Container handling system

Abstract

A system for handling containers and a method for supplying inventory items to distribution stations in warehouses or any other location where order delivery or fulfillment occurs, such as a department store order. The system includes at least one mobile inventory carrier for storing containers, a mini-loading system including a gripping mechanism for retrieving or releasing containers from the at least one mobile inventory carrier, and an autonomous mobile robot unit, wherein the mini-loading system, the mobile inventory carrier, and the autonomous mobile robot unit are distinct units and operate independently of each other.

Description

[0001] Cross-reference to related applications

[0002] This application claims priority to European Patent Application No. 20217951.1, filed on December 31, 2020, the contents of which are incorporated herein by reference in their entirety. Technical Field

[0003] This invention relates to a system for handling containers, a method for supplying inventory, and the use of the system therein. Background Technology

[0004] Over the past 20 years, the exponential growth in internet and smartphone use has fueled the phenomenal growth of e-commerce, which has dramatically changed how products are transferred from retailers to end customers.

[0005] For decades, this has been done in a traditional way: pallets of goods are transferred from production sites or wholesalers to retailers' warehouses. The products are then typically transferred to stores in mixed pallets (i.e., pallets made of boxes, each containing a unique stock unit (SKU)). At the store, the pallets are unpacked, and the boxes are stored in the store's warehouse. Finally, the products are placed on store shelves for customers to choose from.

[0006] The sudden emergence of e-commerce has disrupted this product distribution model that has lasted for decades, and now retailers must handle the picking and packing of items to ultimately deliver ordered items to customers.

[0007] These significant changes in distribution models have substantially increased picking and packing costs because picking items is a far more labor-intensive process than picking pallets or boxes. Additionally, handling boxes and containers in warehouses is more frequent and complex. These costs are typically borne by retailers because customers are very reluctant to pay higher prices when buying goods online.

[0008] This problem is even more severe for department store e-commerce, which constitutes the largest segment of the retail market (40% to 50% of the total retail market), because:

[0009] - The average number of items per online order is significantly higher than in the rest of the retail industry (approximately 50 items per online order).

[0010] - Additional requirements include maintaining multiple temperature zones for perishable items.

[0011] Finally, the department store industry has extremely low profit margins (typically <2%), making it difficult for the industry to absorb the investment needed in the infrastructure to reduce picking, packing, and shipping costs and for online department stores to enjoy a positive bottom line.

[0012] All of these challenges have fueled the development of innovative material handling systems based on autonomous robotic vehicles equipped with container handling systems. These hybrid machines can move freely in warehouse aisles, retrieve containers containing products from shelves, temporarily store them on vehicle-mounted storage racks, and transfer them to designated locations within the warehouse for further processing (WO2017 / 121747, WO2018 / 234155), while other systems, such as those described in US201514719196, suggest similar systems but can only carry one container at a time.

[0013] The main drawback of these conventional systems is that they propose robotic machines that can interact with (retrieve or store) containers, which can be accessed directly from the aisles in front of the shelves. This, in turn, means that a large area of ​​the warehouse would be used as aisles, thus reducing the area available for placing / storing containers.

[0014] Another drawback of these conventional systems is that the autonomous mobile robot (AMR) unit and the container handling system are rigidly tethered to the same platform. As long as one of these components is in operation, the others must remain inactive, limiting the utilization time of each component. For example, when the AMR's battery needs to be connected to a battery charging station, the container handling system must simultaneously remain inactive. In other examples, when the system needs to dock at a distribution station and supply inventory containers to operators, the AMR must remain inactive at the station as long as the task is ongoing. Furthermore, if any component fails, the other component will also malfunction, constituting a single point of failure system.

[0015] Other systems, such as those described in EP0235488 and EP0458722, teach robotic machines that are less flexible in all their components, namely autonomous mobile robots, container handling systems, and storage racks, all of which are firmly bolted to the same platform.

[0016] US2017330269A1 discloses a method for managing inventory carriers using mobile robot units (MRUs) in a container configured to receive online orders at a replenishment station for customer pickup at a delivery station. This method includes receiving an instruction via a mobile robot unit to identify a first inventory carrier, moving the mobile robot unit to the location of the identified inventory carrier, and using the mobile robot unit to transport the identified inventory carrier to the replenishment station for pickup by a delivery vehicle.

[0017] US10029851B1 describes an inventory system having multiple inventory trays and a drive unit for moving the inventory trays. This document discloses an inventory system that utilizes containers and / or other functional components to assist in the separation of automated and manual inventory item handling, such as transporting inventory items to be released from containers by a human operator or by a robotic arm.

[0018] WO2017197285A1 discloses a method for delivering online orders to customers via a fully unmanned system. This method includes replenishing a container via a replenishment port using an inventory carrier carrying a container, and moving the inventory carrier attached to a carrier base equipped with a mobile robot unit in a temperature-controlled room. Additionally, the method includes transferring the inventory carrier at a mini-loading station and loading the order container onto the delivery carrier. The method further includes transferring the delivery carrier and attaching it to a delivery port, allowing the customer to pull out a drawer and retrieve their ordered items after verification.

[0019] WO2019083199A1 describes a goods transfer system that combines an operational model and operational methodology utilizing a robot's autonomous combination of extraction and classification. According to this document, the goods transfer system includes at least one transport vehicle containing a plurality of compartments loaded with goods, and an extraction robot capable of moving the goods loaded on the transport vehicle. The extraction robot receives information about the goods assigned to the plurality of compartments and repositions the goods or replenishes any shortages.

[0020] A fully automated system is needed, featuring one or more autonomous mobile robots capable of assisting with all necessary processing to optimally handle customer orders both online and offline. Summary of the Invention

[0021] This invention relates to systems for handling containers and methods for supplying stocked goods to distribution stations in warehouses or any other location where order delivery or order fulfillment occurs, such as department store orders, and the uses of such systems.

[0022] According to various aspects of the present invention, a system for handling containers is provided, the system comprising at least one mobile storage carrier for storing containers, a mini-loading system including a gripping mechanism for extracting or releasing containers from the at least one mobile storage carrier, and at least one autonomous mobile robot unit, wherein the mini-loading system, the at least one mobile storage carrier, and the at least one autonomous mobile robot unit are different units and operate independently of each other.

[0023] In other aspects of the invention, the at least one mobile inventory carrier is freely mounted in the workplace and the at least one autonomous mobile robot unit is configured to lift and / or rotate the mobile inventory carrier.

[0024] According to other aspects of the invention, the at least one autonomous mobile robot unit is configured to transport the at least one mobile inventory carrier within the workplace.

[0025] In other respects, the mini-loading system includes a base to which the at least one mobile inventory carrier is attached, and the at least one autonomous mobile robot unit is configured to move the mini-loading system and the at least one mobile inventory carrier together within the workplace.

[0026] In other respects, the mini-loading system includes a gantry system comprising a gantry frame, paired gantry joints for movement on the Z and X axes, and a container processor (101e) capable of movement on the Y axis and rotation in the XY plane.

[0027] In other aspects, the gripping mechanism of the mini-loading system includes at least one camera and at least one lighting tool, configured to detect angular and / or linear deviations of the moving inventory carrier 107 to guide the movement of the paired gantry joints (101c, 101d) and the container processor (101e). In other aspects, the at least one camera and the at least one lighting tool are configured to generate streaming video.

[0028] In other aspects, the at least one mobile inventory carrier is lifted by an autonomous mobile robot unit and placed on the base of the gantry-type mini-loading system. The autonomous mobile robot unit is then able to advance below, lifting the mini-loading system and the at least one mobile inventory carrier and moving them within the workplace.

[0029] In other respects, the first base includes a track and one or more wheels connected to the track.

[0030] In other aspects of the invention, the autonomous mobile robot unit is wireless and includes an integrated rechargeable battery.

[0031] In other aspects of the invention, the battery of the autonomous mobile robot unit powers the mini-loading system.

[0032] According to other aspects of the present invention, a method for supplying stocked goods to a distribution station is provided, the method comprising the following steps:

[0033] a) Transporting a first mobile inventory carrier, carrying one or more pre-filled supply containers, from the inventory area of ​​the distribution center to the exchange point using a first autonomous mobile robot unit;

[0034] b) Loading one or more supply containers of the first mobile inventory carrier onto a second mobile inventory carrier placed on the base of the mini-loading system (101) using a mini-loading system, the second mobile inventory carrier being empty before loading;

[0035] c) Repeat steps a and b until the second mobile inventory carrier is completely filled with the donor inventory container;

[0036] d) The loaded second mobile inventory carrier is transported to the pickup station of the distribution center via an autonomous mobile robot unit;

[0037] e) Transfer the second mobile inventory carrier to the base of the mini-loading system serving the pickup station;

[0038] f) Selecting a first supply container from the second mobile inventory carrier using the gripper of the mini-loading system and delivering the first supply container to the operator;

[0039] g) The operator selects at least one item from the first supply container and places it into the order container.

[0040] Steps f and g are repeated until the operator selects items from all the supply containers and places them into the designated order container.

[0041] In other aspects of the invention, a method for supplying stocked goods includes the following steps: an autonomous mobile robot unit arriving at a pickup station of a distribution center;

[0042] - The second mobile inventory carrier is lifted from the base of the mini loading system serving the retrieval station by the autonomous mobile robot unit;

[0043] - The autonomous mobile robot unit returns the second mobile inventory carrier to the inventory area of ​​the distribution center and places it on the base of another mini-loading system.

[0044] In other aspects of the invention, the autonomous mobile robot automatically travels to a charging station to recharge when it is not involved in processing or when its battery level has dropped to an extremely low level.

[0045] In other specific embodiments, the use of a system for handling containers in a distribution center is provided.

[0046] The first effect of having separate, independently operating units is greater utilization of each and all components, and avoidance of single points of failure. If any component of the system fails, it can be replaced by another similar component and operate smoothly alongside the other two. Therefore, the failure of one unit does not necessarily mean that the other components of the system will stop working. Furthermore, the operation of the mini-loading system during charging does not hinder the autonomous mobile robot unit from charging its battery.

[0047] Additionally, when mobile inventory carriers need to be moved from point A to point B within the operating area, only an autonomous mobile robot unit is required to perform this operation. Simultaneously, the mini-loading system can operate in parallel at another location, such as at a retrieval station handling supply containers, or work in conjunction with another autonomous mobile robot unit to perform one of the planned processes.

[0048] The system’s main components, namely the autonomous mobile robot unit, the mini-loading system, and the mobile inventory carrier, have this operational freedom, which increases utilization and leads to a reduction in resource requirements for a given level of throughput.

[0049] In addition, the system's extensive parallel operation significantly reduces temporary shutdowns caused by machine failures. Continuous operation is advantageous because temporary shutdowns in traditional systems due to single points of failure can lead to significant delays in order delivery and may force the activation of further human resources, resulting in increased overall costs and unreliable system quality.

[0050] The term "container" as described in this invention should be interpreted by those skilled in the art to include a variety of object options suitable for holding inventory, such as, but not limited to, ordinary pallets or combinations of pallets and boxes or dekit storage boxes.

[0051] Therefore, it can be understood that the system according to the invention enables a much higher utilization of each and all specific components of the entire system, resulting in fewer resources required compared to the machines suggested by the conventional systems mentioned above.

[0052] Another effect of the system for handling containers disclosed in this invention is its efficient operation in warehouses where inventory is stored in supply containers, which are then stored on movable inventory carriers attached to a base, allowing autonomous mobile robot units to advance beneath, lift, and turn them, or move them from point A to point B within the operating area. In prior art systems (such as WO2017 / 121747), inventory carriers are fixedly attached (e.g., bolted) to the workplace floor, and their gripping mechanisms can retrieve directly accessible inventory via workplace corridors. This results in those systems requiring more space for equivalent inventory storage.

[0053] Furthermore, because the various units of the system are distinct and disassembled, mobile inventory carriers can be stored in a much denser manner (e.g., back-to-back). This means that less storage space is needed to store a similar amount of inventory compared to a conventional system, which can only operate containers that can be directly accessed from the aisle, resulting in a larger number of aisles required when considering a conventional system.

[0054] In addition, when the autonomous mobile robot units according to the invention need to move, for example, from point A to point B in the workplace, they can utilize paths via corridors or under the base of the mobile inventory carrier. This results in less congested corridors, meaning that much more efficient path planning can be applied, which ultimately reduces the number of autonomous mobile robot units required for equivalent throughput compared to conventional systems.

[0055] The system disclosed in this invention allows for the arrangement of inventory carriers at a higher density, which ultimately results in less space required for the same amount of storage. Attached Figure Description

[0056] The foregoing description and the following detailed description will be better understood when read in conjunction with the accompanying drawings. For illustrative purposes, the drawings show specific embodiments of the invention. However, it should be understood that the invention is not limited to the specific embodiments and features described herein. The accompanying drawings, which are included in and constitute a part of this specification, illustrate specific embodiments of the system according to this specification and, together with them, serve to demonstrate the advantages and principles according to this specification.

[0057] Figure 1 This is a 3D diagram of an example workplace where the system could operate, a mini distribution center for online orders or any other type of order, such as supplying stocked items to convenience stores or any other type of store.

[0058] Figure 2 This is a 3D view of a gantry-type mini loading system.

[0059] Figure 3 It is a 3D view of the autonomous mobile robot unit with its lifting mechanism at a high position.

[0060] Figure 4 It is a 3D view of the autonomous mobile robot unit with its lifting mechanism in a low position.

[0061] Figure 5 It is a 3D view of a mobile inventory carrier without containers in the storage tank.

[0062] Figure 6 It is a 3D view of a mobile inventory carrier with a dekit container.

[0063] Figure 7 It is a 3D diagram of a mobile inventory carrier with some containers empty and others filled with stock items.

[0064] Figure 8 This is a 3D view of an autonomous mobile robot unit moving towards the mobile storage carrier.

[0065] Figure 9 This is a perspective view of an autonomous mobile robot unit that has been moved under the mobile storage carrier, lifted for movement, and placed on the base of the mini-loading system.

[0066] Figure 10 It is a three-dimensional view of the mini loading system, the autonomous mobile robot unit, and the mobile inventory carrier placed on the base of the mini loading system.

[0067] Figure 11 A perspective view of a moving inventory carrier carrying supply containers with stocked items is shown.

[0068] Figure 12 A mini loading system with an attached mobile inventory carrier, supported by an autonomous mobile robot unit, is shown. The mini loading system is retrieving supply containers from the mobile inventory carrier and storing them in the carrier's storage slots.

[0069] Figure 13 A perspective view shows the functional wheels of the moving stock carrier guided and securely fastened in tracks attached to the top surface of the base.

[0070] Figure 14 This diagram shows an overview of the inventory receiving station where autonomous mobile robot units transport mobile inventory carriers.

[0071] The following description of embodiments of the invention is taken in conjunction with the accompanying drawings, wherein the same reference numerals denote the same or similar elements. Detailed Implementation

[0072] The vocabulary and terminology used below are for illustrative purposes and should not be construed as limiting. For example, the use of singular pronouns such as "one" is not intended to specify the quantity of operations. Furthermore, the use of directional pronouns such as "upper," "lower," "left," "right," and "back" in the description is for the purpose of clarifying certain elements in the drawings, and not to limit the scope of this description or the claims. It should also be understood that any technical feature of the invention may be used independently or in combination with other features. Other functionally equivalent systems, methods, features, uses, and advantages of the invention will become apparent to those skilled in the art upon review of the drawings and description. All additional systems, methods, features, uses, and advantages are intended to fall within the scope of the invention and to be protected within the scope of the claims.

[0073] Figure 1 The image shows a system 100 for handling containers. Specifically, it shows an autonomous mobile robot unit 102, mobile storage carriers 104 and 107, a wheeled mobile storage carrier 108, and a mini-loading system 101.

[0074] In this embodiment, the mobile storage carrier 104 is freely installed within the workplace, such as... Figure 5 As shown. Free installation can be interpreted as the mobile inventory carrier not being bolted to the workplace floor and being able to be transported. Therefore, the mobile inventory carrier can be as follows: Figure 8 , 9 As shown in Figure 10, the autonomous mobile robot unit 102 lifts, transfers, and places the components onto the base of the mini-loading system.

[0075] Subsequently, the autonomous mobile robot unit is able to lift the mini loading system 101 and the mobile inventory carrier 104 attached to its base, and move them from point A to point B within the workplace.

[0076] In addition to achieving higher utilization of each and all components, this method also makes the system more flexible and efficient because no component is left unused or idle. For example, empty mobile inventory carriers can be transported by autonomous mobile robot units until they are refilled, which avoids human involvement in transporting containers stored on the mobile inventory carriers within the workplace.

[0077] Additionally, an autonomous mobile robot unit 102 with a lifting mechanism, which can be parallel tubular, located at its lowest position is shown, comprising its top surface, bottom surface, and one or more lateral surfaces. The height h is less than the length l and / or width w, as shown below. Figure 3As shown. Other shapes of the autonomous mobile robot unit 102 are also conceivable, such as, but not limited to, cylinders or cubes. The height h of the autonomous mobile robot unit 102 makes it suitable for placement under the base of the mini-loading system 101 or storage carrier 104, and it includes the necessary electronics and mechanisms for lifting and transporting such a base. Additionally, the autonomous mobile robot unit 102 can be wireless and may further include integrated rechargeable energy storage components, such as rechargeable batteries (not shown in the figures), ensuring fully autonomous operation and free movement within the workplace. Various dimensions are possible, with a width w and length l of approximately 1 m and a height of approximately 26 cm. However, those skilled in the art will understand that the dimensions of the autonomous mobile robot unit 102 can vary depending on various factors, such as the complexity of the electronics, the size of the CPU and energy storage components, the size of the lifting counterweight, and the relevant center of gravity of the cargo. The autonomous mobile robot unit 102 of this specific embodiment can lift a mass of approximately 2 tons, but preferably approximately 500 kg. The energy storage device can be replaced, or it can be a special type that is rechargeable but has a short charging time, such as (LiFePO4). In this way, the autonomous mobile robot unit 102 can be adapted to operate at any time and only recharge when it is not involved in any other processing or when its power level is extremely low. In addition, this type of energy storage device provides greater safety because it will not catch fire if it short-circuits. The energy storage device can also be a supercapacitor type, which charges extremely quickly when the autonomous robot unit is traveling on a suitable inductive charging station.

[0078] In other embodiments, when the autonomous mobile robot unit 102 is not performing any processing, it may move to a charging station to charge its energy storage system if necessary.

[0079] In other embodiments, the autonomous mobile robot unit 102 may have one or more drive wheels on its bottom surface for smooth movement. In other embodiments, the autonomous mobile robot unit 102 may also include a number of casters to properly support the vehicle. The drive wheels and casters may also be mounted on the chassis of the vehicle in a manner that allows them to tolerate variations in ground flatness to a certain extent. The autonomous mobile robot unit 102 may have a single wheel at the center of its bottom surface; however, those skilled in the art will understand that such a configuration may reduce the stability of the system 100, especially when fully loaded. The number and size of the wheels depend on the weight that will be lifted by the autonomous mobile robot unit 102.

[0080] On the top surface, the autonomous mobile robot unit can have, for example... Figure 3 and 4The interface of the lifting mechanism 102a shown, and the power supply component for the system (not shown in the figure).

[0081] In other embodiments, the autonomous mobile robot unit 102 can transport the mini-loading system 101 and the mobile storage carrier 104 together anywhere within the workplace. When the mini-loading system 101 is brought near the mobile storage carrier (or vice versa), the autonomous mobile robot unit 102 can move beneath the first base of the mobile storage carrier 104, lift it, and securely mount it onto the second base of the mini-loading system 101, as... Figure 8 , 9 As shown in Figure 10. In this way, the mini loading system and the mobile inventory carrier 104 can be moved within the workplace by an autonomous mobile robot unit.

[0082] In another embodiment, the autonomous mobile robot unit can advance beneath a mobile inventory carrier having a first base, lift it, and transport the mobile inventory carrier to any desired location within the workplace. Such a location can also be predetermined, for example, from a specific point A to a specific point B.

[0083] When a mobile inventory carrier can be transported by an autonomous mobile robot unit and placed on the base of a mini-loading system, such an inventory carrier may also be referred to as a transportable inventory carrier (104).

[0084] According to the present invention and for clarity, the mobile inventory carrier (107) may only be able to be lifted and rotated by an autonomous mobile robot unit. Such a mobile inventory carrier (107) is as follows: Figure 1 and Figure 11 As shown. In other embodiments, the mobile inventory carrier (104) can be transported to any location within the workplace. Additionally, such mobile inventory carriers can be placed on the base of a mini-loading system and thus can be transported together with the mini-loading system by an autonomous mobile robot unit to any location within the workplace. Such mobile inventory carriers (104) may also be referred to as transportable inventory carriers, for example, as... Figure 9 and 10 As shown.

[0085] That said, in other embodiments, the autonomous mobile robot unit 102 can advance, lift, and rotate beneath the mobile storage carrier 107 to position it in a suitable location, preferably adjacent to the mini-loading system 101, where its gripping mechanism can extract containers and place them on another mobile storage carrier 104, which can be transported as defined above in this invention. Figure 12 As shown.

[0086] In other embodiments, the autonomous mobile robot unit 102 may advance beneath the mini-loading system 101, lifting and transporting it to any desired location within the workplace for any necessary operations. In other embodiments, the autonomous mobile robot unit 102 may advance beneath the mini-loading system, while the mobile inventory carrier 104 is placed on the base of the mini-loading system, lifting both the mini-loading system and the mobile inventory carrier 104 together and moving them from any point A within the workplace to any point B.

[0087] In embodiments, the bases of the mobile storage carrier 104 and the mini-loading system 101 are either in a single-plate form or include a top surface and several legs. In a preferred embodiment, the base includes at least three legs, and most preferably includes, for example, legs such as... Figure 10 The four legs shown ensure the stability of the unit while allowing greater weight to be added to the mobile storage carrier 104. However, it must be considered that the mini-loading system 101 and the mobile storage carrier 104 would be effective even with only one leg.

[0088] The base can be made of any known material capable of supporting approximately 300 kg, for example, it can be made of metal, such as steel or preferably aluminum, which is lightweight and capable of bearing greater weight. It can also be made of suitable composite materials. While the top surface of the base can be of any shape, such as rectangular, square, circular, etc., those skilled in the art will understand that, for cost reasons and for transporting the lifting system, the shape of the top surface of the base preferably conforms to the shape and dimensions of the top surface 202 of the mobile inventory carrier 104 or the mini-loading system or the autonomous mobile robot unit 102. The length of the first and second bases can be between 0.8 m and 2 m, preferably between 1 m and 1.5 m, more preferably 1.2 m, and the width of the base can be between 0.8 m and 2 m, preferably between 1 m and 1.5 m, more preferably 1.2 m.

[0089] In this embodiment, the mobile storage carrier comprises a plurality of containers of the same or different sizes. Depending on the size of each shelf, it supports a number of containers 111, ranging from 1 to 30, preferably 5 to 12 to improve efficiency. Figure 5 , 6 As shown in Figure 7. In an embodiment, the mobile storage carrier 104 can stand on a set of legs, at least three legs, and preferably at least four legs for stability. Mobile storage carrier 104 ( Figure 5The mobile storage carrier 104 and its shelving can be made of any known material, such as metal, preferably steel, to support a total weight of approximately 400 kg while being relatively lightweight itself. The mobile storage carrier 104 can be manufactured in any possible manner, including 3D printing. While the mobile storage carrier 104 can be of any size, those skilled in the art will understand that the size of the mobile storage carrier 104 depends on the space available for its movement and the weight it should be able to support. Additionally, its size depends on the desired stability; for example, a very tall mobile storage carrier 104 will have lower stability.

[0090] The mobile inventory carrier 107 is preferably used for supply containers containing inventory. It typically includes several shelves with a number of container storage slots, usually 4-6, but can have any number of slots depending on the container size. Figure 11 ).

[0091] As defined in this invention, a supply container is a container for storing inventory, while an order container is a container for delivery from a pickup station containing items received from the supply container.

[0092] Mobile storage carriers (104, 107) may also have wheels 112 ( Figure 13 Typically, there are four wheels, one on each leg, but it must be considered that it can have any number of wheels. The wheels are guided into appropriate tracks 113, typically two tracks, but any number of tracks are possible. These tracks have recesses at the ends that lock the wheels when they reach their end positions, securing them and preventing them from moving during transport. The tracks are mounted on the top surface of the base, so that the autonomous mobile robot unit 102 can advance from below, lift the base carrying the mobile inventory carriers (104, 107), and move it within the workplace. The wheels are used to roll the mobile inventory carriers (often referred to as "roller frames") when they are outside the robot's workplace, so that the operator can easily push around the mobile inventory carriers (104, 107) to store or load them onto transport vehicles. However, it should be noted that the roller frames, in situations such as... Figure 13 When placed on a suitable base, it can also be lifted, rotated, and / or transported by an autonomous mobile robot unit.

[0093] Each container 111 can be of different shapes, such as a storage box ( Figure 13 ) or tray (104a, b / Figure 6 and 7 (e.g., boxes, card boxes, etc.)

[0094] Therefore, the mini-loading system 101 and the autonomous mobile robot unit 102 are completely different units and operate independently of each other. In this way, any potential failure of any other independent unit—either the autonomous mobile robot unit 102 or the mini-loading system 101—will not limit the ability of other, compliant units to continue operating with the other. Furthermore, when the autonomous mobile robot unit 102 needs charging, this does not limit the mini-loading system's ability to continue working with another autonomous mobile robot unit. This capability, not disclosed in any conventional system, significantly improves the utilization of each component in the system, ultimately reducing the overall cost of owning the system.

[0095] The mini-loading system 101 includes a gripping mechanism for extracting container 111 from mobile storage carrier 107 and releasing it to another mobile storage carrier 104, which may also be referred to as a transportable storage carrier as defined in this invention.

[0096] In other embodiments, the mini-loading system can be a gantry type 101 ( Figure 2 The system includes a gantry frame 101b, a gantry joint Z101c that moves vertically along the Z-axis, a gantry joint X101d that moves horizontally along the X-axis, and a container processor 101e capable of moving along the Y-axis and rotating in the XY plane. The gantry frame can be fixedly attached to a base 101a, which can be flat. The base has several legs, typically four, and the space below the base is sufficient for the autonomous mobile robot unit to propel and reach below, lift the base together with all the mini-loading systems and the mobile inventory carriers 104 (transportable) described in other embodiments, and move them around the workplace.

[0097] In other aspects, the gripping mechanism of the mini-loading system includes a vision servoing system configured to guide the movement of gantry joints 101c, 101d, and 101e to securely handle container 111. In other embodiments, the mini-loading system 101 may further include an elongated column, which may include a track on which the gripping mechanism can move vertically linearly, either upwards or downwards, depending on the desired position of the container on the storage carrier. In another embodiment, the elongated column may be fixedly attached to a base, which may be flat. In this way, an autonomous mobile robotic unit can travel below the base and transport the entire mini-loading system. Based on the position of the storage carrier, the base may optionally be linked to a rail corridor, thereby enabling horizontal movement of the entire mini-loading system 101.

[0098] In other embodiments, the mini-loading system 101 may be attached to the top surface of the autonomous mobile robot unit 102. The autonomous mobile robot unit 102 powers the mini-loading system 101 via its power supply. An opening is provided on the top surface of the autonomous mobile robot unit 102 through which necessary wiring harnesses can reach and connect to the mini-loading system 101. In this way, the autonomous mobile robot unit 102 powers the mini-loading system 101, enabling it to reach the mobile storage carrier 104, load / unload containers 111 onto / from the mobile storage carrier 104. Additionally, the autonomous mobile robot unit 102 may also transport the mini-loading system 101 around warehouses and / or distribution centers. While those skilled in the art will understand that powering the mini-loading system 101 via the autonomous mobile robot unit 102 is more ecologically beneficial and sustainable, in another embodiment, the mini-loading system 101 may be autonomous and include a plug-in or rechargeable or replaceable energy storage device.

[0099] An autonomous mobile robot unit can, for example, move beneath the base of a mini-loading system with an attached mobile storage carrier (104), lift the system, and move it to a position adjacent to the mobile storage carrier 107 to retrieve a container stored on the mobile storage carrier 107. Due to the expected finite linear and angular deviations of the theoretical path, the mobile storage carrier 107 may have small positional errors (typically less than 10 mm laterally and less than 0.5 degrees angularly), which, if not calculated, could lead to collisions between the gripper and the container or the frame of the mobile storage carrier. To eliminate such unintended failures, the gripping mechanism of the mini-loading system 101 is equipped with a camera and lighting system capable of generating streaming video during its movement. This streaming video is further processed by software tools and commands the gripping mechanism to retrieve the target container. More specifically, the video is continuously analyzed by custom software capable of understanding any lateral or angular misalignment and using closed-loop control to guide the motors of the gripper to compensate for any such errors, correcting the final position of the gripper before retrieving the container. This system can also be referred to as a "visual servoing" system. With the support of a vision servo system, the necessary precision for smooth system operation was achieved during gripper operation.

[0100] In other embodiments, the autonomous mobile robot moves the combined mini-loading system and mobile inventory carrier (104) to an adjacent position to another mobile inventory carrier (107), where the first supply inventory container is retrieved by the gripper of the mini-loading system and guided by the gripper's visual servo system to be placed at a storage location on the mobile inventory carrier (104, 107) with appropriate accuracy.

[0101] The system according to the invention includes at least one mobile inventory carrier, an autonomous mobile robot unit, and a mini-loading system, all of which operate independently as different units. The system is capable of supporting all functions involved in the delivery and fulfillment of online orders, as well as all functions of any distribution center that must supply inventory to any physical store such as a shop or convenience store.

[0102] In this embodiment, when inventory is received in a warehouse or distribution center, for example in inventory receiving station 114 ( Figure 14 ), which are typically packaged in containers or boxes stacked on pallets 115 ( Figure 14 To efficiently replenish inventory into the warehouse, autonomous mobile robot unit 102 transports a mobile inventory carrier 104 with a plurality of empty containers 111 located at inventory receiving station 114. Figure 14 The container is then placed on the base of a stationary mini-loading system serving the inventory receiving station. The mini-loading system 101 grabs an empty container 111 from the mobile inventory carrier 104 and presents it to the operator, who then places the desired inventory into the container 111. For ease of operation, a box 117 with incoming inventory from a pallet may already be on the workbench 116, making it easier for the operator to place the desired inventory into the container (see [link]). Figure 14 The same operation is repeated until all containers 111 of the mobile inventory carrier 104 are filled with the desired inventory. Once all containers are filled, the autonomous mobile robot unit transports the mobile inventory carrier 104 to a location near the inventory storage area, where another mini-loading system 101 is waiting to receive the filled mobile inventory carrier 104. The autonomous mobile robot unit then advances to store the individual containers 111 onto other inventory carriers—such as mobile inventory carrier 107—stored in the inventory storage area. In an embodiment, if access to a specific storage location is impossible due to the orientation of the mobile inventory carrier (e.g., the slot of the mobile inventory carrier storing the container is not facing the corridor where the mini-loading system is located), another autonomous mobile robot unit moves under the mobile inventory carrier, lifts it, and rotates it up to 180 degrees, thus enabling the mini-loading system gripper to access the target storage slot of the mobile inventory carrier.

[0103] In another specific implementation, a method for supplying stocked goods to a distribution station is provided, the method comprising the following steps:

[0104] a) Transporting a first mobile inventory carrier with one or more filled supply containers from the inventory area of ​​the distribution center to the exchange point via a first autonomous mobile robot unit (102);

[0105] b) Loading one or more containers (111) of the first mobile storage carrier (104, 107) into the second mobile storage carrier (104, 107) by means of a mini loading system, wherein the second mobile storage carrier (104, 107) is empty before loading;

[0106] c) Repeat steps a and b until the second mobile inventory carrier (104, 107) is completely filled with containers;

[0107] d) The fully loaded second mobile inventory carriers (104, 107) are transported to the pickup station of the distribution center by an autonomous mobile robot unit (102);

[0108] e) Transfer the second mobile inventory carrier (104, 107) to the base of the mini-loading system (101) at the retrieval station;

[0109] f) Select a first supply container from the second mobile inventory carrier (104, 107) and deliver the first supply container to the operator;

[0110] g) The operator selects at least one item from the first supply container and places the item into the order container;

[0111] Steps f and g are repeated until the operator has selected items from all the supply containers and placed them into the order container.

[0112] In a further step, the autonomous mobile robot unit reaches beneath the mobile inventory carrier, lifts it from the base, and moves it back to the inventory storage area to return the supply containers to their original storage slots on the corresponding inventory storage carrier.

[0113] This method ensures fast and accurate delivery of any order from a customer, while guaranteeing that any subsequent orders become available within a reasonable timeframe, because all components of the system work together to transport delivery and inventory carriers to selected locations for loading and delivery of selected goods to the operator.

[0114] In embodiments, the system 100 according to the invention can be used to process materials and goods at different locations. In a preferred embodiment, the system is used in a warehouse for fulfilling online orders. Order fulfillment may occur in a distribution center within the warehouse, including a replenishment station, inventory area, pickup station, and storage area.

[0115] The system can also be used to supply the required inventory to stores, especially convenience stores, which have very limited inventory and cannot store inventory in pallets or even boxes containing only a single item. Instead, they can only store inventory in containers containing several different items.

Claims

1. A system for processing containers, the system comprising: At least one mobile inventory carrier for storing containers; A mini-loading system, the mini-loading system including a gripping mechanism for extracting or releasing containers from the at least one mobile inventory carrier; At least one autonomous mobile robot unit, The mini-loading system, the at least one mobile inventory carrier, and the at least one autonomous mobile robot unit are distinct units that operate independently of each other. The mini-loading system includes a base, the at least one mobile inventory carrier is attached to the base, and the at least one autonomous mobile robot unit is configured to move the mini-loading system and the at least one mobile inventory carrier together within the workplace.

2. The system of claim 1, wherein the at least one mobile inventory carrier is freely mounted in the workplace and the at least one autonomous mobile robot unit is configured to lift and / or rotate the mobile inventory carrier.

3. The system of claim 1, wherein the at least one autonomous mobile robot unit is configured to transport the at least one mobile inventory carrier within the workplace.

4. The system according to any one of claims 1-3, wherein the at least one mobile inventory carrier comprises one or more wheels.

5. The system according to any one of claims 1-3, wherein the mini-loading system comprises a gantry system, the gantry system comprising a frame, a pair of gantry joints, and a container processor.

6. The system of claim 5, wherein the frame is fixedly attached to the base.

7. The system according to any one of claims 1-3, wherein the at least one mobile storage carrier includes a base.

8. The system of claim 7, wherein the base comprises a track and one or more wheels connected to the track.

9. The system according to any one of claims 1-3, wherein the mobile robot unit is wireless and includes an integrated rechargeable battery.

10. The system of claim 9, wherein the battery of the at least one autonomous mobile robot unit powers the mini-loading system.

11. The system of claim 5, wherein the gripping mechanism of the mini-loading system comprises at least one camera and at least one lighting tool.

12. The system of claim 11, wherein the gripping mechanism is configured to identify angular and / or linear deviations of the moving inventory carrier, thereby guiding the movement of the paired gantry joints and the container processor.

13. The system of claim 11, wherein the at least one camera and the at least one lighting tool are configured to generate streaming video, wherein the streaming video is processed by a software tool and commands the grasping mechanism to retrieve the target container.

14. A method for supplying stocked goods to a distribution station, the method comprising the following steps: a) Transporting a first mobile inventory carrier, carrying one or more pre-filled supply containers, from the inventory area of ​​the distribution center to the exchange point using a first autonomous mobile robot unit; b) Loading one or more containers of the first mobile inventory carrier into a second mobile inventory carrier via a mini-loading system, the second mobile inventory carrier being empty before loading, wherein the mini-loading system, the mobile inventory carrier, and the first autonomous mobile robot unit are different units and operate independently of each other, and the mini-loading system includes a base to which at least one of the mobile inventory carriers is attached such that the first autonomous mobile robot unit is configured to move the mini-loading system and at least one of the mobile inventory carriers together. c) Repeat steps a and b until the second mobile inventory carrier is completely filled with the container; d) The fully loaded second mobile inventory carrier is transported to the pickup station of the distribution center by an autonomous mobile robot unit; e) Transfer the second mobile inventory carrier to the base of the mini-loading system located at the extraction station; f) Select a first supply container from the second mobile inventory carrier and deliver the first supply container to the operator; g) The operator selects at least one item from the first supply container and places the item into the order container; Steps f and g are repeated until the operator has selected items from all the supply containers and placed them into the order container.

15. The method of claim 14, further comprising the following steps: - The autonomous mobile robot unit arrives at the pickup station of the distribution center; - The second mobile inventory carrier is placed on the base of the mini-loading system and lifted by the autonomous mobile robot unit; - The autonomous mobile robot unit returns the second mobile inventory carrier back to the inventory area of ​​the distribution center and places it on the base of the mini-loading system.

16. The method of claim 14 or 15, wherein the autonomous mobile robot unit automatically travels to a charging station for charging when it is not involved in any processing or when the battery is low.

17. Use of the system for handling containers according to any one of claims 1-11 in a distribution center.

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