS instructs the third RSRV to retrieve the required tool kit storage unit, which is also referred to as a "tool kit box". In step 1608, the third RSRV retrieves the required tool kit box from the ASRS structure and places the tool kit box on the tool receiving station of the designated robotic manufacturing cell.

[0148] In step 1609, CCS instructs a robot worker to pick up a specified workpiece, wherein the robot worker is operably coupled to a robot picker at another mounting base of the specified robot manufacturing cell. In step 1610, the robot picker picks up the specified workpiece from the workpiece kit box. In step 1611, CCS instructs the robot picker to place the specified workpiece in the work position. In step 1612, CCS determines whether to fasten the specified workpiece to the subassembly located on the workpiece support based on the work order. If fastening is not required, the manufacturing operation continues to step 1616 disclosed below. If the specified workpiece needs to be fastened to the subassembly located on the workpiece support, in step 1613, CCS instructs another robot worker to obtain or pick up the specified tool from the tool kit box, wherein the other robot worker is operably coupled to a robot processing worker at the mounting base of the specified robot manufacturing cell. In step 1614, the robot processing worker obtains the specified tool from the tool kit box. In step 1615, the CCS instructs the robot processing worker to fasten the workpiece to the subassembly using the acquired tool piece. In step 1616, the CCS determines whether more workpieces are needed in the subassembly. If more workpieces are needed in the subassembly, steps 1609 to 1615 of the method disclosed herein are repeated until no more workpieces are needed. If no more workpieces are needed in the subassembly, in step 1617, the CCS instructs the second RSRV or the fourth RSRV to store the workpiece kit box. In one embodiment, the CCS instructs the same second RSRV that transfers the workpiece kit box to the manufacturing cell to store the workpiece kit box. In another embodiment, the CCS instructs another RSRV, i.e., the fourth RSRV, to store the workpiece kit box. In step 1618, the second RSRV or the fourth RSRV stores the workpiece kit box in the ASRS structure. In step 1619, the CCS instructs the third RSRV or the fifth RSRV to store the tool kit box. In one embodiment, the CCS instructs the same third RSRV that transfers the tool kit box to the manufacturing cell to store the tool kit box. In another embodiment, the CCS instructs another RSRV, a fifth RSRV, to store the tool kit box. At step 1620, the third RSRV or the fifth RSRV stores the tool kit box in the ASRS structure. At step 1621, the CCS determines whether the workpiece holder is needed at another manufacturing cell in the manufacturing center. If the workpiece holder is needed at another manufacturing cell, then at step 1622, the CCS instructs the first RSRV to transport the workpiece holder with the subassembly to the next manufacturing cell. At step 1623, the first RSRV transports the workpiece holder with the subassembly to the next manufacturing cell, where steps similar to steps 1605 to 1621 are performed.If the workpiece holder is not needed in another manufacturing cell, then the CCS instructs the first RSRV to store the workpiece holder with the completed subassembly in step 1624. The first RSRV stores the workpiece holder with the completed subassembly for the work order in the ASRS structure in step 1625. When the work order is completed, the manufacturing operation ends 1626.

[0149] Fig.17 1701 is a flowchart of a method for manufacturing a product in a manufacturing system according to an embodiment of the present invention. Consider an example in which the manufacturing system receives 1701 a purchase order for a predetermined quantity of a product, namely, product_X, and then proceeds to purchase 1702 raw materials required for manufacturing the predetermined quantity of product_X. When the manufacturing system receives the raw materials for manufacturing product_X, in step 1703, the raw materials are introduced into a workpiece storage unit in an automated warehouse storage system (ASRS) structure. In step 1704, as shown in FIG. Fig.14 As disclosed in the detailed description of , the computer control system (CCS) of the manufacturing system triggers a material preparation operation in the material preparation area of ​​the manufacturing system to establish a kit or a kit storage unit containing one or more types of workpieces, wherein the one or more types of workpieces are used to manufacture a certain number of each of multiple sub-assemblies that constitute product _X. In step 1705, the CCS determines whether the manufacturing center has available capacity to manufacture a certain number of each of the sub-assemblies of product _X. If there is available capacity, then in step 1706, the CCS configures one of the fully automatic manufacturing cells or robotic manufacturing cells of the manufacturing center to manufacture a certain number of each of the sub-assemblies of product _X. In step 1707, the CCS instructs the robotic manufacturing cell to manufacture a certain number of each of the sub-assemblies of product _X. The robotic manufacturing cell performs the following operations by executing FIG. 16A to FIG. 16C 1704. The manufacturing operation disclosed in the detailed description of the present invention is used to manufacture a certain number of each of the subassemblies of product_X. After manufacturing each of the subassemblies of product_X, in step 1708, CCS determines whether more subassemblies of product_X need to be manufactured to reach the required number. If more subassemblies need to be manufactured to reach the required number, steps 1705 to 1707 are repeated until the required number is reached. If the required number has been reached, in step 1709, CCS determines whether there is available capacity in the manufacturing center to manufacture the predetermined number of product_X. If there is available capacity, in step 1710, CCS configures one of the fully automated manufacturing cells or robotic manufacturing cells in the manufacturing center to manufacture the predetermined number of final assemblies of product_X. In step 1711, CCS instructs the robotic manufacturing cell to use the subassemblies of product_X to manufacture the predetermined number of final assemblies of product_X. When the certain number of product_X is manufactured, the manufacturing operation ends 1712. The manufacturing system disclosed herein allows a large number of variants and models of products to be manufactured in variable quantities.

[0150] Fig.18 FIG. 1 is an architectural block diagram of a manufacturing system 100 according to an embodiment of the present invention, which illustrates the communication between a computer control system (CCS) 131 and components of the manufacturing system 100. Figure 1 and Figure 2 As shown, the components of the manufacturing system 100 include: an automated storage and retrieval system (ASRS) structure 101; a fleet of robotic storage / retrieval vehicles (RSRVs) 306; material preparation workstations 103, 104; and manufacturing cells 106, 107 of a manufacturing center 105. The CCS 131 is in operative communication with the fleet of RSRVs 306, the human-machine interface (HMI) 138 and the light guidance system 139 of the material preparation workstations 103, 104, the robot workers 123a, 123b in the fully automated manufacturing cell 106 or the robotic manufacturing cell 106, and the HMI 140 in the manufacturing cell 107 with human participation. Figure 1 to Figure 2 and Figure 7 As shown, the HMI 138 of the material preparation workstation 103, 104 includes a display screen for displaying instructions for performing material preparation operations in the material preparation area 102 of the manufacturing system 100 to the human worker 703. The light guidance system 139 includes, for example, a place-by-light guidance system and a pick-by-light guidance system. The CCS 131 includes: a network interface 134 connected to a communication network, and at least one processor 132 connected to the network interface 134. As used herein, "communication network" refers to, for example, the Internet, a wireless network, a Bluetooth SIG-implemented wireless network, or a wireless communication network. communication network, implement the Wi-Fi Alliance Networks, ultra-wideband (UWB) communication networks, wireless universal serial bus (USB) communication networks, and ZigBee Alliance The network interface 134 enables CCS131 to connect to a communication network. In one embodiment, the network interface 134 is configured as an interface card, which is also called a line card. The network interface 134 is, for example, an infrared interface, an interface card implementing the Wi-Fi Alliance's interface, Universal Serial Bus interface, Apple's One or more of an interface, an Ethernet interface, a frame relay interface, a cable interface, a digital subscriber line interface, a token ring interface, a peripheral controller interconnect interface, a local area network interface, a wide area network interface, an interface using a serial protocol, an interface using a parallel protocol, an Ethernet communication interface, an asynchronous transfer mode interface, a high-speed serial interface, a fiber distributed data interface, an interface based on the transmission control protocol / internet protocol, an interface based on wireless communication technology, etc., wherein the wireless communication technology is such as satellite technology, radio frequency technology, and near field communication.

[0151] In one embodiment, CCS 131 is a programmable computer system using a high-level computer programming language. CCS 131 is implemented using programmed and dedicated hardware. In the manufacturing system 100 disclosed herein, CCS 131 is connected to ASRS structure 101, RSRV 306, material preparation workstations 103, 104 and manufacturing units 106, 107, so that more than one specially programmed computing system is used to execute the workflow in the manufacturing system 100. CCS 131 further includes a non-transitory computer-readable storage medium, such as a memory unit 137, which is communicatively connected to the processor 132. "Non-transitory computer-readable storage medium" used herein refers to all computer-readable media that include and store computer programs and data. Examples of computer-readable media include hard drives, solid-state drives, optical disks or disks, memory chips, read-only memories (ROMs), temporary register memories, processor caches, random access memories (RAMs), etc. Processor 132 refers to any one or more of a microprocessor, a central processing unit (CPU), a finite state machine, a computer, a microcontroller, a digital signal processor, a logic, a logic device, an application specific integrated circuit (ASIC), a field programmable gate array (FPGA), a chip, etc., or any combination thereof, that can execute a computer program or a series of commands, instructions, or state transitions. In one embodiment, processor 132 is implemented as a processor set including, for example, a programmed microprocessor and a co-processor for mathematics or graphics. CCS 131 is not limited to using processor 132. In one embodiment, CCS 131 uses a controller or a microcontroller. Processor 132 executes modules of CCS 131, such as 137a to 137d.

[0152] The memory unit 137 is used to store program instructions, application programs, and data. The memory unit 137 stores computer program instructions defined by the modules of the CCS 131, such as 137a to 137d. The memory unit 137 is operably and communicatively connected to the processor 132 to execute the computer program instructions defined by the modules of the CCS 131, such as 137a to 137d, so as to execute the workflow in the manufacturing system 100. The memory unit 137 is, for example, a random access memory (RAM) or another type of dynamic storage device, which stores information and instructions for execution by the processor 132. The memory unit 137 also stores temporary variables and other intermediate information used during the execution of instructions by the processor 132. In one embodiment, the CCS 131 further includes a read-only memory (ROM) or other type of static storage device, which stores static information and instructions for execution by the processor 132. In one embodiment, the modules of the CCS 131, such as 137a to 137e, are stored in the memory unit 137.

[0153] The memory unit 137 is configured to store computer program instructions that, when executed by the processor 132, cause the processor 132 to initiate one or more RSRVs 306 to perform one or more of the following: (a) navigate within the ASRS structure 101 and / or navigate through the manufacturing cells 106, 107; (b) retrieve one or more workpieces contained in the one or more storage cells from a storage location of the ASRS structure 101; (c) transfer the one or more workpieces contained in the one or more storage cells to at least one material preparation workstation 103, 104 to package the workpieces into one or more kit storage cells; (d) pick up one or more kit storage cells from the material preparation workstation 103, 104; (e) return and store one or more kit storage cells to a storage location of the ASRS structure 101; (f) retrieve one or more workpieces contained in the one or more storage cells from the corresponding material preparation workstation 103, 104; (g) retrieve one or more kit storage cells from the corresponding material preparation workstation 103, 104; (h) retrieve one or more kit storage cells from the corresponding material preparation workstation 103, 104; (h) retrieve one or more kit storage cells from the corresponding material preparation workstation 103, 104; (i) retrieve one or more kit storage cells from the corresponding material preparation workstation 103, 104; (ii) retrieve one or more kit storage cells from the corresponding material preparation workstation 103, 104; (iii) retrieve one or more kit storage cells from the corresponding material preparation workstation 103, 104; (iv) retrieve one or more kit storage cells from the corresponding material preparation workstation 103, 104; (v ... (g) transferring the one or more kit storage units and at least one of the one or more workpieces contained in another one or more storage units, one or more tool pieces contained in yet another one or more storage units, and one or more workpiece holders to the manufacturing units 106, 107 to manufacture the items; and (h) introducing the items on the final workpiece holders into the ASRS structure 101.

[0154] like Fig.18As shown, CCS 131 further includes a data bus 136, a display unit 133, and a common module 135. The data bus 136 allows communication between modules such as 132, 133, 134, 135, and 137 of CCS 131. The display unit 133 displays information, display interfaces, user interface elements such as check boxes, text input areas, etc. via a graphical user interface (GUI) 133a to, for example, allow a user such as a system administrator to trigger updates to digital records of work orders, enter inventory information, update database tables, etc. to execute workflows in the manufacturing system 100. CCS 131 presents GUI 133a on the display unit 133 to receive input from the system administrator. GUI 133a includes, for example, an online web interface, a web-based downloadable application interface, a mobile device-based downloadable application interface, etc. The display unit 133 displays GUI 133a. The general module 135 of the CCS 131 includes, for example, an input / output (I / O) controller, an input device, an output device, a fixed media drive such as a hard disk drive, a removable media drive for receiving removable media, etc. Computer applications and programs are used to operate the CCS 131. The programs are loaded onto the fixed media drive via the removable media drive, and loaded into the memory unit 137. In one embodiment, the computer applications and programs are loaded directly into the memory unit 137 via a communication network.

[0155] exist Fig.18In the illustrated exemplary embodiment, the CCS 131 includes an order management module 137a, a material preparation management module 137b, a storage unit allocation module 137c, a robot activation module 137d, and a facility database 137e. The order management module 137a defines computer program instructions for receiving work orders with software instructions for executing workflows in the manufacturing system 100. The order management module 137a is configured to update the digital record of the work order in the facility database 137e. The material preparation management module 137b defines computer program instructions for performing material preparation operations in the material preparation area 102 of the manufacturing system 100 based on the work order and manufacturing requirements. The material preparation management module 137b sends instructions and notifications to the HMI 138 of the material preparation area 102 for viewing by human workers 703 participating in at least one material preparation workstation 103. In one embodiment, the material preparation management module 137b also controls a light guidance system 139 that guides pick and place operations in the material preparation area 102. The storage unit allocation module 137c defines computer program instructions for allocating storage units for storing workpieces, specific combinations of workpieces, workpiece holders, tool pieces, specific combinations of tool pieces, etc., at addressed storage locations in the ASRS structure 101. The robot activation module 137d activates one or more RSRVs 306 to perform various storage, retrieval, transfer, and return operations during material preparation operations in the material preparation area 102 and during the manufacturing workflow of the manufacturing cells 106 and 107 of the manufacturing center 105 as disclosed above.

[0156] The processor 132 of the CCS 131 obtains instructions defined by the order management module 137a, the stock management module 137b, the storage unit allocation module 137c, and the robot activation module 137d to perform the various functions disclosed above. The processor 132 obtains instructions for executing modules such as 137a to 137d from the memory unit 137. The instructions obtained by the processor 132 from the memory unit 137 are processed and decoded. After processing and decoding, the processor 132 executes its respective instructions to perform one or more processes defined by those instructions. The operating system of the CCS 131 executes multiple routines to perform multiple tasks required by the specified input device, output device, and memory unit 137 for executing modules such as 137a to 137e. The tasks performed by the operating system include, for example: allocating memory to modules such as 137a to 137e and data used by the CCS 131; moving data between the memory unit 137 and the disk unit; and processing input / output operations. The operating system performs tasks according to the request of the operation, and after performing the tasks, the operating system passes execution control back to the processor 132. The processor 132 continues execution to obtain one or more outputs.

[0157] For purposes of illustration, the detailed description relates to modules such as 137a to 137e running locally on a single computer system; however, the scope of the manufacturing system 100 and method disclosed herein is not limited to modules such as 137a to 137e running locally on a single computer system through an operating system and a processor 132, but can be extended to remotely running over a communication network by using a web browser and a remote server, mobile phone or other electronic device. In one embodiment, one or more computing portions of the manufacturing system 100 disclosed herein are distributed on one or more computer systems (not shown) connected to a communication network.

[0158] The non-transitory computer-readable storage medium disclosed herein stores computer program instructions executable by the processor 132 to perform the workflow in the manufacturing system 100. The computer program instructions implement the processes of the various embodiments disclosed above, and perform additional steps that may be required and expected in the workflow in the manufacturing system 100. When the computer program instructions are executed by the processor 132, the computer program instructions cause the processor 132 to perform the steps of the method disclosed above for performing the workflow in the manufacturing system 100. In one embodiment, a single segment of computer program code containing computer program instructions performs one or more steps of the method disclosed above. The processor 132 fetches and executes these computer program instructions.

[0159] As used herein, a module, tool, or unit refers to any combination of hardware, software, and / or firmware. As an example, the module, tool, or unit may include hardware such as a microcontroller, which is associated with a non-transitory computer-readable storage medium to store computer program code suitable for execution by the microcontroller. Therefore, the module, tool, or unit mentioned in one embodiment refers to hardware specifically configured to recognize and / or execute computer program code to be stored on a non-transitory computer-readable storage medium. The computer program code includes computer-readable and executable instructions and can be implemented in any programming language, such as C, C++, C#, Fortran, Ruby, hypertext preprocessor (PHP), NET, Etc. Other object-oriented, functional, scripting and / or logical programming languages ​​may also be used. In one embodiment, the computer program code or software program is stored as target code on or in one or more media. In another embodiment, the term "module" or "tool" or "unit" refers to a combination of a microcontroller and a non-transitory computer-readable storage medium. Typically, the boundaries of modules or tools or units shown as independent will typically change and may overlap. For example, modules or tools or units may share hardware, software, firmware, or a combination thereof, while retaining some independent hardware, software, or firmware. In various embodiments, modules or tools or units include any suitable logic.

[0160] In the manufacturing system 100 disclosed herein, the scalable manufacturing cells distributed on the grid track structure are connected to the two-dimensional (2D) grid lower track layout of the ASRS structure 101, allowing each manufacturing cell to access a large number of workpieces and workpiece kits and related tooling, tooling kits and workpiece holders. This allows each manufacturing cell to be instantly configured for a variety of on-demand manufacturing processes using only CCS software. The just-in-time delivery of workpieces, tooling and workpiece holders to the manufacturing cells by the RSRV 306 allows for just-in-time manufacturing of subassemblies at any stage of the manufacturing process. The ability to store each subassembly in the ASRS structure 101 between manufacturing processes allows for maximum flexibility because any manufacturing step can be completed as capacity becomes available.

[0161] In addition, in the manufacturing system 100 disclosed herein, all components or parts delivered to the manufacturing unit use a standardized storage unit footprint. The use of a standardized storage unit footprint in a single automated solution for all manufacturing workflows allows for dense storage and predictable management of all items and materials for all manufacturing processes by a single entity as a single collaborative system with any number of manufacturing processes. The manufacturing system 100 disclosed herein allows all manufacturing processes including receiving, material preparation, assembly of subassemblies, and final assembly to be completed by an automated material handling system that does not require conveyors or ground transportation, and the manufacturing units can be software configured as needed. The invention disclosed herein allows all manufacturing processes to be completed by an automated material handling system that does not require conveyors or ground transportation, and the manufacturing units can be software configured as needed.

[0162] Since the lower 2D grid interconnects all manufacturing units, the manufacturing system 100 disclosed herein allows for configuration of on-demand manufacturing operations and shipping items between all manufacturing units in any order. This allows any number of processes to be completed in any order and multiple times if necessary, for example, reworking a subassembly to new specifications, etc. This, coupled with the ability to configure manufacturing units using software commands, allows for easy and flexible addition of new manufacturing processes as factory manufacturing requirements change. As customer expectations for customized products increase rapidly, manufacturers aim to stand out by focusing on the customer experience. The manufacturing system 100 disclosed herein is suitable for easily and flexibly changing conditions and product types without waiting time or losing production or manufacturing time.

[0163] In addition, in the manufacturing system 100 disclosed herein, the same storage medium, i.e., the ASRS structure 101, can be used by all interconnected processes in the preparation area 102 and all manufacturing units 106 to buffer any differences in the process flow. Because materials can be stored infinitely, this provides manufacturers with maximum flexibility and minimizes operational sensitivity to the external environment. In addition, since all manufacturing units 106 are interconnected and managed by the same team of RSRV 306, and are also connected to the ASRS structure 101 navigated by the same team of RSRV 306, the system logic is simplified without the need to transfer components from one workspace entity to another. Therefore, it is not necessary for each process to receive and identify inventory, such as using barcode scanning, radio frequency identification (RFID) scanning, etc., to complete the logical transfer of custody between entities, wherein the entity is the ASRS structure 101, the preparation area 102, and the manufacturing unit 106 of the manufacturing center 105.

[0164] In addition, by integrating vertical storage above the lower 2D grid for transport between workspaces, the manufacturing system 100 disclosed herein solves the problem of relatively large footprints of traditional automation solutions, which maximizes storage density and greatly reduces wasted vertical space. As a result, the end-to-end manufacturing solution is only a fraction of the size of traditional solutions and greatly reduces the actual space required to achieve the same transport effect. This allows manufacturers to integrate storage in their existing facilities to expand their business volume.

[0165] The above-disclosed embodiments of the manufacturing system 100 and method form a great shift in the way manufacturing is achieved, and provide a "virtual conveyor" and sorting capability for the automated system. The 2D grid track structure of the technology allows the RSRV 306 to transport items between any manufacturing units connected to the 2D grid track structure. The movement of the RSRV 306 on the 2D grid track structure is coordinated by the CCS 131, which allows storage units to be provided on time, grouped by work orders, and even delivered to the manufacturing units in a specific order. Without this capability, it would be impossible to use a single integrated automation solution to solve complex processes, because traditional ASRS equipment relies on downstream sorting solutions to deliver items to the work area at the right time and in the right order. Subsequently, the CCS 131 configures the manufacturing unit and performs manufacturing operations using software commands. The manufacturing system 100 disclosed herein increases the scalability of the total capacity, wherein the size of the manufacturing system 100 can be expanded modularly. The manufacturing system 100 disclosed herein provides flexibility in supporting the delivery of standardized manufacturing equipment and components in a repeatable manner.

[0166] The embodiments disclosed herein are not limited to a specific computer system platform, processor, operating system, or communication network. One or more embodiments disclosed herein are distributed in one or more computer systems such as servers, and the computer system is configured to provide one or more services to one or more client computers, or to perform complete tasks in the distributed system. For example, one or more embodiments disclosed herein are executed on a client-server system, and the client-server system includes components distributed between one or more server systems that perform multiple functions according to various embodiments. These components include, for example, executable coding, intermediate coding, or interpreted coding that communicates over a network using a communication protocol. The embodiments disclosed herein are not limited to being executable on any specific system or system group, and are not limited to any specific distributed architecture, network, or communication protocol.

[0167] The examples and illustrative implementations of the various embodiments described above are for explanation only and are by no means to be construed as limitations on the embodiments disclosed herein. Although the embodiments have been described with reference to various illustrative implementations, drawings, and techniques, it should be understood that the words used herein are descriptive and illustrative, rather than restrictive. In addition, although the embodiments have been described herein with reference to specific means, materials, techniques, and implementations, the embodiments herein are not intended to be limited to the details disclosed herein; on the contrary, the embodiments extend to all functionally equivalent structures, methods, and uses as within the scope of the appended claims. With the benefit of the teachings of this specification, those skilled in the art will understand that the embodiments disclosed herein can be modified, and other embodiments can be implemented and changed without departing from the scope and spirit of the embodiments disclosed herein.

Claims

1. A manufacturing system, characterized in that: The manufacturing system comprises: An automated warehouse system structure comprising a three-dimensional array of storage locations distributed throughout a two-dimensional footprint of the automated warehouse system structure at a plurality of storage levels within the automated warehouse system structure; a batch of workpieces, tooling pieces and workpiece supports stored in said storage locations of said automated storage system structure for use in manufacturing articles; and a fleet of robotic storage / retrieval vehicles, wherein each of said robotic storage / retrieval vehicles is navigable in three dimensions within said automated storage system structure to access said storage locations in said three-dimensional array, each robotic storage / retrieval vehicle being configured to carry storage units of compatible size and shape for storage in a storage location of the automated storage system structure, said storage units being configured to accommodate at least workpieces and tooling pieces; and a plurality of manufacturing cells arranged in a serial arrangement outside of the automated storage system structure, wherein storage cells are configured to be transferred to and from storage locations of the automated storage system structure and to and from the manufacturing cells based on the serial arrangement of the manufacturing cells without requiring identification or scanning of the storage cells; and A computer control system in operable communication with each storage / retrieval vehicle, the computer control system being configured to coordinate the movement of the storage / retrieval vehicles on a two-dimensional grid track structure interconnecting each manufacturing cell with the automated storage system structure, and to cause the storage / retrieval vehicles to deliver storage cells just in time, grouped by corresponding work orders, and to arrive at the manufacturing cells in a specific sequence, thereby facilitating just-in-time manufacturing of subassemblies at any stage of the manufacturing process and allowing any number of manufacturing processes to be completed multiple times in any sequence.

2. The manufacturing system according to claim 1, characterized in that: Each of the manufacturing cells is configured to receive the workpiece multiple times to perform multiple processing steps of a manufacturing process.

3. The manufacturing system according to claim 1 or 2, characterized in that: The first manufacturing unit in the manufacturing unit receives the workpiece to perform multiple processing steps of a manufacturing process, then stores the workpiece in the storage position of the automatic storage system structure, and then takes out the workpiece from the storage position of the automatic storage system structure to transfer the workpiece to the second manufacturing unit in the manufacturing unit.

4. The manufacturing system according to claim 1, characterized in that: Further comprising a track structure connected to the automated storage system structure and extending beyond the two-dimensional footprint of the automated storage system structure to define an extension of the automated storage system structure, wherein the track structure is configured to define a travel path, the robotic storage / retrieval vehicle can navigate on the travel path, and the manufacturing units are distributed along the travel path.

5. The manufacturing system according to claim 1, characterized in that: The tool parts are stored in and retrieved from the automated storage system structure of the storage unit and transported to the manufacturing unit by the fleet of robotic storage / retrieval vehicles.

6. The manufacturing system according to claim 1, characterized in that: The storage unit is configured to be carried by the robot in a storage / retrieval vehicle to transfer the storage unit to and from the storage location and to and from the manufacturing unit, and wherein the storage unit comprises: workpiece storage units, each of the workpiece storage units being configured to accommodate the workpiece; and Tool storage units, each of the tool storage units is configured to accommodate the tool.

7. The manufacturing system according to claim 6, characterized in that: The workpiece storage units include inventory storage units and kit storage units, wherein each of the inventory storage units is configured to include a collection of inventory workpieces, and wherein each of the kit storage units is configured to include a kit of mixed workpieces, wherein the mixed workpieces are picked up from the inventory storage units according to a manufacturing process to be performed on the mixed workpieces when the mixed workpieces are transferred to one of the manufacturing units.

8. The manufacturing system according to claim 7, characterized in that: Further comprising at least one material preparation workstation configured to receive the inventory storage unit transferred from the automated storage system structure by the robotic storage / retrieval vehicle to allow the inventory workpiece to be picked up from the inventory storage unit at the at least one material preparation workstation.

9. The manufacturing system according to claim 8, characterized in that: The at least one material preparation station is configured to receive unloading of the workpiece storage unit by the fleet of robotic storage / retrieval vehicles, and travel of the workpiece storage unit therethrough.

10. The manufacturing system according to claim 6, characterized in that: Each of the manufacturing units includes at least one workpiece receiving area configured to receive the workpiece to be processed at the corresponding manufacturing unit, wherein the at least one workpiece receiving area is configured to receive one of the workpiece storage units placed thereon.

11. The manufacturing system according to claim 1, characterized in that: Each of the workpiece supports is configured to hold the workpiece in a predetermined position during manufacturing of an item, and wherein the workpiece supports are stored in the automated storage system structure, and wherein the workpiece supports can be retrieved from the automated storage system structure and transferred to the manufacturing unit by the fleet of robotic storage / retrieval vehicles.

12. The manufacturing system according to claim 11, characterized in that: Each of the workpiece supports has a common footprint with standardized shape and size, each of the storage units is configured to fit within the storage position of the automated storage system structure, and wherein each of the workpiece supports includes a base having a standardized shape and size configured to fit within the storage position of the automated storage system structure.

13. The manufacturing system according to claim 12, characterized in that: Each of the workpiece supports and each of the storage units are configured with a mating arrangement of interface features by which the robotic storage / retrieval vehicle interacts with the workpiece supports and the storage units to allow the workpiece supports and the storage units to be loaded and unloaded into and from the robotic storage / retrieval vehicle.

14. The manufacturing system according to claim 1, characterized in that Each of the manufacturing cells includes at least one workpiece receiving area configured to receive the workpiece to be processed therein.

15. The manufacturing system according to claim 14, characterized in that Each of the manufacturing cells includes two workpiece receiving areas, and wherein each of the two workpiece receiving areas is configured to receive a respective required set of workpieces therein.

16. The manufacturing system according to claim 14, characterized in that: The one or more manufacturing units are located in a two-dimensional grid track structure, and wherein the two-dimensional grid track structure includes multiple sets of cross tracks, the robotic storage / retrieval vehicle can navigate along two dimensions on the cross tracks, and wherein the width of the at least one workpiece receiving area in each of the two dimensions is generally equal to an integer multiple of the distance between two adjacent parallel tracks in the two-dimensional grid track structure.

17. The manufacturing system according to claim 16, characterized in that: The width of the at least one workpiece receiving area in each of the two dimensions does not exceed the distance between two adjacent parallel tracks of the two-dimensional grid track structure.

18. The manufacturing system according to claim 14, characterized in that: Each of the manufacturing units includes at least one robotic picker, which is operable to pick up the workpiece from the at least one workpiece receiving area, and wherein each of the manufacturing units further includes a working area, and the picked workpiece is transferred from the at least one workpiece receiving area to the working area by the at least one robotic picker.

19. The manufacturing system according to claim 16, characterized in that: At least a subset of the manufacturing units are located in a two-dimensional grid track structure, and wherein each of the manufacturing units in the subset includes at least one tool receiving area, the at least one tool receiving area is configured to receive a required tool part therein, and wherein the width of the at least one tool receiving area in each of the two dimensions is equal to the distance between two adjacent parallel tracks of the two-dimensional grid track structure.

20. The manufacturing system according to claim 19, characterized in that The width of the at least one tool receiving area in each of the two dimensions does not exceed the distance between two adjacent parallel rails of the two-dimensional grid rail structure.

21. The manufacturing system according to claim 19, characterized in that Each of the manufacturing units in the subset includes at least one robotic worker, which is mounted on top of a mounting base, which is mounted on or within the two-dimensional grid track structure, and wherein the width of the mounting base in each of the two dimensions is generally equal to an integer multiple of the distance between two adjacent parallel tracks of the two-dimensional grid track structure.

22. The manufacturing system according to claim 21, characterized in that The width of the mounting base in each of the two dimensions does not exceed the distance between two adjacent parallel tracks of the two-dimensional grid track structure.

23. The manufacturing system according to claim 16, characterized in that The two-dimensional grid track structure includes square blocks, and wherein, Each of the square blocks is defined by a first pair of parallel tracks of a two-dimensional grid track structure located in a first direction and a second pair of parallel tracks of a two-dimensional grid track structure located in a second direction, wherein the second direction is perpendicular to the first direction, and wherein each of the manufacturing units occupies a unit space, the area of ​​the unit space being equal to the area of ​​a predetermined number of the square blocks.

24. The manufacturing system according to claim 23, characterized in that The unit space is a square space, the area of ​​which can be divided into nine square subspaces, and wherein the area of ​​each of the nine square subspaces is equal to the area of ​​one of the square blocks of the two-dimensional grid track structure, and wherein four corner subspaces among the nine square subspaces are configured as accommodating areas, which are used to accommodate materials required for the manufacturing unit, and wherein a first pair of middle peripheral subspaces between the four corner subspaces on the first pair of opposite peripheral sides of the unit space are occupied by the robot workers, and wherein a central subspace between the robot workers is configured as a working area, the workpiece is transferred to the working area, and is processed by the robot workers.

25. The manufacturing system according to claim 24, characterized in that A second pair of intermediate surrounding subspaces located between the four corner subspaces on the second pair of opposite surrounding sides of the unit space are adjacent to the working area, and wherein at least one of the second pair of intermediate surrounding subspaces is an unoccupied open area, and the robot stores / retrieves the vehicle configuration to enter and exit the working area through the open area.

26. The manufacturing system according to claim 25, characterized in that Each of the second pair of intermediate peripheral subspaces is an unoccupied open area whereby the robotic storage / retrieval vehicle travels completely through the manufacturing cell.

27. The manufacturing system according to claim 1, characterized in that The plurality of manufacturing units are configured as a multi-layer structure, and the multi-layer structure includes multiple layers of manufacturing units.

28. The manufacturing system according to claim 27, characterized in that Each of the plurality of layers comprises a two-dimensional grid track structure, wherein the two-dimensional grid track structure comprises a plurality of sets of intersecting tracks on which the robotic storage / retrieval vehicle can navigate in two dimensions; and The multi-story structure includes upright frame members interconnecting the cross-tracks of the plurality of stories.

29. The manufacturing system according to claim 28, characterized in that The upright frame members are configured such that the robotic storage / retrieval vehicle can travel in an ascending direction and a descending direction on the upright frame members to transfer between the plurality of levels.

30. The manufacturing system according to claim 29, characterized in that The two-dimensional grid track structure of one layer of the multiple layers of the multi-layer structure is connected to a corresponding layer of the storage layers in the automatic warehousing system structure, and the robot storage / retrieval vehicle is transferred between the automatic warehousing system structure and the multi-layer structure at the corresponding layer.

31. The manufacturing system according to claim 1 or 16, characterized in that: The manufacturing unit includes a fully automatic manufacturing unit and a manually-involved manufacturing unit configured relative to a grid track structure, the two-dimensional grid track structure includes multiple sets of cross tracks, and the robotic storage / retrieval vehicle can navigate along two dimensions on the cross tracks, wherein the fully automatic manufacturing unit is located at a distributed position in a major internal area of ​​the entire two-dimensional grid track structure, and wherein the one or more manually-involved manufacturing units are located in a peripheral area of ​​the two-dimensional grid track structure.

32. The manufacturing system according to claim 8, characterized in that The computer control system comprises: a network interface connected to a communication network; at least one processor connected to the network interface; and a non-transitory computer-readable storage medium communicatively coupled to the at least one processor, wherein the non-transitory computer-readable storage medium is configured to store computer program instructions that, when executed by the at least one processor, cause the at least one processor to activate the robot to store / retrieve a vehicle to: (a) navigating within the automated warehouse system structure and / or navigating through the manufacturing unit; (b) taking out the workpiece contained in a storage unit stored in the storage location of the automatic storage system structure; (c) transferring the workpieces contained in the storage unit to at least one material preparation station to package the materials into a kit storage unit; (d) picking up the kit storage unit from the at least one material preparation workstation; (e) returning and storing the kit storage unit to the storage location of the automated warehouse system structure; (f) removing from the automated storage system structure: at least one of the kit storage units, the workpiece contained in the storage unit, the tool piece contained in the storage unit, and a workpiece support; (g) transferring the kit storage unit and the workpiece contained in the storage unit, the tool piece contained in the storage unit, and the workpiece support to the manufacturing unit to manufacture an article; and (h) introducing the items on the final workpiece support into the automatic storage system structure.

33. A manufacturing system, characterized in that: The manufacturing system comprises: An automated storage system structure comprising a three-dimensional array of storage locations, the storage locations being distributed throughout a two-dimensional footprint of the automated storage system structure across a plurality of storage layers within the automated storage system structure, wherein the automated storage system structure further comprises at least one track assembly layer, the at least one track assembly layer comprising a two-dimensional grid track layout; a batch of workpieces, tooling pieces and workpiece supports stored in said storage locations of said automated storage system structure for use in manufacturing articles; and a fleet of robotic storage / retrieval vehicles navigable along at least two dimensions on the two-dimensional grid track layout within the automated storage system structure, each robotic storage / retrieval vehicle configured to carry a storage unit of compatible size and shape for storage in a storage location of the automated storage system structure, the storage unit configured to accommodate at least a workpiece and a tool piece; a plurality of manufacturing units located outside the automated storage system structure, wherein each of the plurality of manufacturing units includes a plurality of modular components, the manufacturing units are configured to be arranged in a continuous manner outside the automated storage system structure, wherein based on the continuous arrangement of the manufacturing units, the storage units are configured to be transferred to and from storage locations in the automated storage system structure, and to and from the manufacturing units without the need to identify or scan the storage units; a track structure connected to the automated storage system structure and arranged with one or more travel paths that can be traveled by the robotic storage / retrieval vehicle from the automated storage system structure, wherein at least a subset of the manufacturing units are positioned along the track structure; and A computer control system in operable communication with each storage / retrieval vehicle, the computer control system being configured to coordinate the movement of the storage / retrieval vehicles on a two-dimensional grid track structure interconnecting each manufacturing cell with the automated storage system structure, and to cause the storage / retrieval vehicles to deliver storage cells just in time, grouped by corresponding work orders, and to arrive at the manufacturing cells in a specific sequence, thereby facilitating just-in-time manufacturing of subassemblies at any stage of the manufacturing process and allowing any number of manufacturing processes to be completed multiple times in any sequence.

34. The manufacturing system according to claim 33, characterized in that The track structure is a grid track structure including a plurality of sets of intersecting tracks on which the robotic storage / retrieval vehicle can navigate along the at least two dimensions.

35. The manufacturing system according to claim 34, characterized in that Each of the modular assemblies comprises a footprint having a width in at least one of the at least two dimensions equal to an integer multiple of a distance measured between two adjacent parallel tracks of the grid track structure.

36. The manufacturing system according to claim 34, characterized in that The width of the footprint of the modular assembly in each of the at least two dimensions does not exceed the distance between two adjacent parallel tracks of the grid track structure.

37. The manufacturing system according to claim 33, characterized in that The tool parts are stored in the automated storage system structure, and wherein the tool parts can be retrieved from the automated storage system structure and transferred to the manufacturing cell by the fleet of robotic storage / retrieval vehicles.

38. The manufacturing system according to claim 33, characterized in that Each of the modular assemblies includes a receiving station module configured to receive supplies required by each of the manufacturing cells.

39. The manufacturing system according to claim 38, characterized in that The storage unit is configured to be carried by the robot storage / retrieval vehicle to transfer the storage unit to and from the storage location, and to and from the manufacturing unit, and wherein the receiving station module is configured to receive the storage unit.

40. The manufacturing system according to claim 33, characterized in that The storage unit comprises: workpiece storage units, each of the workpiece storage units being configured to accommodate one or more of the workpieces; and Tool storage units, each of the tool storage units is configured to store one or more of the tools.

41. The manufacturing system according to claim 33, characterized in that The track structure is an extension of the two-dimensional grid track layout of the track assembly layer of the automatic storage system structure.

42. A method for executing a workflow in a manufacturing system, characterized in that The method comprises: (a) storing workpieces, tool parts and workpiece supports in corresponding storage locations of the automatic storage system structure in the manufacturing system, wherein the workpieces are stored in workpiece storage units of the storage locations and the tool parts are stored in tool part storage units at the storage locations; (b) using a fleet of robotic storage / retrieval vehicles that can navigate within the automated storage system structure, extracting the workpiece storage unit and a selected workpiece holder from the automated storage system structure according to the requirements of the manufacturing process to be performed by the manufacturing cell outside the automated storage system structure and adjacent to the automated storage system structure, and based on the continuous arrangement of the manufacturing cells outside the automated storage system structure, respectively transferring the one or more workpiece storage units and the selected workpiece holder to the manufacturing cell without identifying or scanning the storage unit; (c) positioning the selected workpiece support at each of the manufacturing cells at a work location accessible to a worker of the manufacturing cell; and (d) at each of the manufacturing units, with the selected workpiece support secured in the working position: (i) transferring the workpiece from the workpiece storage unit to the selected workpiece support; and (ii) performing a processing step of the manufacturing process on the workpiece mounted on the selected workpiece support; (e) Coordinate the movement of storage / retrieval vehicles on a two-dimensional grid track structure interconnecting each manufacturing unit with the automated storage system structure through a computer control system, and enable the storage / retrieval vehicles to deliver storage units on time, grouped by corresponding work orders, and arrive at the manufacturing units in a specific sequence, thereby facilitating the just-in-time manufacture of sub-assemblies at any stage of the manufacturing process and allowing any number of manufacturing processes to be completed multiple times in any sequence.

43. The method according to claim 42, characterized in that The step of using a fleet of robotic storage / retrieval vehicles capable of navigating within the automated warehouse system structure includes the step of using the robotic storage / retrieval vehicles to perform extraction and transfer of the workpiece storage unit and the selected workpiece support from the automated warehouse system structure to the manufacturing unit.

44. The method according to claim 42, characterized in that: The step of storing the workpieces, tool pieces, and workpiece holders in respective storage locations of the automated storage system structure further comprises storing a tool piece storage unit in the automated storage system structure, wherein the tool piece storage unit is configured to accommodate tool pieces used in the manufacturing process; and Prior to performing a processing step of the manufacturing process on the workpiece secured to the selected workpiece support, a subset of the tool storage units is retrieved from the automated storage system structure using one of the robotic storage / retrieval vehicles and the subset of the tool storage units is transferred to the manufacturing cell.

45. The method according to claim 42 or 44, characterized in that The step of performing the processing steps of the manufacturing process on the workpiece fixed on the selected workpiece holder includes: before performing the processing steps of the manufacturing process, according to the requirements of the manufacturing process to be performed on the workpiece by a robot worker, one of the tool parts selected from the subset of the tool part storage unit is attached to the robot worker of the manufacturing unit.

46. ​​The method according to claim 42, characterized in that The step of extracting the workpiece storage unit further includes: transferring at least two workpiece storage units to two corresponding receiving areas of the manufacturing unit; and transferring two workpieces from the two workpiece storage units placed in the two corresponding receiving areas to the selected workpiece support, respectively.

47. The method according to claim 42, characterized in that Further including: removing an unneeded or empty workpiece storage unit from the manufacturing unit, wherein the selected workpiece has been removed from the unneeded or empty workpiece storage unit and there are no more workpieces required for the manufacturing process in the manufacturing unit; as well as An additional workpiece storage unit is transferred to the manufacturing cell using one of the robotic storage / retrieval vehicles, the additional workpiece storage unit including additional workpieces.

48. The method according to claim 47, characterized in that The additional workpiece is for a different manufacturing process to be performed at the manufacturing unit, and wherein the method further comprises: removing the selected workpiece support and the workpiece mounted on the selected workpiece support from the manufacturing unit; using one of the robotic storage / retrieval vehicles to transfer another workpiece support to the manufacturing cell for use in the different manufacturing process; supporting the other workpiece support in the working position; transferring the additional workpiece from an additional workpiece storage unit transported to the manufacturing unit to the other workpiece support; and The processing steps of the different manufacturing process are performed on the additional workpiece.

49. The method according to claim 48, characterized in that Further including: The unneeded or empty workpiece storage units are removed using a robotic storage / retrieval vehicle that is different from the robotic storage / retrieval vehicle that delivers the additional workpiece storage units to the manufacturing cell.

50. The method of claim 42, wherein: Further including: After a finished product is completed by processing the workpieces in a manufacturing cell, the finished product is introduced into the automated storage system structure on one of the robotic storage / retrieval vehicles.

51. The method according to claim 42, characterized in that Further including: After the manufacturing unit completes the finished product through the processing of the workpiece, the finished product is introduced into the automatic storage system structure on the final workpiece support, and the final step is performed on the final workpiece support to complete the finished product.

52. The method according to claim 42, characterized in that Further including: Each of the workpiece storage units is populated with a kit of different workpieces as required by the manufacturing process.

53. The method according to claim 52, characterized in that The filling of each of the workpiece storage units is performed at a material preparation station connected to the automatic storage system structure, and wherein, at the material preparation station: The fleet of robotic storage / retrieval vehicles is configured to deliver inventory storage units retrieved from corresponding storage locations in the automated warehouse system structure, wherein the inventory storage units are configured to include inventory workpieces; picking the different workpieces of the kit from the inventory workpieces stored in the inventory storage unit and compiling into the workpiece storage unit; and Each of the workpiece storage units is transported from the material preparation station by the robotic storage / retrieval vehicle and stored in a corresponding storage location in the automated storage system structure for subsequent retrieval from the automated storage system structure.

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