System and method for dynamically processing objects using intermediate storage cache

Abstract

A method of processing an object using a programmable motion device is disclosed. The method includes: receiving a plurality of received objects at an input region proximate to the programmable motion device; using the programmable motion device to select and grasp a first object of the plurality of received objects from the input area; moving the first object to a cache region using the programmable motion device, the cache region being proximate to the programmable motion device; selecting and grabbing a second object in the plurality of received objects; moving the second object to a first destination location using the programmable motion device; using the programmable motion device to select and grasp the first object from the cache region; and moving the first object to the first destination location using the programmable motion device.

Description

priority

[0001] This application claims priority to U.S. Provisional Patent Application No. 63 / 472,058, filed June 9, 2023, the disclosure of which is incorporated herein by reference in its entirety. Background Technology

[0002] The present invention relates generally to object handling systems, and more particularly to object handling systems that individually dispose of objects being processed (e.g., delivery or sorting) while handling objects.

[0003] Current object processing systems typically involve the processing of large numbers of objects, which are received in organized or unorganized batches and must be sent to their desired destinations based on a list or a specific address on the object (e.g., in a mail system).

[0004] For example, current distribution center sorting systems typically present an inflexible sequence of operations, where a chaotic flow of input objects is first broken down into isolated streams, presented one at a time to a scanner that identifies the objects. Organizing elements (e.g., conveyors, tilting pallets, or manually moving boxes) then transport the objects to their desired destination or further processing station, which may be a box, chute, bag, or conveyor.

[0005] In a typical parcel sorting system, manual or automated systems typically retrieve parcels in arrival order and sort each parcel or object into a collection bin based on a given set of heuristics. For example, all similar types of objects, all objects in a single customer order, or all objects destined for the same shipping destination might end up in one collection bin. A manual or automated system is needed to receive the objects and move each object to its designated collection bin. If the number of different types of incoming (received) objects is large, a large number of collection bins are required.

[0006] Current state-of-the-art sorting systems rely to some extent on manual labor. Most solutions depend on workers who perform sorting by scanning objects from categorization areas (chutes, workbenches, etc.) and placing them in grading locations, conveyors, or collection bins. When a bin is full or the control software system determines that it needs to be emptied, another worker empties the bin into a bag, box, or other container and sends the container to the next processing step. Such systems are limited in throughput (i.e., how quickly a person can sort or empty bins in this way) and number of turns (i.e., how many bins of a given size can be arranged within the range achievable by a person).

[0007] Sometimes, human intervention is necessary when the information about an object to be captured is difficult to obtain through scanning or camera-based systems, or when it involves highly sensitive information, such as the weight of very light objects. For example, if a wide variety of objects needs to be processed, then such a weight detection system must be able to adapt to receiving a wide range of objects.

[0008] There is still a need for more efficient and cost-effective object handling systems that can handle objects of various sizes and weights and efficiently distribute them to processing locations. Summary of the Invention

[0009] According to one aspect, the present invention provides a method for handling objects using a programmable motion device. The method includes: receiving a plurality of received objects at an input area near the programmable motion device; using the programmable motion device to select and grasp a first object from the plurality of received objects from the input area; using the programmable motion device to move the first object to a buffer area near the programmable motion device; selecting and grasping a second object from the plurality of received objects; using the programmable motion device to move the second object to a first destination location; using the programmable motion device to select and grasp the first object from the buffer area; and using the programmable motion device to move the first object to the first destination location.

[0010] According to another aspect, the present invention provides a method for handling objects using a programmable motion device. The method includes: receiving a plurality of objects at an input area near the programmable motion device; selecting, grasping, and moving the plurality of objects from the input area to a plurality of buffer positions in a buffer area in a first order; and selecting, grasping, and moving the plurality of objects from the plurality of buffer positions to at least one destination position in a second order different from the first order.

[0011] According to another aspect, the present invention provides an object processing system including an object processing station that receives objects from an input conveying system and provides the objects to an output system. The object processing system also includes an intermediate buffer area comprising a plurality of intermediate storage locations where a subset of the plurality of objects is placed before being moved to the output system. Attached Figure Description

[0012] The following description can be further understood with reference to the accompanying drawings, in which:

[0013] Figure 1A and Figure 1B An exemplary schematic diagram of an object processing system according to one aspect of the present invention is shown, illustrating an output system having an automatic bagging system. Figure 1A) and an output system with a container packaging system is shown ( Figure 1B );

[0014] Figures 2A to 2D It shows Figure 1A An illustrative schematic plan view of a part of an object processing system, showing a first object being identified. Figure 2A The diagram shows the first object being moved to the intermediate storage location. Figure 2B This indicates that another object is being moved. Figure 2C It also shows that the pose of the new object has been adjusted to be placed at the destination location. Figure 2D );

[0015] Figure 3 An exemplary schematic diagram of another object processing system according to an aspect of the present invention is shown, the other object processing system including an automatic bagging system and an intermediate temporary storage area having a rotating structure;

[0016] Figure 4 An exemplary schematic diagram of another object processing system according to one aspect of the present invention is shown, the other object processing system including an automatic bagging system and an intermediate temporary storage area having an intermediate storage position located on a horizontal rotating track system;

[0017] Figure 5 An exemplary schematic diagram of another object processing system according to an aspect of the present invention is shown, the other object processing system including an automatic bagging system and an intermediate temporary storage area having an intermediate storage location located on a linear actuator;

[0018] Figure 6 An exemplary schematic diagram of another object handling system according to one aspect of the present invention is shown, the other object handling system including an automatic bagging system and an intermediate temporary storage area having an intermediate storage position located on a vertical rotating track system;

[0019] Figure 7A and Figure 7B An exemplary schematic diagram of another object handling system according to one aspect of the present invention is shown, the other object handling system including an automatic bagging system and an intermediate temporary storage area having an intermediate storage position on a rotating tilting tray system, and an output system having the automatic bagging system is shown. Figure 7A ) and an output system with a container packaging system is shown ( Figure 7B );

[0020] Figure 8A and Figure 8B It is shown positioned on top of an automated bagging system. Figure 8A ) and is placed into an automatic bagging system. Figure 8B Enlarged schematic diagram of an illustrative object;

[0021] Figure 9 An exemplary schematic diagram of another object handling system according to one aspect of the present invention is shown, the other object handling system including an automatic bagging system and an intermediate temporary storage area having an intermediate storage location on a rotating cross belt conveyor system;

[0022] Figure 10 It shows Figure 9 An illustrative enlarged view of a part of the system, showing an object being placed into an automated bagging system;

[0023] Figure 11 An exemplary schematic diagram of another object handling system according to an aspect of the present invention is shown, the other object handling system including an automatic bagging system and an intermediate temporary storage area having an intermediate storage location on an unloading pallet conveyor system including push rods for unloading objects;

[0024] Figure 12 It shows Figure 11 An illustrative enlarged view of a part of the system, showing an object being placed into an automated bagging system;

[0025] Figure 13 An exemplary schematic diagram of another object handling system according to one aspect of the present invention is shown, the other object handling system including an automatic bagging system and an intermediate temporary storage area having an intermediate storage location on a cartridge pallet conveyor system;

[0026] Figure 14 It shows Figure 13 An illustrative enlarged view of a part of the system, showing an object being placed into an automated bagging system;

[0027] Figure 15 An exemplary schematic diagram of another object processing system according to one aspect of the invention is shown, the other object processing system including an automatic bagging system and an intermediate temporary storage area having an intermediate storage location which in turn supplies parts to an additional intermediate storage location;

[0028] Figure 16A and 16B It shows Figure 1A An illustrative schematic plan view of a portion of an object processing system, showing a smaller object being presented on top of a larger object at the input area. Figure 16A It also shows that the smaller object has been moved to the intermediate storage location, so that the larger object can now be grabbed and moved. Figure 16B );

[0029] Figure 17 An illustrative diagram of a large object being grasped is shown;

[0030] Figure 18 The image shows the device positioned above the automated bagging system. Figure 17 An illustrative diagram of an object;

[0031] Figure 19 An exemplary schematic diagram of another object processing system according to an aspect of the present invention is shown, the other object processing system including a static intermediate storage location;

[0032] Figure 20 An exemplary schematic diagram of another object processing system according to an aspect of the present invention is shown, the other object processing system including an intermediate storage location on an output conveyor system;

[0033] Figure 21 This illustrates the route to the destination location via a right-angle transfer system. Figure 20 An exemplary schematic diagram of the output conveyor system; and

[0034] Figure 22 It shows Figure 20 An illustrative diagram of an object processing system, in which only one row of intermediate storage locations can be moved at a time.

[0035] The accompanying drawings are shown for illustrative purposes only. Detailed Implementation

[0036] The applicant has identified a need for systems and processes for automating object handling tasks that require grouping objects together. In both robotic and manual picking operations, there are sometimes scenarios where objects must be grouped together in containers to complete the operation. For example, in e-commerce order fulfillment operations, all objects in a customer order must be grouped together in bags, boxes, or other containers before being shipped to the customer. Typically, objects arrive at the packing machine in batches, non-sequentially (e.g., randomly) for this grouping operation. In the batch case, objects from many customer orders arrive at the packing machine mixed together in one or more containers. In the non-sequential case, objects arrive at the picker one by one in a random order (rather than the order in which SKUs are grouped). As used herein, the term "object" refers to units, items, SKUs, products, etc., as well as bags or boxes containing such units, items, SKUs, and products. The applicant has identified temporary storage locations (or caching systems) that can be used in such systems.

[0037] Many e-commerce operations use batch picking to assemble the objects needed for one or more customer orders. In this type of operation, one or more people are responsible for picking all the objects needed to fulfill a number of customer orders. These objects are picked from shelves or automated storage systems and placed into one or more containers, then taken to a second location where a packing output task is performed: objects are again picked from the batch containers, and sorted according to which customer orders require which objects. The method described herein allows robotic pickers to perform packing output tasks more efficiently from the batch-picked transport containers.

[0038] Other e-commerce operations avoid batch processing. The objects needed to fulfill a customer order are sent directly to the packing output location without being picked into intermediate storage containers. For example, conveyor systems and automation technologies such as automated storage systems can be used to send a main storage container holding the required objects to the packing output station. Some operations use mobile robots to perform this delivery task. It's possible that objects for multiple customer orders will be sent to the packing output station without any initial sorting. An object for order A might arrive after an object for order B, followed by an object for order C, then another object for order A, and so on. This requires the packing output operator to maintain an intermediate storage location for each of these orders so that the operator can pick the objects as they arrive. The method described here is also used to address this problem.

[0039] Another use case involves storage systems utilizing mixed SKU containers. When objects are stored together in containers—unlike each container holding a unique object—the challenge for robotic pickers is to locate and pick the correct item from the container. This can be accomplished either by examining the container and identifying the object before picking, or by picking the object first and then identifying it, as is often the case when using a barcode scanner for object identification. The methods described here aim to improve efficiency in both cases because they allow the picker to remove the identified object from the storage container and store it in an intermediate storage location until it is needed later. This use case will be described further below.

[0040] The caching implementations described in this article include both static (non-movable) and dynamic implementations. For example, Figure 1AAn object handling system 10 is shown, including an object handling station 12 at which objects are processed from a feed conveyor system 14 and provided to an output system 16. Inventory items 13 are presented to the object handling system 10 in input bins 11 on the feed conveyor system 14. The inventory items 13 may be pre-sorted, order-specific groups of items, all of which are in one or more input bins 11. Input bins 11 may contain inventory items 13 of mixed SKUs, or they may contain inventory items 13 of any single SKU. The handling station 12 includes a programmable motion device 18 and may also include an intermediate storage area 20 where objects may be temporarily placed before being moved to the output system 16, which may include, for example, an automated bagging system 22.

[0041] The intermediate storage area (or buffer area) 20 includes multiple fixed positions 24 where objects can be placed before being moved to the automated bagging system 22 of the output system 16. The programmable motion device 18 may include, for example, an end effector 26 and one or more computer processing systems 100, 101, the end effector having a vacuum cup coupled to a high-flow-rate vacuum source 28, the computer processing systems controlling the motion of the programmable motion device 18 and all processing and conveying systems in response to sensing inputs and process control systems. The output system 16 may include the automated bagging system 22, which receives objects directly from the input bin 11 or via the intermediate storage area 20 as discussed herein from the programmable motion device 18.

[0042] According to other aspects, and with reference to Figure 1B The output system 16' of the object handling system 10' may include a packing station 21 for receiving empty output transport boxes 15 (e.g., shipping boxes). The object handling system 10' operates a programmable motion device 18 to transfer items from the input box 11 to the output transport box 15 at the packing station 21 to fulfill the current order, and temporarily stores items in an intermediate storage location 24 as described herein using an intermediate storage area 20 as needed. Additionally, items temporarily stored in the intermediate storage location 24 may be selected and placed in the output transport box 15 at the packing station 21 as needed. Thus, the current output transport box 15 at the packing station 21 receives objects directly from the input box 11 or via the intermediate storage area 20 as discussed herein from the programmable motion device 18.

[0043] The system can use the intermediate buffer area 20 to temporarily place some objects while other objects are being handled by the programmable motion device 18. See also... Figures 2A to 2D The system can identify the first object 32 in the input box 30 at the input conveying system 14. Figure 2AIt can grab object 32 and move it to the intermediate storage location 24. Figure 2B The system can return to input box 30 (or any other box located in the input area) and move another object 34 to the same or another intermediate storage location 24. Figure 2C With objects 32 and 34 held in the intermediate storage position, the system can then retrieve a new object 38 from another input bin 36 (e.g., the system knows it is awaiting processing and moves object 38 to the automatic bagging system 22 at the output system 16). Specifically, the system can place object 38 into the bag forming opening 40 of the automatic bagging system 22, such as... Figure 2D As shown. Empty or otherwise completed input boxes 11, such as those containing inventory items 13 with more than one SKU, may be returned to storage inventory or otherwise removed for disposal or reuse, as shown at 46.

[0044] In this way, the system can hold some objects while others are being processed, which provides greater flexibility in packing sequences and in evaluating the input stream before making any decisions about output combination and allocation, for example, by assigning objects to specific destination locations (e.g., as...). Figure 1A Before the bag combinations 42, 44 shown are opened, some or all of the input boxes are opened first. The assigned destination locations (such as bags 42, 44) can be located in the output system 16 on conveyor 17, which leads to either a manual or automated service (e.g., pick-up) area, as referenced below. Figure 21 , Figure 22 Further discussion follows. Additionally, since the programmable motion device places each object (e.g., 32, 34) in the intermediate storage location 24, the system knows the object's identity and its precise location, which facilitates the re-grabbing and subsequent movement of the object.

[0045] Dynamic buffering enables the movement of a desired buffer location to a common point in space (e.g., a first part that has moved relative to a second part). For example, a moving buffer can be provided by a rotating platform, allowing any object on it to be brought to a programmable motion device (e.g., a robot). Such a rotating platform (e.g., rotating in either direction) provides dynamic buffering. This ability to move any buffer location to a common location in space offers several advantages for robotic picking and placement operations:

[0046] For example, Figure 3An object handling system 50 according to another aspect of the invention is shown. This system includes an object handling station 52 where objects are processed from a feed conveyor system 14 and provided to an output system 16, as discussed above. The handling station 52 includes a programmable motion device 18 and may also include an intermediate storage area 54 where objects can be temporarily placed before being moved to the output system 16, which may include, for example, an automatic bagging system 22. The intermediate storage area 54 includes a plurality of intermediate storage locations that are movable, for example, by rotating a partitioned rotating structure 56 relative to a base 60. The partitioned rotating structure 56 may, for example, define a plurality (e.g., four) of intermediate storage locations, any one of which can receive any object (e.g., 58) and can rotate in any rotational direction.

[0047] Therefore, the system provides mobile target cache locations, any of which can be requested to present its contents again to the end effector 26 located at a known position (and orientation) for re-grabbing. The advantage of non-fixed (mobile) caching is that moving the target cache location to a common location in space allows the robot's transfer trajectory to remain approximately constant, regardless of which cache location the robot places the object in. The caching mechanism brings the correct cache location to a given point in space, and the robot always places the object at that cache location, thereby effectively reducing the disposal time for each transferred item to increase the overall throughput of the system.

[0048] Another advantage is that sensing hardware can be shared across cache locations via dynamic (moving) caches. Static caches require that any sensing technology needed to enable the robot to pick from or place items into the cache must be able to see all cache locations. This could require one or more cameras or other sensor devices. By using a mechanism that moves cache locations to the same point in space for picking and placing operations, a single sensing device can be directed to see only that one location, thus eliminating the need for additional sensing hardware.

[0049] Figure 4An object handling system 70 according to another aspect of the invention is shown, comprising a plurality of storage locations moving along a continuous horizontal track loop. System 70 includes an object handling station 72 at which objects are processed from a feed conveyor system 14 and provided to an output system 16, as discussed above. The handling station 72 includes a programmable motion device 18 and may also include an intermediate storage area 74 where objects can be temporarily placed before being moved to the output system 16, which may include, for example, an automatic bagging system 22. The intermediate storage area 74 includes a plurality of intermediate storage locations 76 that move along a track system 78 in a loop, as shown. Each intermediate storage location 76 can receive any object (e.g., 80) for temporary holding during processing as discussed herein. The track 78 may be powered by a power source driving the track system, or each of the intermediate storage locations 78 may be powered to move along a stationary track.

[0050] Figure 5 An object handling system 90 according to another aspect of the invention is shown, comprising a storage location system that moves linearly along at least one linear slider. System 90 includes an object handling station 92 at which objects are processed from a feed conveyor system 14 and provided to an output system 16, as discussed above. The handling station 92 includes a programmable motion device 18 and may also include an intermediate storage area 94 where objects can be temporarily placed before being moved to the output system 16, which may include, for example, an automatic bagging system 22. The intermediate storage area 94 includes a plurality of intermediate storage locations 96 that move linearly back and forth in a slider 98, which moves along linear actuator bases 110, 112 as shown. Each intermediate storage location 96 can receive any object (e.g., 80) temporarily held during processing as discussed herein.

[0051] Figure 6An object handling system 110 according to another aspect of the invention is shown, comprising a plurality of storage locations moving along a continuous vertical track loop. System 110 includes an object handling station 112 at which objects are processed from a feed conveyor system 14 and provided to an output system 16, as discussed above. The handling station 112 includes a programmable motion device 18 and may also include an intermediate storage area 114 where objects can be temporarily placed before being moved to the output system 16, which may include, for example, an automatic bagging system 22. The intermediate storage area 114 includes a plurality of intermediate storage locations 116 that move along a track system 118 in a loop, as shown. Each intermediate storage location 116 can receive any object (e.g., 80) temporarily held during processing as discussed herein. The track 118 may be powered by a power source 120 via drive wheels 122.

[0052] In each of the systems discussed in this paper, sensing systems 82, 84, 86 (e.g., in...) Figures 2A to 2D The sensor system 88 (as shown) provides perceptual data that facilitates the automated handling of objects. An additional sensing system 88 may also be provided on the input conveying system to facilitate the handling of input bins (where input objects are placed in the input bins). Furthermore, the robotic picker can be enhanced with additional sensing, manipulation, and motion planning capabilities to allow the system to detect and understand the geometry and position of the picked object, and then use this understanding to reorient the object for precise placement into a buffer location or any other type of container. This reorientation can be performed about any of three rotational axes: roll, pitch, or yaw. This allows, for example, a cereal box lying flat on its larger side to be rolled so that it stands upright upon placement (or the object can be positioned to fall into a slot, as described below). Figure 18 (As discussed).

[0053] This ability to reorient around a rotation axis allows the system to efficiently pack objects into buffer locations or handle outbound container requirements. For example, if the outbound container is a bag held open in a narrow slot (e.g., in an automated bagging system), the robot can use its reorientation capability to ensure that objects are oriented to fit into that slot when placed into the buffer location or into the bag itself. Mechanisms that allow the buffer location to move contribute to the efficiency of the process, as the desired buffer location can be brought to a common point in space for the robot to place there. This point in space informs the location of any sensing sensors needed to observe the held object and informs the motion planning algorithm responsible for the robot's reorientation movements. These advantages apply to all buffer applications described herein.

[0054] In the simple case of a single order, the robot retrieves an object from a mixed transport container, identifies the object, estimates its hand position, and reorients and places it for packaging, for example, in an automated bagging system. Figure 1A and Figure 1B The passive cache shown is essentially a set of discrete locations where all items for a given order can be grouped together based on certain aspects. The operational concepts include (1) the robot picks an object and identifies which order the object belongs to, (2) if the order currently in the outbound container is the same as the order of the currently picked object, the robot places the object into the outbound container, and (3) otherwise, the robot places the object into the cache location of the order to which the object belongs. Alternatively, the robot can pick objects from the cache and place them into the outbound container of the order, thereby freeing up the cache for later use.

[0055] In this way, the robot can track identified items and know where to go to retrieve them when ready to fulfill an order that requires them. This method is used to enhance the pre-pick identification and post-pick identification strategies described herein. As used herein, the term "passive" means that the picker places an object in a buffer and then picks it out from the buffer at a later time. The buffer is a temporary storage location that allows material handling facilities to operate more efficiently by providing flexibility in order sequencing. The buffer allows items retrieved from inventory or storage to proceed to an object handling system, such as object handling system 10, without all the items required to fulfill an order, or when some items arrive at object handling system 10 out of order, or, for example, when oversized or heavy items constitute part of an order. Additionally, when an order exceeds the capacity of one or more inventory handling boxes or containers, the flexibility allows for fluctuations in the timing or order of inventory items.

[0056] Therefore, according to various aspects, an object processing system is provided that provides intermediate storage of objects during processing. Such a system may include such an intermediate storage area, which may include a set of horizontally arranged, stationary containers without movement or mechanisms, such as... Figure 1A and Figure 1B As shown, the robot can reach any of these containers at any given time to pick the desired item. Intermediate storage areas may include attachments to, for example... Figure 3 The illustrated horizontal rotating circular mechanism comprises any of a set of individual containers such that, when a specific item is needed, the mechanism will rotate (e.g., in either direction of rotation) by a precise amount to present the desired item to be picked. An intermediate storage area may be provided as a set of containers residing on a circular track or a series of conveyors that can be circulated to present, as shown... Figure 4The desired container is shown. The intermediate storage area may include a horizontal linear actuation mechanism that can present a specific container to the robot when desired, such as... Figure 5 As shown. The intermediate storage area may include a set of fixed containers arranged vertically without movement or mechanisms (where the robot can access any of these containers at any given time to pick up the desired item), or a set of containers arranged on a vertically circulating circular track, such as... Figure 6 As shown.

[0057] According to another aspect, the system can provide active caching. Active caching extends the concept of passive caching by allowing cache locations to actively move items to outbound containers. In this specific implementation, the picker places items into the cache, and the cache mechanism is then responsible for placing these items into the final outbound container. This method has several advantages, most notably saving the picker the work of retrieving items from the cache. Some specific implementations of active caching allow the picker to address multiple outbound containers by using the cache as a mechanism for sending items to different outbound locations.

[0058] Depending on various aspects, the intermediate storage area may include multiple tilting devices that are rotatable (e.g., in any direction of rotation) to place the object in its position. For example, Figure 7A An object handling system 130 according to another aspect of the invention is shown. This system includes an object handling station 132 at which objects are processed from a feed conveyor system 14 and provided to an output system 16, as discussed above. The handling station 132 includes a programmable motion device 18 and may also include an intermediate storage area 134 where objects can be temporarily placed before being moved to the output system 16, which may include, for example, an automatic bagging system 22. The intermediate storage area 134 includes a plurality of intermediate storage locations 136 that move in a loop along a track system 138, as shown. Each intermediate storage location 136 can receive any object (e.g., 80) for temporary storage during processing as described herein.

[0059] Each of the intermediate storage locations 136 can be provided as a tilting tray, which can be activated to unload any object on it onto at least one side (e.g., one or both sides). The intermediate storage location 136 with the object on it... Figure 8A The object 80 is shown moving toward the bag forming opening 40 of the automatic bagging system 22. The object 80 is then directly unloaded into the bag forming opening 40 via the intermediate storage position 136 of the tilting tray, as shown. Figure 8BAs shown. In this way, by moving the intermediate storage location around the loop at the intermediate temporary storage area 134, objects can be selectively and directly placed from the intermediate temporary storage area 134 into the loop. Figure 8B The automatic bagging system 22 shown.

[0060] refer to Figure 7B This illustration shows an object handling system 130' according to another aspect of the invention, which includes an object handling station 132 at which objects are processed from a feed conveyor system 14 and provided to an output system 16', as discussed above. The handling station 132 includes a programmable motion device 18 and may also include an intermediate storage area 134 where objects can be temporarily placed before being moved to the output system 16', which may include, for example, a packaging station 21 for receiving empty output transport boxes 15 (e.g., shipping boxes) and a packaging station 19 for receiving empty or partially full output transport boxes 15 from the packaging station 21, as described below. The object handling system 130' operates the programmable motion device 18 to transfer items from an input box 11 to an output transport box 15 at the packaging station 21 to fulfill a current order, and utilizes the intermediate storage area 134 to temporarily store items in an intermediate storage location 136 as described herein, as needed. Items temporarily stored in any of the intermediate storage locations 136 can be selected and grasped by the programmable motion device 18 as needed and placed in the output transport box 15 at the packaging station 21. Alternatively, the output transport box 15 can advance to the packaging location 19, where items temporarily stored in the intermediate storage location 136 can be placed directly into the output transport box 15 via the intermediate temporary storage area 134'. Therefore, the current output transport box 15 at the packaging station 21 receives objects directly from the input box 11 or via the intermediate temporary storage area 134 as discussed herein from the programmable motion device 18. Additionally, the output transport box 15 receives objects directly from the intermediate temporary storage area 134 at the packaging location 19, as discussed herein. Full output boxes 42' and 44' then proceed out of the object handling system 130'.

[0061] Therefore, the object handling system can use an intermediate storage area to hold objects that will later be picked up by a programmable motion device for placement in the output system, or to hold objects that will later fall into the output system via the intermediate storage area. For example, direct transfer from the intermediate storage area to the output system can be used to achieve a desired order of placing objects into bagging stations or containers. Additionally, the efficiency of object picking at object handling station 12 can be achieved by placing the last of the number of objects to be picked for a single output package (e.g., 2, 3, 4, etc.) on the intermediate storage area, so that these objects can be delivered to the output container at packaging location 19, while a new output container presented at packaging location 21 begins receiving objects from the subsequent input bin 11.

[0062] According to another aspect, the intermediate storage area may include multiple circulating belt conveyors. The conveyors can be activated to unload objects into outgoing containers. For example, Figure 9 and Figure 10 An object handling system 150 according to another aspect of the invention is shown. This system includes an object handling station 152 at which objects are processed from a feed conveyor system 14 and provided to an output system 16, as discussed above. The handling station 152 includes a programmable motion device 18 and may also include an intermediate storage area 154 where objects can be temporarily placed before being moved to the output system 16, which may include, for example, an automatic bagging system 22. The intermediate storage area 154 includes a plurality of intermediate storage locations 156 that move in a loop along a track system 158, as shown. Each intermediate storage location 156 can receive any object (e.g., 80) for temporary storage during processing as described herein. Each storage location 156 may be configured as a cross-belt conveyor as shown, or may be provided with a more container-like wall, wherein the bottom plate is actuable to unload objects.

[0063] Each of the intermediate storage locations 156 can be configured as a lateral conveyor, which can be activated to unload any object on it onto at least one side (e.g., one or both sides). The intermediate storage location 156 with objects on it... Figure 9 The object 80 is shown moving toward the bag forming opening 40 of the automated bagging system 22. The object 80 is then directly unloaded into the bag forming opening 40 via the intermediate storage position 156 of the transverse conveyor. Figure 10 As shown. In this way, by moving the intermediate storage position around the loop at the intermediate temporary storage area 154, objects can be selectively and directly placed from the intermediate temporary storage area 154 into the automatic bagging system 22. According to another aspect, the intermediate storage positions 156 can each selectively provide a sudden vibration to shake the object from the storage position, thereby placing the object into the outgoing position.

[0064] According to another aspect, the intermediate storage area may include an automatic cleaning mechanism that pushes the desired object into the outgoing position. For example, Figure 11 and Figure 12An object handling system 170 according to another aspect of the invention is shown. This system includes an object handling station 172 at which objects are processed from a feed conveyor system 14 and provided to an output system 16, as discussed above. The handling station 172 includes a programmable motion device 18 and may also include an intermediate storage area 174 where objects can be temporarily placed before being moved to the output system 16, which may include, for example, an automatic bagging system 22. The intermediate storage area 174 includes a plurality of intermediate storage locations 176 that move in a loop along a track system 178, as shown. Each intermediate storage location 176 can receive any object (e.g., 80) for temporary storage during processing as described herein.

[0065] Each of the intermediate storage locations 176 can be provided as a cross-pushing device, which can be activated to unload any object thereon onto at least one side (e.g., one or both sides) of the cross-pushing device. The intermediate storage location 176 with the object thereon... Figure 11 The object 80 is shown moving toward the bag forming opening 40 of the automatic bagging system 22. The object 80 is then propelled by a pusher 177 as follows: Figure 12 The cross-push intermediate storage position 176 shown is directly unloaded into the bag forming opening 40. In this way, by moving the intermediate storage position around the loop at the intermediate temporary storage area 174, objects can be selectively and directly placed from the intermediate temporary storage area 174 into the automatic bagging system 22. According to another aspect, the system can utilize airflow from push rod 177, which can be held in a rearward position or moved as discussed above.

[0066] According to another aspect, the intermediate storage area may include intermediate storage locations, each including a trapdoor that, when activated, drops an object into an outgoing location. For example, Figure 13 and Figure 14 An object handling system 190 according to another aspect of the invention is shown. This system includes an object handling station 192 at which objects are processed from a feed conveyor system 14 and provided to an output system 16, as discussed above. The handling station 192 includes a programmable motion device 18 and may also include an intermediate storage area 194 where objects can be temporarily placed before being moved to the output system 16, which may include, for example, an automatic bagging system 22. The intermediate storage area 194 includes a plurality of intermediate storage locations 196 that move in a loop along a track system 198, as shown. Each intermediate storage location 196 can receive any object (e.g., 80) for temporary storage during processing as described herein.

[0067] Each of the intermediate storage positions 196 can be provided as a magazine-type device capable of being activated to unload any object thereon onto at least one side (e.g., one or both sides) of the magazine. The intermediate storage position 196 with the object thereon... Figure 13 The object 80 is shown moving toward the bag-forming opening 40 of the automatic bagging system 22. The object 80 is then directly unloaded into the bag-forming opening 40 through the intermediate storage position 196 of the magazine, as shown. Figure 14 As shown. In this way, by moving the intermediate storage location around the loop at the intermediate temporary storage area 194, objects can be selectively and directly placed from the intermediate temporary storage area 194 into the automatic bagging system 22.

[0068] According to other aspects and reference Figure 15 The object handling system 200 may include an object handling station 202, where objects are processed from the feed conveyor system 14 and provided to the output system 16, as discussed above. The handling station 202 includes a programmable motion device 18 and may also include an intermediate storage area 204 where objects can be temporarily placed before being moved to the output system 16, which may include, for example, multiple automated bagging systems 22. The intermediate storage area 204 includes multiple primary intermediate storage locations 206, which in turn feed items to multiple secondary intermediate storage locations 208. The programmable motion device 18 places objects into the primary intermediate storage location 206 in their original position (e.g., when closest to the device 18). Each primary storage location 206 includes a tilted floor and an actuator 210 for selectively allowing any contents therein (e.g., object 230 as shown) to fall into a secondary intermediate location 208. The secondary storage location may also include actuators 212 for selectively allowing any contents therein (e.g., object 232 as shown) to fall into the bag-forming opening 40 of the automated bagging system 22. Thus, the system provides a central location for the object to fall, and a series of actuators can then redirect the falling object so that it lands in the desired intermediate storage location.

[0069] Each of the intermediate storage positions 206 is positioned on a rotating platform relative to the base and is rotatable in either direction of rotation, and each of the intermediate storage positions 208 is positioned on a rotating stage relative to the base, as shown, and is rotatable in either direction of rotation. Guide ramps may be provided to facilitate the transfer of objects between positions 206 and 208, and between position 208 and output position 16 (e.g., where the bag forms an opening 40). Therefore, each intermediate storage position may include an inclined base plate and utilize an actuated sidewall that opens one of the sidewalls, thereby allowing the desired object to slide down into the outgoing container.

[0070] Depending on various aspects, robotic pickers use different technologies to identify objects. Some technologies allow the picker to identify an object before picking it, thus allowing it to pick a specific object from a container storing many objects. Other technologies (such as detecting and reading barcodes) typically only come into play after the picker has held the object and can see it from all sides.

[0071] For example, Figure 16A An input box or transport box 45 with a received container is shown. Figure 1A The system, in which the input bin or transport bin comprises multiple objects 47 situated on top of a larger object 48, first performs the task of bagging the larger object 48 before subsequently bagging the remaining objects 47. The object processing system 12 uses an intermediate buffer area 20 to temporarily hold any of the objects 47, allowing it to identify and remove the larger object 48 for bagging in the automated bagging system 22. (Reference) Figure 16B Object 47 is shown placed in multiple intermediate storage locations 24, such that object 48 is exposed to the sensing system 82 and the end effector 26 of the articulated arm 18. Object 48 can then be grasped by the end effector 26 of the articulated arm 18 (e.g., ...). Figure 17 (as shown), and then directly moves to the automatic bagging system 22. Once at the automatic bagging system 22, the articulated arm 18 can manipulate the orientation and posture of the object (e.g., Figure 18 As shown, the objects are correctly placed into the bag forming opening 40 of the automatic bagging system 22. The system can then add any further (e.g., smaller) objects (e.g., any of the objects 47) to the automatic bagging system 22. In this way, not only can objects be placed at the destination location with the desired orientation and posture, but the order in which the objects are packaged or placed can also be dynamically controlled.

[0072] Both methods can benefit from a utility cache. This cache is primarily used not for separating items by order, but rather for temporarily storing objects picked from inbound containers. This allows the picker to remove picked objects, making other objects in the container visible and available for picking. For example, when picking from a batch picking carton, the picker might want to remove objects on top of a stack in the carton to see what's underneath. In this case, the picker can use a utility cache to store these objects after picking them.

[0073] By providing the robotic picker with different locations for placing objects, the robotic system can remember where it places identified objects in its cache. This allows the picker to quickly find the object again without having to identify it once more.

[0074] According to another aspect, an intermediate storage area can be provided as a destination location where objects are provided in destination containers. For example, the outbound container itself can act as a cache location, providing temporary storage when the outbound container is full. In this method, the picker places objects directly into each outbound container without intermediate locations. This requires the picker to be able to address multiple outbound containers, allowing it to place objects for order A into the container for order A, and so on for other orders. Similar to... Figure 1A and Figure 1B In this system, intermediate storage locations are used for temporary storage, but in this case, the storage location is provided as an outbound container.

[0075] Figure 19 A portion of an object handling system 250 is shown, which includes a feed conveying system 14 for supplying objects to a programmable motion device 18 and an outbound container 260 disposed on a fixed surface 262. The outbound container may be, for example, a transport container, and the system uses the outbound container 260 as a temporary storage location when the outbound storage container is packaged for transport.

[0076] Figure 20 A portion of an object handling system 252 is shown, which includes a feed conveyor system 14 that provides objects to a programmable motion device 18 and an outbound container 260 disposed on a box tray 270 on a conveyor surface 272. The container 260 and the box tray 270 may be temporarily held in place by doors 274, 276 (e.g., in an orderly manner due to the box tray 270). Similarly, the outbound container may be, for example, a transport container, and the system uses the outbound container 260 as a temporary storage location when the outbound storage container is packaged for transport.

[0077] Further reference Figure 21 Figure 1 to Figure 15 The output system can be connected to either a manual or automated service system, for example, for processing completed containers or packages. For example... Figure 21 As shown at 300, conveyor 17 leads to an automated processing area equipped with a bidirectional diverter 302 (e.g., as a liftable belt adjustable between the rollers of conveyor 17) to guide objects thereon into one of two boxes or containers 304 on either side of conveyor 17. The boxes or containers 304 may be further provided on pull-out drawers 306. Objects (e.g., bags) 308 and 310 are, for example, transferred to boxes or containers 304 on the far side and near side of conveyor 17, respectively. Figure 21As shown. Once a pair of opposing boxes or cartons 304 are full or otherwise processed, their associated pull-out drawer 306 can be removed for further processing.

[0078] Further reference Figure 22 , Figure 20 The system can release a group of containers 260 at a time by actuating one of the two doors 274, 276 simultaneously (when container 260 is full or has otherwise completed processing), as shown at 262. In this way, a piecewise flow of containers can be provided to additional manual or automated processing systems. Empty containers 260 on the box tray 270 can be replenished as needed. Figure 20 and 22 In the system.

[0079] Those skilled in the art will recognize that many modifications and variations can be made to the embodiments disclosed above without departing from the spirit and scope of the invention.

Claims

1. A method of processing objects using a programmable motion device, the method comprising: receiving a plurality of received objects at an input area proximate to the programmable motion device; selecting and grasping, using the programmable motion device, a first object of the plurality of received objects from the input area; moving, using the programmable motion device, the first object to a staging area proximate to the programmable motion device; selecting and grasping a second object of the plurality of received objects; moving, using the programmable motion device, the second object to a first destination location; selecting and grasping, using the programmable motion device, the first object from the staging area; and moving, using the programmable motion device, the first object to the first destination location.

2. The method of claim 1, wherein the first object is not yet associated with an assigned destination location when moved to the staging area.

3. The method of any one of claims 1-2, wherein the first destination location is not ready to receive the first object when the first object is moved to the staging area.

4. The method of any one of claims 1-3, wherein the staging area receives a plurality of staging objects including the first object.

5. The method of any one of claims 1-4, wherein the staging area comprises a first portion that moves relative to a second portion, the first portion comprising a first portion area for receiving the first object.

6. The method of claim 5, wherein the first portion receives a plurality of staging objects in a plurality of first portion areas.

7. The method of claim 6, wherein the first portion comprises an actuation mechanism for ejecting a staging object from any of the first portion areas.

8. The method of any one of claims 1-7, wherein the plurality of received objects are provided in at least one tote or bin at the input area.

9. The method of any one of claims 1-8, wherein a plurality of destination locations are disposed proximate to the programmable motion device.

10. The method of any one of claims 1-9, wherein the first destination location comprises an automated bagging system.

11. The method of any one of claims 1-10, wherein the staging area is provided by a dynamically assigned destination location of a plurality of destination locations including the first destination location.

12. A method of processing objects using a programmable motion device, the method comprising: receiving a plurality of objects at an input area proximate to the programmable motion device; selecting, grasping, and moving, in a first order, the plurality of objects from the input area to a plurality of staging locations at a staging area; and selecting, grasping, and moving, in a second order different from the first order, the plurality of objects from the plurality of staging locations to at least one destination location. ​ ​ 13. The method of claim 12, wherein the plurality of objects includes a first object, the first object being in a first position in the first order of the plurality of objects moved to the plurality of buffer locations, and wherein the first object is not associated with an assigned destination location when moved to the buffer area.

14. The method of any of claims 12-13, wherein the plurality of objects includes a first object, the first object being in a first position in the first order of the plurality of objects moved to the plurality of buffer locations, and wherein the first object is associated with an assigned destination location, but the destination location is not ready to receive the first object when the first object is moved to the buffer area.

15. The method of any of claims 12-14, wherein the buffer area includes a first portion that moves relative to a second portion, the first portion including a first portion area for receiving the first object.

16. The method of claim 15, wherein the first portion receives a plurality of buffer objects in a plurality of first portion areas.

17. The method of claim 16, wherein the first portion includes an actuation mechanism for ejecting a buffer object from any of the first portion areas.

18. The method of any of claims 12-17, wherein the plurality of received objects are provided in at least one tote or bin at the input area.

19. The method of any of claims 12-18, wherein a plurality of destination locations are disposed proximate to the programmable motion device.

20. The method of any of claims 12-19, wherein the first destination location includes an automated bagging system.

21. The method of any of claims 12-20, wherein the buffer area is provided by a dynamically assigned destination location of a plurality of destination locations including the first destination location.

22. An object processing system including an object processing station that receives objects from an input conveyor system and provides objects to an output system, the object processing system further including an intermediate buffer area including a plurality of intermediate storage locations at which a subset of a plurality of objects are placed prior to being moved to the output system.

23. The object processing system of claim 22, wherein the intermediate buffer area includes intermediate storage locations that move.

24. The object processing system of claim 23, wherein the intermediate storage locations move horizontally in a loop.

25. The object processing system of any of claims 23-24, wherein the intermediate storage locations move vertically in a loop.

26. The object processing system of any of claims 23-25, wherein the intermediate storage locations move linearly in a reciprocating manner.

27. The object processing system of any of claims 22 to 26, wherein each object of the plurality of objects is provided to the output system via the intermediate storage location.

28. The object processing system of claim 27, wherein each intermediate processing location comprises a tilted tray.

29. The object processing system of claim 27, wherein each intermediate processing location comprises a conveyor segment.

30. The object processing system of claim 27, wherein each intermediate processing location comprises a pop-out drop segment.

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