Systems and methods for production and fulfillment

Abstract

Aspects of the present application relate to an order fulfillment system. The order fulfillment system may include one or more product introduction zones. A given product introduction area may contain a plurality of product storage devices and a product transfer device, and each product storage device holds a plurality of products, and the product transfer device is operable to transfer a product of the plurality of products into a transport container. The order fulfillment system may include an autonomous mobile robot (AMR). A given AMR may be moved to a shipping container delivery system to receive a shipping container. The AMR may then move the transport container to the product transfer apparatus to receive the product. The AMR may then be moved to at least one further location for further processing of the transport container. Conveniently, the order fulfillment system may be combined with a production system. In an arrangement in which the product storage equipment is a universal container, when the universal container is empty, it may be returned to the production system to refill the product.

Description

Technical Field

[0001] This disclosure generally relates to systems and methods for production and performance. Background Technology

[0002] Containers are used to package many different kinds of products. One form of container used in the packaging industry is the container generally referred to as a "box," which can be used to hold a variety of products and sometimes other products as well. Some people in the packaging industry refer to boxes used to package one or more products as "cartons." Additionally, some containers / boxes are referred to as "cartons" by some people in the industry. In this patent document, including the claims, the terms "case," "carton," and "container" are used interchangeably to refer to boxes, cartons, pallets, sleeves, and / or cartons, etc., that can be used to package any type of item containing products and other cartons.

[0003] Boxes come in a variety of configurations and are made from a wide range of materials. However, many boxes are foldable and are formed from a flattened state (often referred to as a box blank). Boxes can be made from a variety of foldable materials, including but not limited to cardboard, particleboard, paperboard, corrugated fiberboard, other types of corrugated materials, plastic materials, composite materials, and even combinations thereof.

[0004] Each product is obtained from one or more locations in a storage facility such as a warehouse, the products are loaded into boxes, the loaded boxes are sealed, and the loaded boxes are then shipped to the customer, which can be used to fulfill the customer's order for one or more products.

[0005] However, there are many obstacles to providing efficient methods and systems for fulfilling customer orders, especially when it is expected that orders can be fulfilled for a large number of customers, each of whom may have orders for a variety of different types and / or quantities of products. Summary of the Invention

[0006] According to one aspect of the present invention, an order fulfillment system is provided. The order fulfillment system includes: a first product introduction area comprising: a plurality of product storage devices, each holding a plurality of products; and a first product transfer device operable to transfer a first product from the plurality of products held by the first product storage device to a transport container. The order fulfillment system further includes a transport container autonomous mobile robot (AMR) and a transport container delivery system operable to deliver the transport container to the transport container AMR. The transport container AMR is operable to: travel to the transport container delivery system according to instructions from the transport container AMR; wait to receive the transport container at the transport container delivery system; travel to the first product transfer device while holding the transport container and according to instructions from the transport container AMR; at the first product transfer device, wait for the first product to be transferred from the product storage device to the transport container by the first product transfer device according to instructions from the transport container AMR; and travel to at least one location for further processing of the transport container while holding the transport container containing the first product and according to instructions from the transport container AMR.

[0007] According to one aspect of the present invention, a method for operating a fulfillment system is provided. The system includes: a first product introduction area including a plurality of product storage devices, each of the plurality of product storage devices holding a plurality of products; a first product transfer device operable to transfer a first product from a first plurality of products held by the first product storage device into a transport container; a transport container autonomous mobile robot (AMR); and a transport container delivery system operable to deliver the transport container to the transport container AMR. The method includes: the transport container AMR traveling to the transport container delivery system; waiting to receive the transport container from the transport container delivery system; while holding the transport container, traveling to the first product transfer device in the first product introduction area; waiting at the first product transfer device to receive the first product from the product storage devices into the transport container; and while holding the transport container containing the first product inside, traveling to at least one location for further processing of the transport container.

[0008] According to one aspect of the present invention, an order fulfillment system is provided. The order fulfillment system includes: a first product introduction area comprising a plurality of pallets, each of the plurality of pallets holding a plurality of products; a product transfer device operable to transfer a first product from a pallet selected from the plurality of pallets; an autonomous mobile robot (AMR) for transport containers; and a transport container delivery system operable to deliver a selected transport container to the transport container AMR. The transport container AMR is operable to: travel to the transport container delivery system and wait at the transport container delivery system to receive the selected transport container; while holding the selected transport container, travel to the product transfer device in the product introduction area; wait at a first product transfer location to receive the first product from the selected pallet into the selected transport container; and while holding the selected transport container containing the first product inside, travel to at least one location for further processing of the selected transport container.

[0009] According to one aspect of the present invention, a method of operating a fulfillment system is provided. The fulfillment system includes: a first product introduction area comprising a plurality of pallets, each pallet holding a plurality of products; a product transfer device operable to transfer a first product from a selected pallet, the selected pallet being chosen from the plurality of pallets; an autonomous mobile robot (AMR) for transport containers; and a transport container delivery system operable to deliver a selected transport container to the transport container AMR. The method includes: the transport container AMR traveling to the transport container delivery system; waiting at the transport container delivery system to receive the selected transport container; while holding the selected transport container, traveling to the product transfer device in the product introduction area; waiting at a first product transfer location to receive the first product from the selected pallet into the selected transport container; and while holding the selected transport container containing the first product inside, traveling to at least one location for further processing of the selected transport container.

[0010] According to one aspect of the present invention, an order fulfillment system is provided. The order fulfillment system includes a processor and a pallet autonomous mobile robot (AMR). The processor is operable to generate pallet autonomous mobile robot (AMR) instructions, and the pallet AMR is configured to receive these instructions from the processor. The pallet AMR is configured to travel to a pallet receiving position according to the pallet AMR instructions, receive a selected pallet at the pallet receiving position, travel to a product storage area while holding the selected pallet, and release the selected pallet. The pallet holds at least one product, which corresponds to at least one inventory unit.

[0011] According to one aspect of the present invention, a method for operating a fulfillment system is provided. The fulfillment system includes a processor and a pallet autonomous mobile robot (AMR), the processor being operable to generate pallet AMR instructions. The method includes the pallet AMR receiving pallet AMR instructions from the processor, traveling to a pallet receiving position according to the pallet AMR instructions, receiving a selected pallet at the pallet receiving position, traveling to a product storage area while holding the selected pallet, and releasing the selected pallet, wherein the selected pallet holds at least one product, the at least one product corresponding to at least one inventory unit.

[0012] According to one aspect of the invention, a system is provided. The system includes: a mobile device operable to move one or more of a plurality of stacked cartons on a pallet positioned in a carton movement location, wherein at least some of the cartons contain at least one product, and the carton stack is supported on the pallet; and a processor operable to generate mobile device instructions. The mobile device is operable to receive mobile device instructions from the processor, engage a selected carton from the plurality of cartons in the carton stack, and move the selected carton and any cartons stacked above the selected carton.

[0013] According to one aspect of the invention, a method is provided. The method comprises: moving one or more of a plurality of stacked cartons vertically stacked on a pallet in a carton stack positioned at a carton movement location, wherein at least some of the cartons contain at least one product, and the carton stack is supported on the pallet; and engaging a selected carton from the plurality of cartons in the carton stack, and optionally moving the selected carton and any cartons stacked above the selected carton by lifting.

[0014] According to one aspect of the invention, a system for delivering products is provided. The system includes a transport trailer configured to receive and store at least one pallet, a pallet autonomous mobile robot (AMR) operable to transport the pallet, and a processor operable to transmit instructions to the pallet AMR. The instructions cause the pallet AMR to navigate to a pallet receiving position outside the transport trailer and engage the pallet, navigate to a storage position within the transport trailer and release the pallet at the storage position, and navigate away from the transport trailer when no pallet is present. The transport trailer includes an internal storage space defined by a ceiling surface, side wall surfaces, and a floor surface, and the floor surface is configured to facilitate navigation of the pallet AMR within the transport trailer.

[0015] According to one aspect of the invention, a method is provided for delivering products by loading pallets onto a transport trailer using a pallet autonomous mobile robot (AMR), the transport trailer being configured to receive and store pallets. The method includes the pallet AMR navigating to a pallet receiving location outside the transport trailer and engaging the pallet, navigating to a storage location within the transport trailer and releasing the pallet at the storage location, and navigating away from the transport trailer when no pallet is present.

[0016] According to one aspect of the invention, a system for delivering products is provided. The system includes a transport trailer configured to receive and store at least one pallet, a pallet autonomous mobile robot (AMR) operable to transport the pallet, and a processor operable to transmit instructions to the pallet AMR. These instructions cause the pallet AMR to navigate to a pallet receiving position inside the transport trailer and engage with a given pallet, navigate to a storage position outside the transport trailer and release the given pallet at the storage position, and navigate away from the given pallet.

[0017] According to one aspect of the invention, a method is provided for delivering products using a pallet autonomous mobile robot (AMR) to unload a transport trailer capable of receiving and storing pallets. The method includes the pallet AMR navigating to a pallet receiving position inside the transport trailer and engaging a given pallet, navigating to a storage position outside the transport trailer and releasing the given pallet at the storage position, and navigating away from the given pallet.

[0018] According to one aspect of the invention, a system for loading and transporting products is provided. The system comprises: a source of multiple products, wherein the system is operable to transfer multiple products onto a pallet located at a pallet loading position; a transport trailer configured to receive and store at least one pallet; a pallet autonomous mobile robot (AMR) operable to move the pallet; and a processor operable to transmit instructions to the pallet AMR. These instructions cause the pallet AMR to navigate to a pallet receiving position and engage with a given pallet holding multiple products, navigate to a storage position in the transport trailer and release the given pallet at the storage position, and navigate away from the transport trailer in the absence of a given pallet.

[0019] According to one aspect of the invention, a system for loading products onto pallets is provided. The system comprises: a source of products; a product transfer device operable to load at least one product provided by the source of products into each of a plurality of cartons at a loading station, thereby forming a plurality of loaded cartons; a loaded carton stacking device operable to form a stack of loaded cartons; a device operable to load the stack of loaded cartons onto a pallet to form a loaded pallet; an autonomous pallet mobile robot (AMR) operable to engage with and move the loaded pallet while supporting the stack of loaded cartons; and a processor operable to transmit instructions to the pallet AMR. These instructions cause the pallet AMR to navigate to the pallet receiving location, engage with unloaded pallets at the pallet receiving location, navigate with unloaded pallets to the container stack receiving location, receive container stacks to form loaded pallets, navigate away from the container stack receiving location with loaded pallets, and travel to a location for further processing while engaging loaded pallets.

[0020] According to one aspect of the present invention, a method for loading products onto a pallet is provided. The method includes: loading at least one product provided by a source into each of a plurality of empty cartons to form a plurality of loaded cartons; forming a stack of loaded cartons from the plurality of loaded cartons; loading the stack of loaded cartons onto a pallet to form a loaded pallet; engaging the loaded pallet with an autonomous pallet moving robot (AMR); and moving the loaded pallet while supporting the stack of loaded cartons.

[0021] According to one aspect of the invention, a system for delivering products to a performance operation is provided. The system includes a production operation comprising a source of products; a product transfer device operable in the production operation to transfer a plurality of products provided by the source of products onto a pallet located at a pallet loading position; and a first transport trailer operable to receive and store at least one pallet, the first transport trailer being capable of navigating an autonomous mobile robot (AMR) therein and a first production pallet AMR in the production operation. The first production pallet AMR is operable to navigate to a pallet receiving position, engage a loaded pallet holding a plurality of products at the pallet receiving position, navigate to a storage position in the transport trailer, release the loaded pallet at the storage position, and navigate away from the transport trailer when no pallet is loaded. The system also includes a fulfillment operation, which comprises a first fulfillment pallet AMR operable to navigate to a storage location on a first transport trailer, engage the loaded pallet at the storage location, navigate to a pallet storage location within the fulfillment operation, release the loaded pallet at the pallet storage location, and navigate away from the pallet storage location when no pallet is loaded. When the first transport trailer is loaded with a pallet, the first transport trailer is operable to transport the loaded pallet from the production operation to the fulfillment operation.

[0022] According to one aspect of the invention, a method for delivering products to a fulfillment operation is provided. The method includes: transferring a plurality of products, supplied by a product source, onto a pallet at a production operation to form a loaded pallet; navigating to the loaded pallet by a first production pallet autonomous mobile robot (AMR); engaging the loaded pallet by the first production pallet AMR; navigating to a storage location in a transport trailer by the first production pallet AMR; releasing the loaded pallet at the pallet storage location by the first production pallet AMR while the transport trailer is in the production operation; and navigating away from the transport trailer by the first production pallet AMR without a loaded pallet.

[0023] According to one aspect of the present invention, a method for performing an operation is provided. The method includes: navigating by a first autonomous mobile robot (AMR) performing the operation to a pallet storage location on a first transport trailer performing the operation; engaging a loaded pallet by the first AMR, the loaded pallet holding multiple products; moving the loaded pallet by the first AMR to the location of the operation; emptying most or all of the multiple products from the loaded pallet by components of the operation to form a return pallet; navigating by a second AMR performing the operation to the return pallet; and moving the return pallet by the second AMR to a pallet storage location on a second transport trailer located at the location of the operation.

[0024] According to one aspect of the present invention, a method for operating a production operation is provided. The method includes: forming a loaded pallet by loading multiple products onto a pallet; navigating to the loaded pallet by a first autonomous mobile robot (AMR) at the production operation location; moving the loaded pallet onto a first transport trailer by the first AMR; navigating to a return pallet located on a second transport trailer at the production operation location by a second AMR at the production operation location; and removing the return pallet from the second transport trailer by the second AMR.

[0025] According to one aspect of the invention, a transport trailer is provided. The transport trailer includes an internal storage space defined by a ceiling surface, side wall surfaces, and a floor surface. The floor surface includes a first configuration to facilitate navigation of an autonomous mobile robot (AMR) within the transport trailer.

[0026] According to one aspect of the invention, a transport trailer is provided. The transport trailer includes an internal storage space defined by a ceiling surface, side wall surfaces, and a floor surface. The transport trailer also includes a plurality of airbags positioned on the side wall surfaces. The plurality of airbags have a first state and a second state, in which the airbags are inflated with pressurized air to engage the side surfaces of a cargo box supported on a pallet stored in the internal space, and in which the airbags are depressurized and disengaged from the side surfaces of the cargo box.

[0027] According to one aspect of the invention, a transport container blank delivery system is provided for delivering transport container blanks to an upright transport container delivery system. The transport container blank delivery system includes a transport container blank pallet holding a plurality of transport container blanks and a transport container blank autonomous mobile robot (AMR). The transport container blank AMR is configured to travel to a transport container blank pallet receiving position, engage the transport container blank pallet at the transport container blank pallet receiving position, and travel to a blank transfer position, wherein the blank transfer position is close to the upright transport container delivery system. The transport container blank delivery system further includes a blank transfer device that is close to the blank transfer position and the upright transport container delivery system, the blank transfer device being operable to transfer a plurality of transport container blanks from the transport container blank pallet to the upright transport container delivery system.

[0028] According to one aspect of the present invention, a method is provided for operating a fulfillment system comprising an autonomous mobile robot (AMR) for transport container blanks. The method includes: the transport container blank AMR traveling to a transport container blank pallet receiving position; the transport container blank AMR engaging a transport container blank pallet at the transport container blank pallet receiving position, the transport container blank pallet holding a plurality of transport container blanks; and the transport container blank AMR traveling to a blank transfer position approaching a transport container delivery system.

[0029] According to one aspect of the invention, a system for delivering transport container blanks to a performance operation is provided. The system comprises: a production operation operable to provide a source of transport container blanks; a product transfer device operable during the production operation to transfer a plurality of transport container blanks provided by the source of transport container blanks onto a transport container blank pallet located at a pallet loading position; a first transport trailer configured to receive and store the transport container blank pallet; a production pallet autonomous mobile robot (AMR) operable during the production operation to move the transport container blank pallet; and a processing system operable to transmit production pallet AMR instructions to the production pallet AMR. The production pallet AMR instructions cause the production pallet AMR to navigate to a pallet receiving position, engage the transport container blank pallet holding the plurality of transport container blanks, navigate to a storage position in the transport trailer, release the transport container blank pallet at the storage position, and navigate away from the transport trailer without carrying the transport container blank pallet. When the first transport trailer is loaded with a transport container blank pallet, the first transport trailer can be operated to transport the transport container blank pallet from the production operation to the fulfillment operation.

[0030] According to one aspect of the present invention, a method for delivering transport container blanks to a performance operation is provided. The method includes: transferring a plurality of transport containers onto a transport container blank pallet; navigating to the transport container blank pallet by a pallet autonomous mobile robot (AMR); engaging the transport container blank pallet, which holds the plurality of transport container blanks, with the pallet AMR; navigating to a storage location on a transport trailer by the pallet AMR; releasing the transport container blank pallet from the storage location by the pallet AMR; and navigating away from the transport trailer without carrying the transport container blanks.

[0031] According to one aspect of the present invention, an order fulfillment system is provided. The order fulfillment system includes a processor operable to generate carton forming instructions and autonomous mobile robot (AMR) instructions. The order fulfillment system further includes a carton forming system configured to receive carton forming instructions from the processor, select carton blanks from a plurality of bins according to the carton forming instructions, and form the carton blanks into upright cartons. The order fulfillment system also includes an AMR configured to receive AMR instructions from the processor, travel to the carton forming system according to the AMR instructions, receive the upright cartons from the carton forming system, travel to a station in a product introduction area according to the AMR instructions, receive the product into the upright cartons at the station, and travel to a position for further processing of the upright cartons while maintaining the upright cartons containing the product inside, according to the AMR instructions.

[0032] According to another aspect of the present invention, an order fulfillment system is provided. The order fulfillment system includes a processor operable to generate a transport container selection instruction and an autonomous mobile robot (AMR) instruction. The order fulfillment system further includes a transport container delivery system configured to receive the transport container selection instruction from the processor and, according to the transport container selection instruction, select a transport container from a plurality of transport containers. The order fulfillment system also includes an AMR configured to receive an AMR instruction from the processor, proceed to the transport container delivery system according to the AMR instruction, receive the selected transport container from the transport container delivery system according to the AMR instruction, proceed to a station in a product introduction area while holding the selected transport container, receive the product into the selected transport container at the station, and, according to the AMR instruction, proceed to a position for further processing of the selected transport container while holding the selected transport container containing the product inside.

[0033] According to another aspect of the present invention, a carton closing and sealing system is provided. The carton closing and sealing system includes an autonomous mobile robot (AMR), a processor operable to generate AMR instructions, a transport container delivery system configured and operable to deliver a transport container to the AMR, and a sealing device operable such that the transport container is sealed when the AMR moves past a sealing device on which the transport container is placed. The AMR can be configured and operable to receive AMR instructions from the processor, and according to the AMR instructions, travel to the sealing device and move through the sealing device to seal the transport container.

[0034] According to another aspect of the invention, an autonomous mobile robot (AMR) for transporting a receiver is provided. The AMR includes a mobile trolley, a control system for controlling the operation of the autonomous mobile robot, a first belt having an upper surface, a first lug fastened to the upper surface of the first belt, a second belt having an upper surface, and a second lug fastened to the upper surface of the second belt. The control system is operable to control and adjust the position of the first lug relative to the second lug for movement between a first position and a second position, wherein in the first position the spacing between the first lug and the second lug is adapted to allow the receiver to be positioned between or removed from between the first lug and the second lug, and in the second position the spacing between the first lug and the second lug provides side surfaces for the first lug and the second lug to engage the receiver, thereby securing the receiver between the first lug and the second lug.

[0035] According to another aspect of the present invention, an autonomous mobile robot (AMR) for transporting receiving items is provided. The AMR includes a mobile trolley, a control system for controlling the operation of the autonomous mobile robot, and a receiving item securing mechanism. The receiving item securing mechanism is operable to releasably secure the receiving item to the mobile trolley during movement within a warehouse when the receiving item carries at least one product from a product order and when the receiving item carries no product. The control system is operable to control and adjust the operation of the transport container securing mechanism between a first state and a second state. In the first state, when the transport container carries at least one product from a product order and when the transport container carries no product, the transport container is secured to the mobile trolley and can move within the warehouse. In the second state, the transport container can be removed from the mobile trolley.

[0036] According to another aspect of the invention, a product unloading system is provided. The product unloading system includes a product rack for storing products. The product rack includes a plurality of storage layers for storing products thereon, the plurality of storage layers being spaced apart from each other and vertically arranged within the product rack. The product rack also includes a plurality of raised platforms configured for an autonomous mobile robot (AMR) to travel thereon, each of the plurality of raised platforms being positioned close to a corresponding storage layer among the plurality of storage layers. The product unloading system further includes a lifting system comprising a lifting platform for raising the AMR between a ground plane and the plurality of raised platforms. The product unloading system further includes a product retrieval robot for retrieving a product from one of the plurality of storage layers and unloading the product onto a receiver held by the AMR at a corresponding storage layer among the plurality of storage layers.

[0037] According to another aspect of the invention, a fulfillment system is provided. The order fulfillment system includes a processor operable to generate carton forming instructions, product retrieval instructions, and autonomous mobile robot (AMR) instructions. The order fulfillment system further includes a carton forming system configured to receive carton forming instructions from the processor, select carton blanks from a plurality of bins according to the carton forming instructions, and form the carton blanks into upright cartons. The order fulfillment system also includes a product retrieval robot configured to receive product retrieval instructions from the processor and retrieve products from a product rack at a product storage location according to the product retrieval instructions. The order fulfillment system also includes an AMR (Automatic Vehicle Controller), which is configured to receive AMR instructions from the processor, proceed to the carton forming system according to the AMR instructions, receive upright cartons from the carton forming system, proceed according to the AMR instructions, while keeping the upright cartons on the product rack, receive products from the product take-out robot into the upright cartons at the product rack, and proceed according to the AMR instructions to a position for further processing of the upright cartons while keeping the upright cartons containing products inside.

[0038] According to another aspect of the invention, a fulfillment system is provided. The fulfillment system includes a processor operable to generate a receiving item delivery instruction and an autonomous mobile robot (AMR) instruction. The fulfillment system also includes a carton delivery system configured to receive the receiving item delivery instruction from the processor and, according to the receiving item delivery instruction, select a chosen receiving item from a selection of receiving items for delivery. The fulfillment system includes an AMR configured to receive an AMR instruction from the processor, proceed to the receiving item delivery system according to the AMR instruction, receive the selected receiving item from the receiving item delivery system, proceed to a station in a product introduction area while holding the selected receiving item, receive the product into the selected receiving item at the station, and, according to the AMR instruction, proceed to a position for further processing of the selected receiving item while holding the selected receiving item containing the product inside the selected receiving item.

[0039] According to another aspect of the invention, a fulfillment system is provided. The fulfillment system includes a processor operable to generate transport container selection instructions and autonomous mobile robot (AMR) instructions. The fulfillment system also includes a transport container delivery system configured to receive the transport container selection instructions from the processor and, based on the transport container selection instructions, select a transport container from a plurality of transport containers. The fulfillment system also includes an AMR configured to receive AMR instructions from a processor, travel to a transport container delivery system according to the AMR instructions, receive a selected transport container from the transport container delivery system according to the AMR instructions, travel to a station in a product introduction area while holding the selected transport container, wherein the product introduction area includes a product tower containing multiple compartments for storing products, and wherein at least one of the multiple compartments contains one or more products corresponding to at least one inventory unit, receive a first product into the selected transport container at the station according to the AMR instructions, travel to a given product storage rack in a storage area while holding the selected transport container, wherein the storage area includes multiple product storage racks that store products in pallets, receive a second product into the selected transport container at the given product storage rack, and travel to a location for further processing of the selected transport container while holding the selected transport container containing the first and second products according to the AMR instructions.

[0040] According to another aspect of the invention, a fulfillment system is provided. The fulfillment system includes a processor operable to generate carton forming instructions, product retrieval instructions, and autonomous mobile robot (AMR) instructions. The fulfillment system further includes a carton forming system configured to receive carton forming instructions from the processor, select carton blanks from a plurality of available carton blanks according to the carton forming instructions, and form the carton blanks into upright cartons. The fulfillment system also includes a product retrieval robot configured to receive product retrieval instructions from the processor and retrieve products from a product storage location according to the product retrieval instructions. The fulfillment system also includes a reusable container and an AMR (Automatic Carrier Regulator). The reusable container contains multiple products for fulfilling multiple orders. When multiple products are removed from the reusable container to fulfill multiple orders, the reusable container becomes an empty reusable container. The AMR is configured to receive AMR instructions from a processor, proceed to a carton forming system according to the AMR instructions, and receive upright cartons from the carton forming system. According to the AMR instructions, while maintaining the upright cartons, it proceeds to a product loading station, where products are received into the upright cartons. According to the AMR instructions, while maintaining the upright cartons containing products, it proceeds to a position for further processing of the upright cartons, wherein further processing of the upright cartons includes removing the upright cartons from the AMR. Subsequently, according to the AMR instructions, it proceeds to and receives an empty reusable container, and according to the AMR instructions, while maintaining the empty reusable container, it proceeds to a position for further processing of the empty reusable container.

[0041] According to another aspect of the invention, a fulfillment system is provided. The fulfillment system includes a processor operable to generate transport container delivery instructions, generate product retrieval instructions, and generate autonomous mobile robot (AMR) instructions. The fulfillment system further includes a transport container delivery system configured to receive transport container delivery instructions from the processor and, based on the transport container delivery instructions, select a transport container from a plurality of available transport containers. The fulfillment system also includes a product retrieval robot configured to receive product retrieval instructions from the processor and, based on the product retrieval instructions, retrieve products from a product storage location. The fulfillment system further includes a reusable container containing a plurality of products for fulfilling multiple orders; when multiple products are removed from the reusable container to fulfill multiple orders, the reusable container becomes an empty reusable container. The fulfillment system also includes an AMR (Automatic Transport Regulator), which is configured to receive AMR instructions from the processor, travel to the transport container delivery system and receive the transport container according to the AMR instructions, travel to the product loading station while holding the transport container according to the AMR instructions, receive the product into the transport container at the product loading station, travel according to the AMR instructions, and reach a location for further processing of the transport container while holding the transport container containing the product, wherein further processing of the transport container includes removing the transport container from the AMR, thereafter, moving and receiving an empty reusable container on the AMR according to the AMR instructions, and traveling to a location for further processing of the empty reusable container while holding the empty reusable container according to the AMR instructions.

[0042] According to another aspect of the invention, a method for receiving products into a fulfillment center is provided. The method includes transmitting instructions to a first autonomous mobile robot (AMR) causing the first AMR to navigate to a container storage structure in a first transport trailer, the container storage structure holding containers containing multiple products, and transporting the container storage structure to a product introduction area where individual products can be removed from the containers. The method further includes transmitting instructions to a second AMR causing the second AMR to navigate to a container storage structure in the product introduction area where the containers no longer hold products, transporting the container storage structure to a second transport trailer, and navigating away from the second transport trailer which does not have a container storage structure.

[0043] Other aspects and features of the invention will become apparent to those skilled in the art from the following description of specific embodiments of the invention in conjunction with the accompanying drawings. Attached Figure Description

[0044] The accompanying drawings illustrate embodiments of the invention by way of example only, wherein... Figure 1AA portion of a carton forming system according to an exemplary embodiment of this application is illustrated in a top-right front perspective view. Figure 1B The various aspects according to this application are illustrated in a schematic flowchart. Figure 1A The power and control subsystem is part of the carton forming system; Figure 2 The diagram is shown in the top-down right rear view perspective. Figure 1A A carton forming system; Figure 3 The diagram is shown in the top-down perspective view on the right. Figure 1A A carton forming system; Figure 4 Previously, schematic elevation drawings were shown. Figure 1A The cardboard box forming system, but with several components omitted; Figure 5 The rear view schematic elevation drawing is shown. Figure 1A The cardboard box forming system, but with several components omitted; Figure 6A The bin subsystem according to various aspects is illustrated in a top-right perspective view; Figure 6B The diagram is illustrated in a top-down, right-side perspective view. Figure 6A The hopper subsystem, but with several components omitted; Figure 6C The elevation view on the right is shown. Figure 6A The hopper subsystem, but with several components omitted; Figure 6D The diagram is shown in the top view plan. Figure 6A The silo subsystem; Figure 7 The perspective view on the right is shown below. Figure 1A The carton forming system, but several components are omitted to show the blank feeding system, two upright heads with moving equipment, and folding and sealing equipment; Figure 8 The diagram is shown in the top-down right rear view perspective. Figure 7 Each component; Figure 9 The diagram shows... Figure 7 Top-down right front perspective view of each component; Figure 10A The blank of a slotted box with a generally flattened tubular configuration is illustrated in a plan view. Figure 10B The previous elevation drawing was shown. Figure 10A The blank of a regularly slotted box; Figure 10C The side elevation view is shown. Figure 10A The blank of a regularly slotted box; Figure 10D The perspective view is shown. Figure 10A The blank of a regularly slotted box; Figure 10E It is illustrated in another perspective view. Figure 10A The blank of a regularly slotted box; Figure 11 The right perspective view schematically illustrates the open state. Figure 10A blanks; Figure 12 The schematic right perspective view illustrates the... Figure 11 The blank is the blank after one step in the sequence of transforming it into an upright cardboard box; Figure 13 The schematic right perspective view illustrates the... Figure 12 The blank is the blank after one step in the sequence of transforming it into an upright cardboard box; Figure 14 The schematic right perspective view illustrates the... Figure 13 The blank is the blank after one step in the sequence of transforming it into an upright cardboard box; Figure 15 The schematic right perspective view illustrates the... Figure 14 The blank is the blank after one step in the sequence of transforming it into an upright cardboard box; Figure 16 The schematic right perspective view illustrates the... Figure 15 The blank is the blank after one step in the sequence of transforming it into an upright cardboard box; Figure 17 The various aspects according to this application are illustrated in a schematic right perspective view. Figure 1A The cardboard box forming system, but only the part shown is in the diagram. Figure 10A The blanks are processed into individual moving parts, erector heads, and some parts of folding and sealing devices in the sequence of stages of forming upright cartons. Figure 18 The schematic right perspective view illustrates the various aspects of the application being in the position of Figure 10A The continuous stages of processing blanks into upright cardboard boxes. Figure 17 A carton forming system; Figure 19 The schematic right perspective view illustrates the various aspects of the application being in the position of Figure 10A The continuous stages of processing blanks into upright cardboard boxes. Figure 17 A carton forming system; Figure 20 The schematic right perspective view illustrates the various aspects of the application being in the position of Figure 10A The continuous stages of processing blanks into upright cardboard boxes. Figure 17 A carton forming system; Figure 21 The schematic right perspective view illustrates the various aspects of the application being in the position of Figure 10A The continuous stages of processing blanks into upright cardboard boxes. Figure 17 A carton forming system; Figure 22 The schematic right perspective view illustrates the various aspects of the application being in the position of Figure 10A The continuous stages of processing blanks into upright cardboard boxes. Figure 17 A carton forming system; Figure 23 The schematic right perspective view illustrates the various aspects of the application being in the position of Figure 10A The continuous stages of processing blanks into upright cardboard boxes. Figure 17 A carton forming system; Figure 24 The schematic right perspective view illustrates the various aspects of the application being in the position of Figure 10A The continuous stages of processing blanks into upright cardboard boxes. Figure 17 A carton forming system; Figure 25 The schematic right perspective view illustrates the various aspects of the application being in the position of Figure 10A The continuous stages of processing blanks into upright cardboard boxes. Figure 17 A carton forming system; Figure 26 The elevation view is shown later. Figure 17 Components of a carton forming system; Figure 26A The schematic perspective view is shown. Figure 1A It is part of the folding and sealing equipment of the carton forming system; Figure 27 The schematic right perspective view illustrates the various aspects of the application being in the position of Figure 10A The continuous stages of processing blanks into upright cardboard boxes. Figure 17 A carton forming system; Figure 28 The schematic right perspective view illustrates the various aspects of the application being in the position of Figure 10A The continuous stages of processing blanks into upright cardboard boxes. Figure 17 A carton forming system; Figure 29 The schematic right perspective view illustrates the various aspects of the application being in the position of Figure 10A The continuous stages of processing blanks into upright cardboard boxes. Figure 17 A carton forming system; Figure 30A top right perspective view of a first embodiment of an erector head according to various aspects of this application is shown; Figure 31 yes Figure 30 Side elevation view of the head of the erector; Figure 32 yes Figure 30 A right-angle perspective view of the head of the erector; Figure 33 yes Figure 30 A bottom view of the head of the erector; Figure 34A This is a top right perspective view of a second embodiment of the erector head according to various aspects of this application; Figure 34B yes Figure 34A Right elevation view of the head of the erector; Figure 35A The illustration shows the unpacking stage of the carton blank according to various aspects of this application. Figure 34A The head of the erector; Figure 35B The illustration shows another stage of opening the carton blank according to various aspects of this application. Figure 34A The head of the erector; Figure 35C The illustration shows a further stage of opening the carton blank according to various aspects of this application. Figure 34A The head of the erector; Figure 36 The illustrations show various aspects according to this application. Figure 34A The erector head and the sealing device in the stage of erecting the carton blank to form an upright carton; Figure 37 The illustrations show various aspects according to this application. Figure 34A The erector head and the sealing device in the stage of erecting the carton blank to form an upright carton; Figure 38 The illustrations show various aspects according to this application. Figure 34A The erector head and the sealing device in the stage of erecting the carton blank to form an upright carton; Figure 39 The illustrations show various aspects according to this application. Figure 34A The erector head and the sealing device in the stage of erecting the carton blank to form an upright carton; Figure 40 The illustrations show various aspects according to this application. Figure 34A The erector head and the sealing device in the stage of erecting the carton blank to form an upright carton; Figure 41 The illustrations show various aspects according to this application. Figure 34A The erector head and the sealing device in the stage of erecting the carton blank to form an upright carton; Figure 42 The illustrations show various aspects according to this application. Figure 34A The erector head and the sealing device in the stage of erecting the carton blank to form an upright carton; Figure 43 The illustrations show various aspects according to this application. Figure 34A The erector head and the sealing device in the stage of erecting the carton blank to form an upright carton; Figure 44 The illustrations show various aspects according to this application. Figure 34A The erector head and the sealing device in the stage of erecting the carton blank to form an upright carton; Figure 45 Alternative embodiments of a carton forming system according to various aspects of this application are illustrated in schematic perspective views; Figure 46 The plan view illustrates a cardboard box blank for pallets that can be processed according to various aspects of this application; Figure 47 A perspective view illustrates a cardboard blank for a slotted carton (RSC) for wrapping rules, which can be processed according to various aspects of this application; Figure 48 A perspective view illustrates a cardboard blank for a slotted carton (RSC) for wrapping rules, which can be processed according to various aspects of this application; Figure 49 The perspective view illustrates an HSC box that can be formed according to various aspects of this application; Figure 50 The illustration depicts an action according to one aspect of this application. Figure 1A Alternatives to carton forming systems; Figure 51 The plan view illustrates one aspect of the application. Figure 50 Alternatives to carton forming systems; Figure 52 The locations of order fulfillment according to various aspects of this application are illustrated in a schematic floor plan. Figure 53 The illustration shows a top right perspective view of an example autonomous mobile robot with a trolley carrying an outer box, according to various aspects of this application. Figure 53A The diagram shows... Figure 53 The example autonomous mobile robot is shown in a top-right perspective view, with a transport container added. Figure 54The various aspects according to this application are illustrated in cross-sectional perspective views. Figure 53 Autonomous mobile robots; Figure 55A The cross-sectional view illustrates various aspects according to this application. Figure 53 Part of the outer casing of an autonomous mobile robot; Figure 55B The cross-sectional view illustrates various aspects according to this application. Figure 53 Part of the outer casing of an autonomous mobile robot; Figure 56 A portion of the performance center is illustrated in a schematic floor plan; Figure 56A An embodiment of an order fulfillment center is illustrated in a schematic floor plan. Figure 57 The illustration shows example steps in a method for fulfilling an order according to various aspects of this application; Figure 58 The illustration shows yet another example of an autonomous mobile robot according to various aspects of this application; Figure 59 A schematic plan view illustrates a carton forming system with multiple hoppers according to various aspects of this application. Figure 59 The carton forming system is shown in Figure 1 to... Figure 44 An alternative embodiment of the carton forming system, wherein some components of the hopper are omitted for clarity; Figure 60 The perspective view on the right side illustrates various aspects according to this application. Figure 59 A carton forming system; Figure 60A The enlarged view illustrates various aspects according to this application. Figure 60 This is part of a carton forming system, with additional components shown in the illustration; Figure 61 The illustrations show various aspects according to this application. Figure 59 Rear left perspective view of the carton forming system; Figure 62 The following perspective views illustrate various aspects according to this application. Figure 59 A carton forming system; Figure 63 The following perspective views illustrate various aspects according to this application. Figure 59 Part of the carton forming system; Figure 64 The order fulfillment system according to various aspects of this application is illustrated in schematic diagrams; Figure 65 The illustration shows various aspects that can be implemented according to this application. Figure 64 The sample labels generated and used in the system; Figure 66 The illustration shows various aspects that can be implemented according to this application. Figure 64 Another sample label generated and used in the system; Figure 67 The diagram shows that it can be used Figure 64 Samples of box packaging images generated and used in the system; Figure 68 An example arrangement of a box top seal according to various aspects of this application is illustrated in a left front perspective view; Figure 69 The illustration shows a schematic plan view of the order fulfillment location according to an example embodiment of this application; Figure 70 The illustration shows an example embodiment according to this application. Figure 69 A perspective view of a portion of the product unloading system in the order fulfillment center; Figure 71 The illustration shows an exemplary embodiment according to this application. Figure 69 A floor plan of an embodiment of an order fulfillment center; Figure 72 The diagram shows... Figure 69 A perspective view of multiple boxes in the order fulfillment center is introduced into the site; Figure 73 The diagram shows... Figure 69 A perspective view of the order verification, box sealing, and labeling sites at the order fulfillment center; Figure 74 The diagram shows... Figure 69 A perspective view of the route transit points of the order fulfillment center; Figure 75 The illustration shows a perspective view of a tower that can be used to store products according to an exemplary embodiment of this application; Figure 76 A schematic plan view illustrates an order fulfillment location according to an example embodiment of this application, which can be considered as... Figure 52 Order fulfillment center and Figure 69 The hybrid of order fulfillment centers; Figure 76A An exemplary embodiment according to this application is illustrated in a schematic plan view. Figure 76 The order fulfillment location is shown, and multiple separate areas are also displayed. Figure 77 The illustration shows a robotic pickup arm that can be used in a pallet removal process involving pallets, according to an exemplary embodiment of this application. Figure 78A A side view illustrates an exemplary embodiment of a tape unwinder / stripper end actuator according to this application, which can be coupled with... Figure 77The robotic pickup arm is coupled for depalletization processing; Figure 78B The diagram is shown in top view. Figure 78A End actuator of the tape unwinding machine / tape stripper; Figure 79 A perspective view illustrates a standardized storage box according to an exemplary embodiment of this application; Figure 80 The illustration shows a perspective view of a pallet according to an example embodiment of this application, the pallet being composed of... Figure 79 It is constructed from standardized storage boxes and standardized pallet bases; Figure 81 A perspective view illustrates a stack of structures according to an exemplary embodiment of this application. Figure 53 A perspective view of multiple cargo boxes on an autonomous mobile robot; Figure 82A A schematic plan view illustrates an exemplary embodiment of the present application. Figure 76 Alternatives to order fulfillment centers: order fulfillment locations; Figure 82B A schematic plan view illustrates an exemplary embodiment of the present application. Figure 82A Alternatives to order fulfillment centers: order fulfillment locations; Figure 83 The perspective view illustrates the maintenance of an exemplary embodiment according to this application. Figure 53 Multiple cargo boxes in the structure of an autonomous mobile robot; Figure 84 A perspective view illustrates multiple cargo boxes maintained in another structure of an autonomous mobile robot according to an exemplary embodiment of this application; Figure 85 The illustration shows the layout of a delivery trailer according to an exemplary embodiment of this application; Figure 86 The figure illustrates a customer order processing matrix according to an example embodiment of this application; Figure 87 The diagram illustrates, in schematic form, an order fulfillment center at the center of a supplier network of products to be stored in the order fulfillment center, according to an example embodiment of this application; Figure 88 A general pallet according to an example embodiment of this application is illustrated in the upper right perspective view; Figure 89 The illustration shows a loading of an example embodiment of this application in [the following text is incomplete and requires further context: "in the figure"] Figure 88 The top right perspective view of a stack of generic cartons on a generic pallet.

[0045] Figure 90A plan view illustrates the configuration of a plurality of universal pallets according to an example embodiment of the present application, the plurality of universal pallets being loaded with a plurality of stacked universal cartons arranged in a cell; Figure 91 An elevation view illustrates an example embodiment according to this application. Figure 90 The cell contains multiple universal pallets loaded with multiple stacked universal containers; Figure 91A An elevation view illustrates another cell according to an example embodiment of this application, which includes multiple universal pallets loaded with multiple stacked universal cartons; Figure 92 A floor plan diagram illustrates the configuration of 20 cells according to an example embodiment of this application; Figures 93A to 93H The elevation view illustrates a series of steps in which a product according to an example embodiment of this application is removed from a general cargo box in a cell and loaded into a transport container or receiver; Figure 94A A schematic floor plan illustrates the first layer of an order fulfillment center according to an example embodiment of this application, as... Figure 82B Alternatives to order fulfillment centers; Figure 94B A schematic floor plan illustrates the second layer of an order fulfillment center according to an example embodiment of this application, wherein the first layer of the order fulfillment center is located in... Figure 94A The diagram in the middle; Figure 95 The illustration shows a transport trailer partially filled with universal pallets according to an example embodiment of this application, in the intermediate state of being unloaded into a first order introduction partition of an order fulfillment center, wherein the layers are as follows: Figure 94A and Figure 94B As shown; Figure 96 The illustration shows a configuration for carrying multiple general-purpose pallets according to an example embodiment of this application. Figure 95 A sectional plan view of the transport trailer; Figure 97 The illustration shows a cross-sectional elevation view of a transport trailer according to an example embodiment of the present application, the transport trailer being equipped with inflatable airbags and configured to carry multiple universal pallets; Figure 98 An example embodiment according to this application is illustrated in a sectional rear view. Figure 97 Delivery trailers; Figure 99 A floor plan illustration shows an automated product loading and palletizing process at a production facility according to an example embodiment of this application; Figure 100 The illustration shows an example embodiment according to this application. Figure 99Elevation view of the process; Figure 101 An elevation view illustrates a transport container entry site according to an example embodiment of this application; Figure 102 The diagram illustrates a closed-loop system according to an example embodiment of the present application, in which multiple full and multiple empty general cargo boxes are continuously delivered between an order fulfillment center and a production facility. Figure 103A The illustration shows control components of an example control system at a fulfillment center according to an example embodiment of the present application. The control components are illustrated as including a central control unit, multiple AMR modules, multiple cell modules, and multiple product identification modules. Figure 103B The illustration shows an example embodiment according to this application. Figure 103A Example components of an AMR module in an example control system; Figure 103C The illustration shows an example embodiment according to this application. Figure 103A An example component of a cell module in an example control system; Figure 103D The illustration shows an example embodiment according to this application. Figure 103A An example of components in a central control unit of an example control system, the central control unit being illustrated as including a processing device, a memory, a network interface, and a data storage; Figure 103E The illustration shows an example embodiment according to this application. Figure 103D The data structure for data storage is shown in the diagram; and Figure 103F The illustration shows an example embodiment according to this application. Figure 103D The diagram illustrates the application of data storage. Detailed Implementation

[0046] The idiom "garbage in, garbage out" (often abbreviated as GIGO) is a common phrase in computer science and information technology. It conveys a simple but important principle: the quality of the output or result is determined by the quality of the input data.

[0047] Essentially, if you input inaccurate, incomplete, or low-quality data into a computer system or algorithm, you should expect the output or result to be equally flawed or unreliable. No matter how complex a system's processing capabilities are, if the input data is flawed, the output will likely be flawed as well.

[0048] This principle applies to a wide range of systems, not just computers. It also applies to decision-making, problem-solving, general information processing, and automation. Therefore, to obtain meaningful and reliable results, it emphasizes the importance of ensuring that all inputs are accurate, well-structured, and relevant to the problem being addressed. Chaos refers to an extremely disordered or unpredictable state in a system. The automation industry knows from experience that chaos cannot be fully automated. Chaos theory describes complex systems that are highly sensitive to initial conditions, meaning that small changes in the initial state can lead to drastically different results over time. These systems are nonlinear, and their behavior is difficult to predict precisely.

[0049] Automation involves using machines, computers, and / or algorithms to perform tasks without human intervention. Automation relies on established rules, algorithms, or processes to perform tasks efficiently and consistently. The inherent unpredictability and sensitivity to initial conditions in chaotic systems make them difficult to automate effectively. Because automation depends on predictable and well-defined processes, creating algorithms or machines capable of accurately handling chaotic situations can be considered difficult.

[0050] Providing efficient methods and systems for order fulfillment, particularly based on collecting order items from various types of product storage areas, can present a variety of challenges. Automating the consolidation of products required for order fulfillment can be challenging, especially considering the sheer number of different products a fulfillment center may store and manage. For example, some fulfillment centers may store and manage millions of different products for order fulfillment. Furthermore, there is little control over how products intended for storage at the fulfillment center arrive there.

[0051] Figure 1A , Figure 1B , Figure 2 and Figure 3Examples of carton / box forming systems 100 that can be used as part of a product order fulfillment system are illustrated in various forms and from various angles. The carton forming system 100 may include a frame 109. The frame 109 may have a series of panels 103 integrated therewith, which may be made of plastic or glass and may or may not be transparent or translucent. One or more panels 103 may be configured to operate as hinged doors, allowing access to the interior portions of the carton forming system 100. The carton forming system 100 may also include a hopper 110 adapted to receive, hold, and move multiple carton blanks 111 when they are in a substantially flat state. The carton forming system 100 includes at least a first erector head 120a and a second erector head 120b for removing carton blanks from the hopper 110. The upright heads 120a and 120b can pick up the carton blank 111 from the hopper 110 and then manipulate the carton blank 111 so that, with the assistance of other components of the carton forming system 100, the carton blank 111 is transformed into an upright carton.

[0052] The erector heads 120a and 120b can be moved by a moving subsystem. The moving subsystem may include one or more moving devices. For example, a first erector head 120a may be mounted to and moved by a first moving device 115a. A second erector head 120b may be mounted to and moved by a second moving device 115b. In some embodiments, only a single erector head and moving device may be provided, but this may result in lower productivity of the erected cartons compared to providing multiple, particularly two or more moving devices and erector heads as illustrated in the figures.

[0053] The carton forming system 100 may also include a folding and sealing device 130, which may be configured to fold one or more folds of each carton blank and provide a seal for the one or more folds as part of the process of forming a fully upright carton. Cooperating with the erector heads 120a, 120b, the folding and sealing device 130 may be configured to process the carton blanks 111 carried by both the first erector head 120a and the second erector head 120b in an alternating sequence. The carton forming system 100 may also include a carton unloading conveyor 117 for receiving the carton blanks 111 and removing them after they are fully upright.

[0054] The structural / mechanical components of the carton forming system 100 can be made of any suitable material. For example, the frame members and many parts that make up the erector heads 120a, 120b, the moving parts 115a, 115b, the folding and sealing device 130, and the hopper 110 can be made of steel or aluminum, or any other suitable material. Aluminum is particularly suitable for most parts. However, the plate that holds the suction cups on the erector head and the flange mounted on the gearbox shaft can be made of stainless steel to improve strength and rigidity. Parts and components can be attached together in conventional ways, such as, for example, by bolts, screws, welding, etc.

[0055] exist Figure 1B The diagram illustrates an example of a power and data / communication configuration scheme for a carton forming system 100. The operation of the components of the carton forming system 100, as well as the overall operation of the carton forming system 100, can be controlled by a programmable logic controller (“PLC”) 132. The PLC 132 can be accessed by a human operator via a human-machine interface (HMI) module 133 mounted on a frame 109. The HMI module 133 can communicate electronically with the PLC 132. The PLC 132 can be any suitable PLC and can, for example, include units selected from the Logix 5000 series devices manufactured by Allen-Bradley / Rockwell Automation, such as the ControlLogix 5561 device. The HMI module 133 can be a Panelview part number 2711P-T15C4D1 module, also manufactured by Allen-Bradley / Rockwell Automation. It should be noted that not all sensors, motors, servo motors, drive devices, vacuum units, vacuum generators, and vacuum suction cups are included. Figure 1B It is specifically marked in the text.

[0056] Electrical power can be supplied to the PLC 132 / HMI 133 and all kinds of servo motors and DC motors, which will be described further herein. Compressed / pressurized air can also be supplied to the vacuum generator and pneumatic actuators via valve devices such as solenoid valves controlled by the PLC 132, all of which will be described further herein. Servo motors can be connected to and communicate with servo drives, which in turn communicate with and are controlled by the PLC 132. Similarly, DC motors can be connected to and controlled by DC motor drives that communicate with and are controlled by the PLC 132; again, all of which will be described further herein. Additionally, various other sensors communicate with the PLC 132 and can also (although not shown) be supplied with electrical power.

[0057] Now for reference Figures 10A to 10E and Figure 11 A describes an example of a tubular carton blank 111 that can be processed by system 100 to form a regular slotted carton (RSC). It should be clear that system 100 can process other types of carton blanks, tubular carton blanks, and tubular carton blanks of different sizes.

[0058] like Figure 10A , Figure 10B , Figure 10C , Figure 10D , Figure 10E As shown, each carton blank 111 can generally be initially formed and provided in a flattened tubular configuration. Each carton blank 111 has a height dimension "H"; a length dimension "L"; and a main panel length "Q" (see Figure 1). Figure 10A Each of the three dimensions of a given carton blank 111 processed by the carton forming system 100 is input into the PLC 132. In response to these input data, the PLC 132 can determine whether the carton forming system 100 is capable of processing the given carton blank 111 without manual intervention to adjust one or more components of the carton forming system 100. If the PLC 132 determines that adjustments can be made without manual intervention, the PLC 132 can make necessary adjustments to the position and / or movement of at least some of the components forming the carton forming system 100, including adjustments to the movement paths of the erector heads 120a, 120b as the erector heads move and throughout their processing sequence.

[0059] However, in some carton forming systems 100, for carton blanks 111 of certain sizes, PLC 132 can determine that some type of human intervention can facilitate setting and adjusting the positioning / orientation of at least some of the components of the system 100, thereby enabling the carton forming system 100 to process the carton blank 111, and thus notifying the operator of the carton forming system 100.

[0060] The carton blank 111 may have opposing main panels A and C, which are integrally interconnected to a pair of opposing secondary panels B and D to form a generally cuboid blank when opened. An overlap strip of carton blank material may be provided between panel B and panel A, which may be sealed by conventional means such as a suitable adhesive to provide an overlap seam connection near “P” (see [link to documentation]). Figure 10A This overlap can connect plates A, B, C, and D as follows: Figure 10A The diagram shows a continuous blank typically having a flattened tubular configuration. Multiple such carton blanks 111 in this flattened configuration can be delivered to the vicinity of a carton forming system 100, which can erect the carton blanks 111 into, for example... Figure 11The generally open tubular configuration is shown in the figure.

[0061] In addition, such as Figures 10A to 10E and Figure 11 As shown, the carton blank 111 may have a first set of upper main folds and secondary folds E, H, L, I provided on one side of the respective main panels and secondary panels A, B, C, D. A second set of main folds and secondary folds F, G, K, and J are also provided on the opposite lower / bottom sides of the main panels and secondary panels A, B, C, D. It is worth noting that in other embodiments, cartons with other side panel configurations can be formed. Panels and folds can be connected to adjacent folds and / or panels by predetermined fold lines / crease lines (shown in dashed lines). These fold lines / crease lines can be formed, for example, by weakened areas of material and / or creases formed by crease forming equipment. The function of the fold lines is to allow a panel such as, for example, panel A to rotate relative to an adjacent panel such as, for example, panel D or panel B, along the fold line. Folds can also be folded and rotated about the fold lines that connect the folds to their respective panels.

[0062] like Figure 11 As shown, a first reference line "W1" can be specified for the carton blank 111. This first reference line "W1" passes through the midpoint of the fold line between panel D and fold plate K, and the midpoint of the fold line between panel B and fold plate J. Based on the input dimensions H, L, and Q of the carton blank 111, PLC 132 can determine the first reference line W1 for a specific carton blank 111 or a group of carton blanks 111 to be processed. A second reference line "W2" can be specified for the carton blank 11. This second reference line "W2" can be determined by PLC 132 and extends along the fold line between panel A and fold plate F, and is generally parallel to the fold line between panel A and fold plate F. The first reference line W1 will be parallel to the second reference line W2. PLC 132 can also determine the relative position of the bottom of the upright carton, as this will be aligned with a vertical reference plane passing through the first reference line W1 and the second reference line W2. The position of the second reference line W2 and the position of the reference plane can be shown to be aligned with other components in the carton forming system 100 to ensure that the carton is correctly positioned during processing by the system 100. Furthermore, the vertical distance R between the first reference line W1 and the second reference line W2 can be calculated by the PLC 132. This calculation ensures that the PLC 132 knows where it needs to position the erector head so that the top plate A and the corresponding first reference line W1 are correctly positioned throughout the entire process of the carton forming system 100 processing the blank.

[0063] As the carton blank 111 moves longitudinally through the carton forming system 100, and as the various components of the carton forming system 100 engage the carton blank 111 during its movement, the carton forming system 100 can be shown as capable of tracking and modifying the position of the carton blank 111, particularly the vertical position of the first reference line W1 of the carton blank 111. This can be shown as ensuring that the carton blank 111 being processed is properly positioned relative to its associated system components, such that the system components engage the carton blank 111 at appropriate positions on the carton blank 111 during its processing.

[0064] As will be described below, the carton blank 111 can be converted from a generally flattened tubular configuration to an open tubular configuration, and the folds can be folded and sealed to form the desired upright carton configuration. The upright carton can be configured as a top-opening carton, suitable for being delivered to a carton loading conveyor with an upward-facing opening or a side-facing opening suitable for side loading.

[0065] The carton blank 111 may have folds, the material of which may be combined with connecting mechanisms (such as, for example, the application of adhesives, sealing tapes or mechanical connections, such as those provided in so-called "Klick-lok™" carton blanks) to interconnect the surfaces of the folds to link or otherwise interconnect the folds to adjacent folds (or, in some embodiments, link the folds to a panel) to hold the carton in its desired upright configuration.

[0066] The carton blank 111 can be made of any suitable material(s) configured and adapted to allow for desired folding / bending / displacement of the material to achieve a desired configuration. Examples of suitable materials include particleboard, cardboard, or corrugated fiberboard. It should be noted that the carton blank 111 can be formed from a material that is rigid or semi-rigid and not easily folded, but which is divided into separate panels and folds by creases or hinge-type mechanisms, so that the carton blank 111 can be erected and formed.

[0067] The components of the carton forming system 100 will now be described, in which various specific configurations of the suitable hopper 110 can be employed. Now, in particular, refer to... Figure 3 , Figure 6A , Figure 6B , Figure 6C , Figure 6D and Figure 7The hopper 110 can be configured to hold a plurality of carton blanks 111 stacked vertically in a flattened configuration, and is operable to move the stacked carton blanks 111 longitudinally in a direction generally parallel to the longitudinal axis Y under the control of the PLC 132 to a pick-up position, at which the first erector head 120a or the second erector head 120b can retrieve the carton blanks 111 from the hopper 110.

[0068] The hopper 110 may include a single conveyor or other blank feeding device configured to deliver carton blanks 111 to a pick-up position. Figures 1A to 9 In the embodiment illustrated in the figure, two conveyors are disclosed: a feed conveyor 204 and an alignment conveyor 206. However, as will be described below with respect to other embodiments, the blank feeding device may be configured with multiple feed conveyors to feed carton blanks 111 from multiple hoppers holding carton blanks 111 with different configurations. This enables the carton forming system 100 to automatically, selectively and sequentially erect cartons of different sizes, types, and / or configurations.

[0069] Return to Figures 1A to 9 In the carton forming system 100, a feed conveyor 204 can be configured and operable to move stacked carton blanks 111 from a stacking input position (where the stacked carton blanks can be loaded onto the feed conveyor 204, for example, by manual or robotic placement) to a position where the stacked carton blanks 111 are transferred to an alignment conveyor 206 that is horizontally and laterally aligned. The alignment conveyor 206 can be longitudinally positioned downstream of the feed conveyor 204 and can be used to move the stacked carton blanks 111 to a pick-up position. A hopper 110 can load and initially hold a large number of vertically stacked carton blanks 111 resting on the feed conveyor 204. The rear wall 212 is mounted to the lower part of the hopper frame, generally indicated by 202. The rear wall 212 can be configured to prevent one or more stacks of carton blanks 111 from falling backward when initially loaded onto the feed conveyor 204. The rear wall 212 can have a generally flat, vertically and laterally oriented surface facing the stacked carton blanks 111. The rear wall 212 and the feed conveyor 204 can have appropriate lengths to allow for the continuous storage of a satisfactory number of stacked carton blanks 111 on the feed conveyor 204. The PLC 132 can control the operation of the feed conveyor 204 to move one stack at a time to the alignment conveyor 206.

[0070] The feed conveyor 204 may have one or more stacks of carton blanks 111 arranged longitudinally on the feed conveyor belt 214, such that they can be sequentially fed onto the alignment conveyor 206. A sensor may be provided near the feed conveyor 204 to monitor the number of stacks waiting on the feed conveyor 204, and this sensor may be operable to send a warning signal to the PLC 132 to alert the operator that the hopper 110 is low and needs to be replenished (e.g., because the stack handled by the erector head 120 is the only remaining stack on the alignment conveyor 206). This sensor may be a sensor manufactured by Allen-Bradley with part number 42GRP-9000-QD.

[0071] Of particular note is that multiple stacks of carton blanks 111 can be provided on the feed conveyor 204. Each stack may contain some kind of information indicator, which can be read by an information reader such as an electronic or optical reading device. For example, a barcode may be provided on the stacked carton blanks 111, such as on the top or bottom carton blanks 111 of the stack. The barcode can be read by a properly positioned barcode reader. The barcode reader may communicate with the PLC 132. The barcode can provide information indicating the characteristics of the carton blanks 111 in the stack. For example, the barcode may indicate the size and / or type of the carton blanks 111 in a particular stack. Other information indicators and reading systems may be used, such as, for example, radio frequency identification (RFID) tags / chips and RFID readers. The information can then be automatically provided to the PLC 132 by the information reader. The PLC 132 can determine whether the current configuration of the carton forming system 100 is capable of handling the specific type / size of the carton blank 111 without manual adjustment of any components. It has been considered that, within a certain range of carton blank types / sizes, the carton forming system 100 can handle different types / sizes of carton blanks 111 without manual adjustment of any components of the system 100. As discussed above, the barcode / RFID tag can provide information about the dimensions of the carton blank 111, and then the PLC 132 can determine the following adjustments that may be made (if any): (a) operation of the erector device; (b) the hopper 110 and the compaction device within the hopper 110; (c) providing a suitable path for the movement of the mobile subsystem to properly pick up the blank from the hopper and to handle it appropriately by the erector device and the folding and sealing device; and (d) the ability of the components of the folding and sealing device to handle a specific carton blank 111 or a specific stack of carton blanks 111. As a result, the carton forming system 100 is able to automatically handle at least some different types / sizes / configurations of carton blanks 111 to form different upright cartons without requiring manual operator adjustments to any components of the carton forming system 100.

[0072] The feed conveyor 204 may include a series of laterally and horizontally oriented rollers 210 mounted to the lower part of the hopper frame 202 for free rotation. The rollers 210 allow the stack to move generally horizontally and longitudinally downstream toward the alignment conveyor 206. A feed conveyor belt 214 may be provided, and the feed conveyor belt 214 may be driven by a motor such as a DC motor or a frequency converter (see [link to relevant documentation]). Figure 1B The feed motor 291 is a suitable feed motor. The feed motor 291 can be a DC motor and can be controlled by a PLC 132 via a DC motor driver (all sold by Oriental as model AXH-5100-KC-30).

[0073] The feed conveyor belt 214 may have an upper belt portion supported on rollers 210. Once the PLC 132 is given an instruction (such as by a human operator via HMI module 133), the upper belt portion of the feed conveyor belt 214 can be moved longitudinally downstream toward the alignment conveyor 206. In this way, the feed conveyor belt 214 can move stacked carton blanks 111 longitudinally downstream, wherein the lateral outer portions of the stacked carton blanks 111 are supported on rollers 210. The PLC 132 can control the feed motor 291 via a motor driver, and therefore, the feed conveyor 204 can be operated to move and transfer the stack toward and onto the alignment conveyor 206.

[0074] The alignment conveyor 206 may also include a series of laterally oriented rollers 208 mounted for free rotational movement to the lower part of the hopper frame 202. The alignment conveyor belt 216 may be driven by an alignment motor 292, which may be similar to the feed motor 291 and have a corresponding motor driver. The alignment motor 292 may also be controlled by a PLC 132. The alignment conveyor belt 216 may be equipped with an upper belt portion supported on the rollers 208, and stacked carton blanks 111 may be supported on this upper belt portion. The feed conveyor belt 214 may be operated to further longitudinally move the stacked carton blanks 111 until the front face of the stack abuts the generally flat, vertically and laterally oriented inward surface of the front end wall 218.

[0075] The feed conveyor belt 214 of the feed conveyor 204 and the alignment conveyor belt 216 of the alignment conveyor 206 can be made of any suitable material such as Ropanyl.

[0076] A gap sensor 242, such as the Allen-Bradley model 42KL-D1LB-F4, can be positioned within the horizontal gap between the feed conveyor belt 214 and the alignment conveyor belt 216. The gap sensor 242 can be positioned and operated to detect the presence of the leading edge of the stacked carton blank 111 when it begins to move across the gap between the feed conveyor belt 214 and the alignment conveyor belt 216. Upon detecting this leading edge, the gap sensor 242 can send a digital signal to the PLC 132 (see [link to PLC 132]). Figure 1BThis signal indicates that the stack has moved to a position where the alignment conveyor 206 can begin to move. The PLC 132 then activates the alignment motor 292 of the alignment conveyor 206, causing the top portion of the alignment conveyor belt 216 to begin moving the stack downstream. In this way, the carton blanks 111 of the stack can be "transferred" from the feed conveyor 204 to the alignment conveyor 206.

[0077] Once the rear edge of the stacked blanks 111 has passed the gap sensor 242, a signal can be sent to PLC 132 (see [link]). Figure 1B In response, PLC 132 sends a signal to shut down the feed motor 291 of the feed conveyor belt 214 that drives the feed conveyor 204. The feed conveyor 204 is then in a state ready to load another stack of blanks 111. Meanwhile, the alignment conveyor belt 216 can continue to operate as it moves the stacked carton blanks 111 to the pick-up position.

[0078] The presence of stacked carton blanks 111 at the pick-up position can be detected by a presence sensor 240, which can be a sensor of the same type as the gap sensor 242. The presence sensor 240 can detect the presence of the leading edge of the stacked carton blanks 111 at the pick-up position and can send a digital signal to the PLC 132, thereby notifying that a stack of carton blanks is in the pick-up position. At this pick-up position, the stacked carton blanks 111 can be "aligned," and thereafter, once correctly aligned, individual carton blanks 111 can be sequentially retrieved from the stack by alternating engagement of the erector heads 120a, 120b with the topmost carton blank 111 in the stack.

[0079] The hopper 110 can be configured and operable such that stacked carton blanks 111 can be properly positioned and oriented at the pick-up position so as to be properly engaged by one of the erector heads 120a, 120b. During the longitudinal movement of the stacked carton blanks 111 via the feed conveyor 204 and the alignment conveyor 206, the left-hand side of the stacked carton blanks 111 can be supported and guided by a left-hand side guide wall 200. The left-hand side guide wall 200 can be mounted to the lower part of the lower frame 202 and can be oriented substantially vertically and can extend longitudinally for substantially the entire length of the feed conveyor 204 and the alignment conveyor 206.

[0080] The right side of the hopper 110 adjacent to the feed conveyor 204 can remain generally open; however, a right-side guide wall 201 can be provided on the right side aligned with the conveyor 206.

[0081] exist Figures 6A to 6DThe diagram illustrates in more detail the possible installation arrangements of the left-hand guide wall 200 and the right-hand guide wall 201. In this regard, the lower frame portion 202 may include bottom support plates 251, 255, 259, and 263 supported on the ground terrain / floor, wherein the bottom support plates 251, 255, 259, and 263 are spaced apart from each other and oriented in a generally laterally parallel relationship. Each of the support plates 251, 255, 259, and 263 has one of the tracks 253, 257, 261, and 265 respectively mounted on its upper surface. The left-hand guide wall 200 may be supported by a connector block 267, which is adapted to and slid laterally on and relative to the tracks 253 and 261. Similarly, the right-hand side guide wall 201 can be supported by a connector block 269, which is adapted to the tracks 257 and 265 and can slide laterally relative to the tracks 257 and 265.

[0082] A drive mechanism can be provided to drive each of the left-hand guide wall 200 and the right-hand guide wall 201 on their respective tracks. For the left-hand guide wall 200, a drive mechanism that communicates electronically with a PLC 132 can be provided. For example, a servo motor 258 with a geared head (see...) can be provided. Figure 1B Furthermore, the servo motor 258 communicates electronically with the PLC 132 via a servo driver. An example that can be used is a servo motor MPL-B1530U-VJ42AA manufactured by Allen-Bradley, combined with a servo driver 2094-BC01-MP5-S also manufactured by Allen-Bradley and a gear head AE050-010 manufactured by Apex for the MPL-A1520.

[0083] Lead screw 262 can be interconnected to servo motor / gear head 258. Lead screw 262 can pass through a nut, such as brass nut 264. Brass nut 264 can be securely fixed to plate 293. Plate 293 can be interconnected with spaced-apart, generally vertically oriented rod members 294. Rod members 294 can be interconnected to support a frame (not shown) forming part of the left-hand side guide wall 200. By activating servo motor / gear head 258, rotation of the servo motor can rotate lead screw 262. When lead screw 262 passes through nut 264, nut 264 moves inward or outward to the ground, thereby causing left-hand side guide wall 200 to slide inward or outward on tracks 252, 261 depending on the direction of rotation of lead screw 262. An encoder can be provided within or associated with servo motor 258, and the encoder can rotate with the rotation of the corresponding drive shaft of the servo driver. The encoder can communicate with and provide signals to the servo drive, which can then transmit the information to the PLC 132. Therefore, the PLC 132 can determine the longitudinal position of the screw 262 in real time, and consequently, the lateral position of the left-hand guide wall 200, and can operate the servo motor 258 to adjust the position of the left-hand guide wall 200. A specific type of encoder that can be used is called an "absolute" encoder. Once the encoder is calibrated so that the position of the screw 262 is "zeroed," the encoder can maintain its zero-position calibration even if the carton forming system 100 is powered off. However, since the left-hand guide wall 200 does not move during the processing of the carton blank 111, alternatively, the mechanism for adjusting the lateral position of the left-hand guide wall 200 can be a simple manual crank mechanism, rather than a servo drive motor communicating with the PLC 132. It should be noted that the correct position of the left-hand guide wall 200 during the processing of the stacked carton blanks 111 is as follows: Figure 7 As shown, the left-hand side guide wall 200 is adjacent to the left edge of each stacked carton blank 111. The correct positioning of the left-hand side guide wall 200 can be shown to ensure that when the blank is flattened, the first reference line W1 is correctly laterally aligned so that it can be picked up by the erector heads 120a, 120b and moved through the folding and sealing device 130, as described in detail below, to achieve proper folding and sealing of the carton blank 111 into the upright carton.

[0084] Similarly, for the right-hand guide wall 201, a drive mechanism 260 that also communicates electronically with the PLC 132 can be provided (which may be the same type of component used for the left-hand guide wall 200). For example, a servo motor with a gear head, referred to as "drive mechanism 260," can be provided, and this servo motor also communicates electronically with the PLC 132 via a servo driver. A lead screw 266 can be interconnected to the servo motor / gear head 266 (which may be, for example, servo motor / gear head 268). The lead screw 266 can pass through a nut, such as a brass nut 264 (not visible in the figure). The nut can be securely fixed to a plate 295. The plate 295 can be interconnected with spaced-apart, generally vertically oriented rod members 296. The rod members 296 can be generally indicated by 271 (see Figure 295). Figure 6C The right-hand side guide wall 201 is part of a side wall support frame interconnected. By activating the drive mechanism 260, the rotation of the servo mechanism can rotate the screw 266. Because the screw 266 passes through the nut, the nut moves inward or outward towards the ground, causing the right-hand side guide wall 201 to slide on the tracks 257, 265. An encoder can be provided within or associated with the drive mechanism 260, and the encoder can rotate in association with the rotation of the corresponding drive shaft of the servo motor. The encoder can communicate with the servo driver and therefore provide signals to the PLC 132. Therefore, the PLC 132 can determine the longitudinal position of the screw 266 in real time, and thus, the lateral position of the right-hand side guide wall 201. Therefore, the PLC 132 can operate the drive mechanism 260 to adjust the position of the right-hand side guide wall 201. An "absolute" encoder can also be used in this application.

[0085] During the operation of the carton forming system 100 for uprighting the carton, the left-hand guide wall 200 can remain stationary, but the right-hand guide wall 201 can move laterally as part of the blank stacking alignment process, thereby providing generally longitudinal alignment of the side edges of the stacked carton blanks 111 when the carton blanks 111 are held between the left-hand guide wall 200 and the right-hand guide wall 201.

[0086] The lateral compaction device can be fixed to the right-hand side guide wall 201 and can be used to affect the lateral alignment of the front and rear edges of the stacked carton blanks 111, that is, the front and rear edges of the stacked carton blanks 111 are substantially aligned with the vertical axis Z, such as... Figure 7As shown. The lateral compaction device, generally indicated by 275, may include horizontally and longitudinally oriented support plates 270, which can be attached at either end to vertical members of a sidewall support frame 271. Block rails 272 may be attached to the outer surface of the horizontally and longitudinally oriented support plates 270. A slider 273 is fixed to the block rails 272 for longitudinal sliding movement along the block rails 272. A pair of upright support plates may be attached to the sliders 273, with the upper ends of the support plates fixed to a double-acting pneumatic actuator 276, such as part #170927 of model DFM-25-80-PA-KF manufactured by Festo. The double-acting pneumatic actuator 276 may have one or more piston arms (because the piston arms are retracted, so in Figure 6B and Figure 6C (Not visible in the image). The piston arm of the double-acting pneumatic actuator 276 can reciprocate between a retracted position and an extended position—rearward and forward in the longitudinal direction. (Reference) Figure 1B The pneumatic actuator can be supplied with pressurized air via an electro-solenoid valve, causing the piston arm to retract and extend. The solenoid valve can be a Festo-manufactured model CPE14-M1Bh-5J-1 / 8, controllable by a PLC 132. Alternatively, a linear servo drive system—similar to the system described in combination with the movement of the left-hand guide wall 200 and the right-hand guide wall 201—can be provided for the double-acting pneumatic actuator 276. Such a servo drive system can be controlled by a PLC 132. The PLC 132 can adjust both the left-hand guide wall 200 and the right-hand guide wall 201, as well as the movement of the double-acting pneumatic actuator 276 for lateral compaction, so that the hopper 110 can be automatically adjusted to handle various sizes of carton blanks 111.

[0087] It should be noted that during the operation of the carton forming system 100 to erect the carton, the slider 273 does not move along the block track 272. The slider 273 and the components directly or indirectly attached thereto, including the double-acting pneumatic actuator 276, can be shown as not moving longitudinally during operation. However, when processing carton blanks 111 of a specific size, the longitudinal position of the slider 273 can be adjusted during the setup of the carton forming system 100.

[0088] Attached to the end of the piston arm of the double-acting pneumatic actuator 276 is a transverse plate 278 that can pass through a longitudinally extending slot 279 through the right-hand side guide wall 201. The end of the transverse plate 278 away from the piston arm attachment is attached to a vertical tamping plate 280, which is laterally positioned inward from the inner surface of the right-hand side guide wall 201. Retraction of the piston arm of the double-acting pneumatic actuator 276 causes the transverse plate 278 to engage with the rear edge of the stacked carton blanks 111, and the front and rear edges of the carton blanks 111 can be laterally aligned when the front edges of these carton blanks 111 are pushed against the inner surface of the front end wall 218. Although the actuator 276 is illustrated as pneumatic, it should be understood that other non-pneumatic alignment devices can be used. For example, a linear servo drive communicating with a PLC 132 can be employed. As can be seen, the linear servo drive will perform the same function as the double-acting pneumatic actuator 276, but the linear servo drive can electronically position the vertical tamping plate 280, and therefore the operator does not need to manually adjust the vertical tamping plate 280 during system setup.

[0089] Through the operation of PLC 132 and the correct adjustment of the right-hand side guide wall 201 and the vertical tamping plate 280, the carton blank 111 can be precisely moved to a known pick-up position, and the orientation of the carton blank 111 can be "aligned" to be a stacked blank against the front end wall 218, thus ensuring that the carton blank 111 is in the correct position engaged by the upright heads 120a and 120b.

[0090] Specifically, once the stacked carton blanks 111 have substantially reached the pick-up position, PLC 132 can send a signal to drive mechanism 260 to cause drive mechanism 260 to move the right-hand side guide wall 201 laterally inward toward the side of the stacked carton blanks 111. PLC 132 can be shown as causing drive mechanism 260 to move a sufficient distance to cause the edges of carton blanks 111 to contact the longitudinally aligned inner surface of the right-hand side guide wall 201 along their length. However, PLC 132 does not cause the right-hand side guide wall 201 to move to the extent that it forms a force on the stacked carton blanks 111 that causes the carton blanks 111 to bend and / or be damaged. It can be seen that such damage occurs in response to the carton blanks 111 being compressed to a significant degree between the left-hand side guide wall 200 and the right-hand side guide wall 201. PLC 132 is able to do this by using the included dimension H of the carton blanks 111 that has been input into PLC 132 (see...). Figure 10AThe size of the right-hand guide wall 201 is used to determine how much it is moved toward the left-hand guide wall 200. For different sizes of carton blanks 111, the amount of slight compression can be fine-tuned, for example, through trial and error. It should be noted that for many sizes of carton blanks 111, the manufacturers of the carton blanks 111 follow industry standard carton sizes.

[0091] Once longitudinal alignment is achieved via movement of the right-hand side guide wall 201, the double-acting pneumatic actuator 276 of the PLC 132 is activated, causing the vertical tamping plate 280 to engage the rear edge of the stacked carton blanks 111. The PLC 132 can cause the drive mechanism 260 to move a sufficient distance to cause the rear edges of the carton blanks 111 to contact the laterally aligned inner surface of the vertical tamping plate 280 along their length. However, it can be observed that the amount of retraction of the piston arm does not cause the vertical tamping plate 280 to move to the extent that the force generated by the retraction on the stacked carton blanks 111 would cause the carton blanks 111 to bend and / or be damaged. It is noteworthy that excessive compression of the carton blanks 111 between the vertical tamping plate 280 and the front end wall 218 may result in bending and / or damage. Proper manual positioning and securing, for example by tightening the screws that pass through the slider 273 for proper positioning, can fix the double-acting pneumatic actuator 276 at a proper longitudinal position on the block track 272.

[0092] To recap, the double-acting pneumatic actuator 276 can straddle the left-hand side guide wall 200. For a specific size / shape of carton blank 111, the double-acting pneumatic actuator 276 can be manually adjusted in the front-rear direction so that when the double-acting pneumatic actuator 276 retracts, the vertical tamping plate 280 is in the correct position to push the carton blank 111 against the front end wall 218 without squeezing the carton blank 111.

[0093] The sliding assembly containing the double-acting pneumatic actuator 276 may also have a pointer or indicator, and may have a digital scale on the fixed part of the hopper 110 to assist in quickly and manually adjusting the double-acting pneumatic actuator 276 to the correct position on the block track 272 of a known carton size.

[0094] To recap, the example steps in the compaction sequence used to ensure that the carton blank 111 is correctly positioned at the pick-up location include the following steps: 1. Under the control of PLC 132, the right-hand side guide wall 201 is extended wide enough so that even if the stacked carton blanks 111 are not aligned and / or the stacked carton blanks 111 are not fully aligned with each other and are not fully aligned with respect to the X-axis and Y-axis, the stacked carton blanks 111 can still enter the alignment conveyor 206.

[0095] 2. Align the stacked carton blanks 111 with the conveyor belt 216 and advance them until the carton blanks 111 are adjacent to the front end wall 218.

[0096] 3. The double-acting pneumatic actuator 276 extends, and then the right-hand side guide wall 201 retracts to contact the side of the stacked carton blanks 111, and presses the right-hand side guide wall 201 toward the left-hand side guide wall 200. This aligns the carton blanks 111 such that the side edges of the carton blanks 111 are aligned with each other and with the longitudinal sidewalls of the left-hand side guide wall 200 and the right-hand side guide wall 201.

[0097] 4. The double-acting pneumatic actuator 276 can retract and then the vertical tamping plate 280 presses the stacked carton blanks 111 forward, thereby aligning the stacked carton blanks 111 so that the front and rear edges of the carton blanks 111 are vertically aligned with each other and with the inner surface of the vertical tamping plate 280 and the inner surface of the front end wall 218.

[0098] 5. The carton blank 111 is then correctly positioned so that the upright heads 120a, 102b can begin picking up the blank from the stack.

[0099] Turning now to other components of the carton forming system 100, in order to remove the blank from the hopper 110, at least a first engagement device may be provided to engage the panel of the carton blank 111, and thus hold and move the blank. In the case that the carton blank 111 is a tubular blank, the carton forming system 100 may provide a first engagement device for engaging one panel (e.g., panel A) of the carton blank 111, and the carton forming system 100 may provide a second engagement device for engaging a second panel (e.g., panel B) of the carton blank 111. The first and second engagement devices may include one or more suction cups for providing suction to the panels generally perpendicular to the surfaces of the panels being engaged, as described further below. Other suitable types of engagement devices may be employed. The first and second engagement devices may be rotatable relative to each other, such that the first panel may be rotatable relative to the second panel. The first and second engagement devices may be mounted to a common erector head.

[0100] refer to Figure 7The carton forming system 100 may be equipped with a movement subsystem, which may be implemented as a pair of moving devices, each of which supports and moves one of the erector heads 120a, 120b. Each of the erector heads 120a, 120b may have a dedicated, independently driven and controlled moving device. Thus, the first erector head 120a may be supported and moved by the first moving device 115a. Similarly, the second erector head 120b may be supported and moved by the second moving device 115b. The first moving device 115a may be constructed in substantially the same manner as the second moving device 115b. The first moving device 115a may be configured as a mirror image of the second moving device 115b. In this way, the first moving device 115a can support the first erector head 120a from the right-hand side and the second moving device 115b can support the second erector head 120b from the left-hand side, so that the erector heads 120a, 120b can both move along a common longitudinal and vertical path. The common path of the erector heads 120a and 120b can be substantially located on or parallel to the path parallel to the path. Figure 7 The vertical axis Z and the longitudinal axis Y are cyclic paths in the plane. Therefore, the movement of the erector heads 120a and 120b can be limited to the vertical direction Z and the longitudinal direction Y (i.e., parallel to the plane). Figure 7 In the directions of the Z-axis and Y-axis, and in the lateral direction X (i.e., parallel to the direction of the Z-axis and Y-axis), and in the lateral direction X (i.e., parallel to the direction of the Z-axis and Y-axis). Figure 7 There may be no substantial movement in the direction of the X-axis. If the movement of the erector heads 120a and 120b is limited to the Z and Y directions, the mobile device in each direction can be constructed to be relatively less complex than if movement in all three directions is required.

[0101] The movement of the erector heads 120a and 120b via the corresponding mobile devices 115a and 115b can be synchronized, allowing the erector heads 120a and 120b to travel along the same longitudinal and vertical paths while moving out of phase with each other, so that one erector head does not interfere with the other, as will be further described below. Therefore, the relative positions of the two erector heads 120a and 120b can be arranged such that the erector heads 120a and 120b do not collide with each other or otherwise interfere with each other during operation of the carton forming system 100.

[0102] This document will only describe the detailed construction of the second mobile device 115b. It will be understood that the first mobile device 115a can be constructed in a substantially identical manner to a mirror image of the second mobile device 115b. Special References Figure 4 , Figure 5 , Figure 7 , Figure 8 , Figure 9 and Figure 17 The second moving device 115b may include a vertical moving device and a horizontal moving device. The vertical moving device may include a generally hollow, vertically oriented support tube 169 with a generally rectangular cross-section. The support tube 169 may be formed from a single tubular material piece, or may be shaped into opposing, vertically extending and oriented surfaces 164, 165, 166, and 168 that can be interconnected using conventional mechanisms such as bolts or welding. The support tube 169 may be fixed to a horizontally extending support plate 182. The horizontally extending support plate 182 may be interconnected with a vertically extending support plate 180. The bottom of the vertically extending support plate 180 may be interconnected to the lower end of the support tube 169 via a series of angled plates 183.

[0103] A freely rotatable "b" pulley 155b can be installed at the upper end of the support tube 169. At the bottom end of the vertically extending and oriented surfaces 164, 166, the second erector head 120b can be securely attached to the support tube 169 by means of a horizontally extending mounting plate. The horizontally extending mounting plate can be connected to the support tube 169. The support tube 169 can engage with a pair of spaced-apart mounting blocks 190a, 190b, which can be connected with bolts passing through bolt holes 191a, 191b in the mounting blocks 190a, 190b. The bolt holes 191a, 191b can also pass through the mounting plate at the bottom of the support tube 169. Therefore, when the second erector head 120b is interconnected with the support tube 169, the second erector head 120b can be seen moving in space together with the support tube 169.

[0104] To support the support tube 169 and the second erector head 120b connected thereto, and to facilitate horizontal movement of the support tube 169 and the second erector head 120b, a horizontal movement device can be provided. The horizontal movement device may include a sliding block 158, which can be moved horizontally using a guide rail system. The horizontal movement device can provide a pair of spaced-apart, longitudinally and horizontally extending short internal blocks, each internal block fitting onto a longitudinally extending guide rail 160, 162 that firmly supports the internal block but allows the internal block to slide horizontally relative to the longitudinally extending guide rail 160, 162. An example of a suitable guide rail system is a steel Bosch Rexroth ball bearing guide system, with ceramic balls inside the block to allow the block to slide on the guide rail. The longitudinally extending guide rails 160, 162 are generally horizontally oriented and can be attached to the frame 109. Sliding block 158 can be mounted to longitudinally extending guide rails 160, 162 for horizontal sliding along the longitudinally extending guide rails 160, 162. Fixed to the front surface of sliding block 158 are four freely rotatable pulleys: "a" pulley 155a; "c" pulley 155c; "d" pulley 155d; and "f" pulley 155f. As described below, a drive belt can be shown surrounding these four freely rotatable pulleys. Sliding block 158 can also use a guide rail system to allow support tube 169 to be connected to sliding block 158 and also to move vertically relative to sliding block 158. Therefore, vertically and longitudinally extending guide rails can extend vertically along the rear surface of support tube 169. The support block can have a slider interconnected with the vertical guide rail on support tube 169. Therefore, support tube 169 can slide horizontally relative to sliding block 158. Similarly, the suitable guide rail system is the Bosch Rexroth ball guide rail system mentioned above.

[0105] A drive device may also be provided to drive the horizontal and vertical moving parts. For example, the drive device may include a pair of drive motors interconnected to a drive belt, which in turn interconnects to the horizontal and vertical moving parts. For instance, the drive device may include a left-belt drive motor 150 (which may be a servo motor, such as model MPL-B330P-MJ24AA manufactured by Allen-Bradley), which may be mounted on a longitudinally extending beam member 108 connected to the frame 109 (see Figure 1a). Figure 2 and Figure 3The left drive motor 150 may have a left drive wheel 152. Similarly, the right drive motor 154, which may also be a servo motor like the left drive motor 150, may be mounted on the beam member 108 connected to the frame 109. The right drive motor 154 may have a right drive wheel 156. The left drive wheel 152 may be longitudinally spaced from the right drive motor 154 and may be horizontally aligned with the right drive motor 154. Both the left drive motor 150 and the right drive motor 154 may be driven at different speeds in both directions, and such rotation may be controlled by the PLC 132 via servo drive (see [link]). Figure 1B Both the left-side drive motor 150 and the right-side drive motor 154 can be equipped with two separate ports 364a and 364b. One of ports 364a and 364b can be used to provide a power line, and the other of ports 364a and 364b can be used as a communication line for communication with the PLC 132. It should be noted that all servo motors described in this document can be similarly equipped. The left-side drive motor 150 and the right-side drive motor 154 can also have a third input terminal that allows for an electric braking mechanism.

[0106] The first mobile device 115a may also include a continuous drive belt 153. The continuous drive belt 153 may be made of, for example, polyurethane, and steel wires pass through it. The drive belt 153 can be engaged and driven by a left drive motor 150 and a right drive motor 154 under the control of a PLC 132. The PLC 132 can independently control the operation of both the left drive motor 150 and the right drive motor 154 via corresponding servo drives. The drive belt 153 can be shown as continuously extending from a starting position on the bottom left side of the support tube 169, at which a right belt block 159a is firmly attached to the support tube 169. From this starting position, the drive belt 153 extends upward on a first drive belt portion 153g to an "f" pulley 155f, passing over the upper side of the "f" pulley 155f. Drive belt 153 extends horizontally from pulley "f" 155f along the second drive belt portion 153h to the left drive wheel 152. Drive belt 153 then wraps around and is engaged by the left drive wheel 152, and on the third drive belt portion 153a below pulley "a" 155a, extends upward along the fourth drive belt portion 153b to pulley "b" 155b. From there, drive belt 153 extends around pulley "b" 155b, downward on the fifth drive belt portion 153c to pulley "c" 155c, wraps around pulley "c" 155c along the sixth drive belt portion 153d to the right drive wheel 156. After wrapping around and being engaged by the right drive wheel 156, drive belt 153 extends continuously from around the right drive wheel 156 to the seventh drive belt portion 153e, reaching the upper side of pulley "d" 155d. From pulley "d" 155d, drive belt 153 extends vertically downwards along the eighth drive belt section 153f to the right belt slider 159a, where it terminates. Since drive belt 153 is interconnected with support tube 169 via right and left belt sliders 159a, drive belt 153 vertically supports support tube 169 at the bottom and also vertically at the top, as it passes over pulley "b" 155b at the top. Therefore, drive belt 153 can also be shown as indirectly supporting the second erector head 120b vertically. Furthermore, by adjusting the relative rotation of left drive wheel 152 and right drive wheel 156, the relative lengths of all belt sections can be adjusted by operating left belt drive motor 150 and right belt drive motor 154. Therefore, the relative vertical position of support tube 169 relative to slider 158 can be adjusted. Additionally, by adjusting the relative rotation of the left drive wheel 152 and the right drive wheel 156, and by operating the left belt drive motor 150 and the right belt drive motor 154, the horizontal position of the sliding block 158 on the guide rails 160 and 162 can be adjusted, thereby changing the horizontal position of the support tube 169 and the second erector head 120b.Understandably, by adjusting the rotational direction and speed of the drive wheels 152 and 156 relative to each other, the support tube 169 can move vertically and / or horizontally in space within the physical constraints imposed, particularly by the positions of the left drive wheel 152 and the right drive wheel 156, the length of the drive belt 153, and the length of the support tube 169. (See reference.) Figure 17 You will understand the following. In particular: If both the left drive wheel 152 and the right drive wheel 156 remain stationary, then the position of the support tube 169 will not change. If the left drive wheel 152 and the right drive wheel 156 rotate relative to each other in the same clockwise direction and at the same speed, then the support tube 169 and the corresponding second erector head 120b can be shown as moving horizontally from right to left. If the left drive wheel 152 and the right drive wheel 156 rotate relative to each other in the same counterclockwise direction and at the same speed, then the support tube 169 and the corresponding second erector head 120b move horizontally from left to right. If the left drive wheel 152 rotates counterclockwise and the right drive wheel 156 rotates in the opposite clockwise direction, but the left drive wheel 152 and the right drive wheel 156 rotate relative to each other at the same rotational speed, then the support tube 169 and the corresponding second erector head 120b can be shown as moving vertically downward in a straight line; and If the left drive wheel 152 rotates clockwise and the right drive wheel 156 rotates in the opposite counterclockwise direction, but the left drive wheel 152 and the right drive wheel 156 rotate relative to each other at the same rotational speed, then the vertically extending and oriented surfaces 164, 166 move vertically upward in a straight line.

[0107] It will be understood that if the speeds and directions of the left drive wheel 152 and the right drive wheel 156 change in different ways, then the movement of the support tube 169 and the corresponding second erector head 120b can form a movement with both a vertically upward component and a vertically downward component, and a horizontal right-to-left component and a left-to-right component. Therefore, any desired path within these two degrees of freedom (vertical and horizontal) can be created for the support tube 169 and the corresponding second erector head 120b. For example, a path with curved sections can be created. By independently controlling the rotational direction and speed of the left belt drive motor 150 and the right belt drive motor 154, the PLC 132 can cause the support tube 169 and the corresponding second erector head 120b to move along any path in the vertical and horizontal directions, so that the second erector head 120b carries the carton blank 111 through the various processing steps performed by the carton forming system 100. It is worth noting that the path is physically constrained by the spacing between the left drive wheel 152 and the right drive wheel 156, the "b" pulley 155b and the bottom of the support tube 169.

[0108] It will also be understood that by providing two opposing mobile devices 115a and 115b, the movement of each of the first erector head 120a and the second erector head 120b can be coordinated and synchronized such that even if the first erector head 120a and the second erector head 120b move along the same path, their movements are out of phase. For example, the phase difference between the first erector head 120a and the second erector head 120b can be 180 degrees.

[0109] Therefore, movement of one erector head 120 will not interfere with movement of the other erector head 120. Encoders can be provided for each of the left belt drive motor 150 and the right belt drive motor 154, and the encoders can rotate in association with the rotation of the corresponding left drive wheel 152 and right drive wheel 156. The encoders can communicate with the PLC 132. Therefore, the PLC 132 can know / determine / monitor the position of the drive belt 153 in space in real time, and thus can determine and know the position of the second erector head 120b in space at any given time. A specific type of encoder that can be used is called an "absolute" encoder. Therefore, the carton forming system 100 can be zeroed such that, due to the calibration of the two encoders of both the left belt drive motor 150 and the right belt drive motor 154, the zero-zero position of the erector head 120 in the Z and Y directions is set within the PLC 132. This zero-zero position can be set so that the erector head 120 is in its horizontally leftmost and vertically highest position. As the second erector head 120b moves through the given processing sequence of the carton blank 111, the PLC 132 can then track the position of the second erector head 120b essentially in real time.

[0110] For each of the two individual erector heads 120a and 120b, the PLC 132, the encoders associated with the left belt drive motor 150 and the right belt drive motor 154, and the corresponding servo drives on each of the devices 115a and 115b can be set to a zero-zero position. As the erector heads 120a and 120b move independently through a given processing sequence of carton blanks 111, the PLC 132 can then track the positions of the two erector heads 120a and 120b substantially in real time.

[0111] Associated with the second mobile device 115b is a generally horizontally oriented first track assembly 114 having a first track input end 114a and a first track output end 114b. A generally vertically oriented second track assembly 118 is also provided, having a second track input end 118a and a second track output end 118b. The first track assembly 114 and the second track assembly 118 may each have a cavity extending along their length. Within the cavities of the first track assembly 114 and the second track assembly 118, hoses carrying pressurized air / vacuum and wires carrying electrical / communication signals can be accommodated. The first track assembly 114 allows such hoses and wires to move longitudinally when the support tube 169 and the second erector head 120b move longitudinally. The second track assembly 118 allows such hoses and wires to move vertically when the support tube 169 and the second erector head 120b move vertically. Hose and wire can extend from an external source to enter at the first track input end 114a and exit at the first track output end 114b. Once exiting from the first track output end 114b, the hose and wire can extend to enter at the second track input end 118a and exit at the second track output end 118b. These hoses and wires can then enter from the second track output end 118b into the first input hose 191 and the second input hose 192 on the second erector head 120b (see...). Figure 30 In this manner, both pressurized air / vacuum and / or electrical communication lines can be introduced from a location outside the frame 109 to the movable second erector head 120b. An example of a suitable tracked device is the E-Chain cable-carrying system, model #240-03-055-0, manufactured by Ignus. It should be noted that in other embodiments, electrical communication between the PLC 132 and the second erector head 120b can be implemented using commercially available wireless technology.

[0112] The second erector head 120b is at Figure 30 , Figure 31 , Figure 32 and Figure 33 The first erector head 120a is illustrated separately. The first erector head 120a can be constructed in the same manner as the second erector head 120b, but unlike the second erector head 120b, which can be supported from the left side by the second mobile device 115b, it can be supported from the right side by the first mobile device 115a.

[0113] The second erector head 120b may have a body with an overall designation of 300. The body 300 may consist of multiple parts. Many of the parts of the second erector head 120b may be made of robust materials, such as metals (e.g., aluminum, steel, etc.), hard and strong plastics, or other suitable materials containing composite materials.

[0114] The second erector head 120b can generally be configured to process carton blanks 111 of a certain size range that can be formed into cartons. The second erector head 120b can be configured for easy attachment to the support tube 169 using mounting blocks 190a, 190b and bolts, allowing for easy interchangeability of the erector head 120. This easy interchangeability of the erector head 120 makes the carton forming system 100 easily adaptable in some cases to forming cartons of different sizes / shapes from carton blanks 111 with different configurations.

[0115] In one embodiment, the second erector head 120b may include a rotatable paddle 310 connected to a distal end portion 314a of a paddle arm 314. The paddle arm 314 may have a proximal end portion 314b opposite the distal end portion 314a. The proximal end portion 314b may be formed with a circular opening facilitating connection of the paddle arm 314 to a paddle shaft 316. The paddle 310 may rotate together with the paddle shaft 316 about the longitudinal axis of the paddle shaft 316. The paddle shaft 316 may be connected to a rotary actuator 399, such as a double-acting rotary pneumatic actuator manufactured by Festo (engineered part #DSM-32-270-CC-FW-AB). The rotary actuator 399 may cause the paddle shaft 316 to rotate clockwise and counterclockwise by up to 270 degrees about its axis. The rotary actuator 399 can be supplied with pressurized air via hoses (not shown) connected to the first port 395 and the second port 397. These hoses can also be connected to a solenoid valve device 340 that can be controlled by the PLC 132. In this way, the clockwise and counterclockwise rotation of the paddle 310 can be controlled by the PLC 132.

[0116] The bottom suction plate 327 is also formed as part of the body 300 of the second erector head 120b. The bottom suction plate 327 is generally shaped in a square cross configuration to provide flanged openings for the suction cups. A suction cup 312 is positioned in each of the flanged openings of the bottom suction plate 327. It should be noted that although various types of suction cups can be used on the second erector head 120b, the preferred type is the Piab-manufactured model B40.10.04AB. Two suction cups 312 are mounted to a generally longitudinally oriented first support block 319a, while the other two suction cups are mounted to a generally longitudinally oriented second support block 319b.

[0117] The first support block 319a and the second support block 319b are generally longitudinally oriented in a parallel relationship spaced apart from each other, and are connected to other components of the body 300. Each of the first support block 319a and the second support block 319b has an open channel that interconnects each suction cup 312 with an outlet of the vacuum generator 330. The vacuum generator 330 can be any suitable vacuum generator device, such as, for example, the Pisco VCH12-016C. Each suction cup 312 can be shown as having an inlet interconnected with a hose (not shown) that can transport pressurized air to the vacuum generator 330. The vacuum generator 330 converts the pressurized air supplied to the vacuum inlet into a vacuum at one of a plurality of vacuum outlet ports. The vacuum outlet port is interconnected with a given suction cup 312 among a plurality of suction cups 312 via channels in the first support block 319a and the second support block 319b, enabling the given suction cup 312 to achieve vacuum force. The solenoid valve device 340 can be disposed along a pressurized air passage extending between the vacuum generator 330 and a pressurized air source, which can be an air compressor (see [link]). Figure 1B The solenoid valve device can be, for example, a Festo model CPE14-M1BH-5L-1 / 8. The solenoid valve device 340 can communicate electronically with and be controlled by a PLC 132. In this way, the PLC 132 can open and close the vacuum force supply to each of the suction cups 312. To properly guide the compressed air, the valve in the solenoid valve device 340 can be actuated between open and closed positions by a solenoid in response to a signal from the PLC 132. The wires transmitting signals to and from the PLC 132 can also operate the solenoid valve device 340 via a first input hose 191.

[0118] The first downwardly extending end portion 323a of the first support block 319a has a first opening 331a configured to receive a laterally mounted shaft 342. The laterally mounted shaft 342 can be mounted to rotate within the first opening 331a. The second downwardly extending end portion 323b of the second support block 319b has a second opening 331b configured to receive a laterally mounted shaft 342. The laterally mounted shaft 342 can be mounted to rotate within the second opening 331b.

[0119] A gear assembly 360 may be mounted at one end of the laterally mounted shaft 342, the gear assembly 360 being configured to rotate together with the laterally mounted shaft 342. The gear 360 may interconnect with the drive wheel of the gearbox 362 to form a helical gear connection. The gearbox 362 may be driven by a servo motor 364 mounted above the gearbox 362. The servo motor 364 may also be a model MPL-B1530U-VJ44AA manufactured by Allen-Bradley, and the gearbox 362 may be a model AER050-030 FOR MPL-A1520 AB SERVO MOTOR manufactured by Apex.

[0120] exist Figure 30 In this embodiment, servo motor 364 is shown with two independent servo motor ports 364a and 364b (individually or jointly, 364). One of the servo motor ports 364 can be used for power supply lines, and the other servo motor port can be used for communication lines to facilitate communication with the servo driver and PLC 132. It should be noted that all servo motors described in this application can be configured similarly. Servo motor 364 can communicate with the servo driver (see [link to application]). Figure 1B The connection to and communication with the servo motor 364 is controlled by PLC 132. An encoder can be provided within or associated with the servo motor 364. The encoder can rotate in association with the rotation of the corresponding drive shaft of the servo motor 364. The encoder can communicate with and provide signals to the servo driver, and thus to the PLC 132. The PLC 132 is able to determine the rotational position of the laterally mounted shaft 342. Therefore, when an appropriate signal is provided from the PLC 132, the servo motor 364 can be operated and can cause the laterally mounted shaft 342 to rotate in a specific desired direction at a specific desired speed for a desired time. Thus, the PLC 132 can control the rotational position of the laterally mounted shaft 342.

[0121] Mounted to a laterally mounted shaft 342, between a first end portion 323a and a second end portion 323b is a rotator device generally indicated by 350. The rotator device 350 is securely attached to the laterally mounted shaft 342 and can be shown rotating together with the laterally mounted shaft 342. The rotator device 350 includes a rotating arm 351, one end of which is fixedly mounted to the laterally mounted shaft 342. A mounting block 353 is attached to the other opposite end of the rotating arm 351.

[0122] The mounting block pneumatic actuator device 325 can be fixed to the mounting block 353, which can be, for example, model DFM-12-80-PA-KF or part #170905 manufactured by Festo. The mounting block pneumatic actuator device 325 can be supplied with pressurized air, thereby activating a device controlled by a solenoid valve device 340 in the supply line. The solenoid valve device 340 can communicate with and be controlled by a PLC 132 (see [link to PLC 132]). Figure 1B The mounting block pneumatic actuator 325 can be actuated to reciprocate the piston arm 326 between an extended position and a retracted position. The PLC 132 can send a signal to the solenoid valve 340 to operate the mounting block pneumatic actuator 325, thereby extending the piston arm 326 at a specific angular position of the rotating arm 351 and / or a specific position of the second erector head 120b. This specific angular position or specific position can be provided by an encoder associated with the servo motor 364. Similarly, the PLC 132 can send a signal to the solenoid valve 340 to cause the piston arm 326 to retract to a specific angular position of the laterally mounted shaft 342, and / or to retract the piston arm 326 to a specific angular position of the rotating arm 351, and / or to retract the piston arm 326 to a specific position of the second erector head 120b.

[0123] At approximately the same time that the suction cup 312 has contacted the downward-facing surface of the panel D and / or the rotation of the rotating arm 351 is about to begin or has already begun, the PLC 132 can actuate the mounting block pneumatic actuator 325 through the action of the solenoid valve device 340. When the rotating arm 351 has rotated approximately 45 degrees, the piston arm 326 can be fully extended.

[0124] Mounting block 328 is mounted to the distal end of each piston arm 326. Mounting block 328 can be configured to support a pair of piston arm suction cups 320. Each mounting block 328 may have an opening channel (not shown) interconnecting each piston arm suction cup 320 with an outlet of a vacuum generator 330. The vacuum generator 330 can be any suitable vacuum generator device, such as, for example, model VCH12-016C manufactured by Pisco. As indicated above, each vacuum generator 330 has an inlet port interconnected with a hose (not shown) that can transmit pressurized air to the vacuum generator 330. The vacuum generator 330 converts the pressurized air supplied at the inlet port into a vacuum at an outlet port. The outlet port is interconnected with one of the piston arm suction cups 320 via a channel in mounting block 328, allowing the suction cup to apply a vacuum force. A solenoid valve device 340 can be inserted into a pressurized air passage extending between each vacuum generator 330 associated with the piston arm suction cup 320 and a pressurized air source. The solenoid valve device 340 can be electronically interconnected (via wireless or wired communication) to and controlled by the PLC 132. In this way, the PLC 132 can also turn the vacuum force supply to each piston arm suction cup 320 on and off.

[0125] refer to Figure 11 The suction cup 312 can be used to engage and hold the carton blank 111 on the top plate A. Once the carton blank 111 has been removed from the top of the stacked carton blanks 111, the rotating arm 351 can rotate approximately 180 degrees, allowing the piston arm suction cup 320 of the rotator device 350 to engage and hold the carton blank 111 on the lower side panel D. Once the piston arm suction cup 320 has engaged panel D, the rotating arm 351 can rotate 90 degrees rearward in the opposite direction of rotation. The opposing vacuum forces formed by the upper suction cup 312 and the lower piston arm suction cup 320 can be shown as causing the carton blank 111 to change from a flattened configuration to an open configuration when panel D is rotated approximately 90 degrees relative to panel A. The air suction force generated at the outer surfaces of the piston arm suction cup 320 and the suction plate suction cup 312 can be made sufficiently large that, when activated, the piston arm suction cup 320 and the suction plate suction cup 312 can engage the top plate A and hold the top plate A in a fixed position relative to the second erector head 120b, and rotate the plate D relative to plate A to open the tubular carton blank 111 into a generally rectangular configuration. The vacuum generated at the piston arm suction cup 320 and the suction plate suction cup 312 can also be deactivated by sending a signal to the solenoid valve device 340 at an appropriate time via the PLC 132.

[0126] Each erector head 120a, 120b can be configured to handle a wider range of different sizes / sizes of carton blanks 111 by providing additional piston arm suction cups and suction plate suction cups positioned at different locations on the erector heads 120a, 120b. The piston arm suction cup 320 and suction plate suction cup 312 can each be a "self-sealing" or "self-closing" suction cup, i.e., the suction cup can automatically clog if it does not engage and seal with the surface of the specific blank being processed. This automatic closing can be shown as maintaining vacuum / suction on other suction cups interconnected with a pressurized air / vacuum source and engaging with the panel of the carton blank 111. In this way, each of the erector heads 120a, 120b can be adapted to handle a wider variety of sizes / sizes of carton blanks 111 and the cartons / boxes that can be formed therefrom.

[0127] During the rotation of the rotating arm 351, the extension of the piston arm 326, which mounts the pneumatic actuator device 325, assists in opening the carton blank 111. Preferably, the piston arm 326 can be fully extended when the rotating arm 351 has rotated to a position approximately 30 to 60 degrees toward returning to the 90-degree position, and more preferably, when the rotating arm 351 is at approximately 40 to 50 degrees, and most preferably, when the rotating arm 351 is at approximately 45 degrees. The extension of the piston arm 326 and the piston arm suction cup 320 in a generally tangential direction relative to the rotation of the rotating arm 351 can be shown as compensating for the offset of the axis of rotation of the rotating arm 351 relative to the axis of rotation of the carton blank 111 extending along the fold line between panels A and D. Once the rotating arm 351 has rotated, such as to 90 degrees, the effect of the extension of the piston arm 326 ensures that panel D is also at a 90-degree angle to panel A.

[0128] Once the carton blank 111 has been opened to Figure 11 As shown in the configuration, PLC 132 can send a signal to solenoid valve device 340, which causes rotary actuator 399 to rotate paddle shaft 316, and thus paddle 310. Paddle 310 can then engage the rear fold plate K of carton blank 111, causing the rear fold plate K to fold around its fold line, at which it is connected to panel D. Thus, the rear fold plate K can fold inward toward the bottom opening of carton blank 111. The front bottom fold plate J can also fold around its fold line, which connects the front bottom fold plate J to panel B, by engaging the upper fold guide / plow 700 and lower fold guide / plow 701, which form part of folding and sealing device 130. As the carton blank 111, held by the second erector head 120b, moves longitudinally downstream into the folding and sealing device 130, the front bottom fold J can be folded inward, such that both the bottom folds K and J are folded inward to begin forming the bottom of the carton.

[0129] Another notable feature of the second erector head 120b is that it can provide a carton position sensor device and may include a reciprocating sensor rod 380. When not in contact with the carton blank 111, the reciprocating sensor rod 380 extends downward through a hole 381 in the bottom suction plate 327, below the plane height of the suction cup 312. When the second erector head 120b moves vertically downward to remove the carton blank 111 from the stack of carton blanks 111 in the hopper 110, the movement of the second erector head 120b can be shown as generally vertically downward just before the suction cup 312 contacts the upper surface of the carton blank 111. Before the suction cup 312 contacts the surface of the panel A of the carton blank 111, the sensor rod 380 can be shown engaging the surface of the panel A, which can be elastically displaced due to a spring mechanism that biases the sensor rod 380 downward, causing the sensor rod 380 to be pushed upward. This upward movement of the sensor rod 380 relative to the bottom suction cup 327 can be shown as physically causing the sensor (not shown) to be activated, and in response, a signal is sent to the PLC 132. This sensor can be an inductive proximity sensor. The metal cylinder fixed to the sensor rod 380 can be sensed by the sensor circuitry, as the movement of the metal cylinder can be shown as changing the inductance of the sensing loop inside the sensor. This sensor can be an Allen-Bradley 871FM-D8NP25-P3. In response to the reception of this signal, the PLC 132 decelerates the left belt drive motor 150 and the right belt drive motor 154, causing the final few centimeters (e.g., 3.5 cm) of downward movement toward the suction cup 312 before contact with the upper surface of panel A to occur at a much slower rate, and the PLC 132 also knows how much further vertically the second erector head 120b will be lowered to form proper contact between the suction cup 312 and panel A. It should also be noted that the sensor rod 380 and the associated sensor device can also be used to ensure that the PLC 132 knows whether the carton blank 111 remains engaged with the second erector head 120b until it reaches the appropriate release position (e.g., once the carton has been erected) once it has been engaged in the hopper 110.

[0130] The specific arrangement of the suction cups and rotating paddles on the erector head 120 can be designed based on the configuration of the carton blank and the specific panels and folds that need to be rotated. It will also be understood that on the illustrated erector head 120, the suction cups are used to apply force to hold and / or rotate the panels of the carton blank 111. However, it should be clear that alternative engagement mechanisms can be used instead of the suction plate suction cup 312 and the piston arm suction cup 320.

[0131] Please refer to Figures 1 to 12. Figure 15 and Figure 17 At the folding and sealing device 130, the guide rail and plow-shaped device can be configured such that all remaining folds of the carton blank 111 are properly folded to prepare for sealing, thereby producing a carton configuration suitable for delivery to an opening of an unloading conveyor such as unloading conveyor 117. The folding and sealing device 130 may include the following components: upper folding guide rail / plow-shaped device 700; lower folding guide rail / plow-shaped device 701; carton support plate 703; unloading chute 750; upper fold plate closing device 705; lower fold plate closing device 707; right-hand compression device 706; left-hand compression device 704; and glue applicator 709 (see Figure 1). The glue applicator 709 may have one or more nozzles positioned to apply adhesive to folds such as folds J and K. Each of the guide rail and actuator devices of the folding and sealing device 130 may be supported by a rod or other member to interconnect the various components to the support frame 109.

[0132] The upper folding actuator device 705 may include an upper pneumatic actuator device 704a, the piston arm of which is connected to the upper plowshare 708a. Similarly, the lower folding actuator device 707 may include a lower pneumatic actuator device 704b, the piston arm of which is connected to the upper plowshare 708b. The upper pneumatic actuator device 704a and the lower pneumatic actuator device 704b may be manufactured by Festo, model DFM-25-100-PA-KF, part #170928.

[0133] The right-hand compression device 706 may include a central pneumatic actuator device 710, which has horizontally aligned and extendable telescopic support rods 712, 714 positioned on either side of the central pneumatic actuator device 710. The central pneumatic actuator device 710 may be part #163309, model DNC-32-100-PPV-A, manufactured by Festo. (See also: Special Reference) Figure 26 The central pneumatic actuator device 710 may have a piston arm that is connected together with the ends of support rods 712 and 714 to a longitudinally extending sealing plate 716. The longitudinally extending sealing plate 716 may have a longitudinally extending upper guide rail 717a and a longitudinally extending lower guide rail 717b attached thereto. When the piston arm of the central pneumatic actuator device 710 extends horizontally and laterally inward to actuate flaps F and G to engage flaps K and J positioned below, the upper guide rail 717a may be positioned to engage the upper main flap F, and the lower guide rail 717b may be positioned to engage the lower main flap G.

[0134] The left-hand compression device 704 has a left-hand actuator arm 711, which can be actuated by a left-hand actuator device 719, which has a vertically and longitudinally arranged left-hand compression plate 720 attached to the end of the actuator arm. The left-hand actuator device 719 can be a double-acting pneumatic actuator (not shown) that can be supplied with pressurized air via a hose, wherein the airflow is controlled by a solenoid valve device 340, which can be controlled by a PLC 132. Other embodiments are also possible. For example, refer to... Figure 26A A servo-driven actuator including a mounting block 741 can be provided for the left-hand actuator arm 711. The mounting block 741 is movable along a guide rail 745, which is fixed to a horizontally and longitudinally extending plate forming part of the left-hand support frame 746. The mounting block 741 can slide horizontally along the guide rail 745. An L-shaped plate 743 interconnects the left-hand actuator arm 711 to the mounting block 741. The mounting block 741 can also be connected on its underside to a continuous drive belt 757 using, for example, nuts and bolts. The drive belt 757 is made of any suitable material, such as the same material used for the belts of the first mobile device 115a and the second mobile device 115b, i.e., a polyurethane synchronous belt with steel wires passing through it. The continuous drive belt 757 can extend between a freely rotating pulley 759 mounted to one end of the left-hand support frame 746 and the drive wheel of the left-hand servo motor 761. The left-hand servo motor 761 can be an Allen-Bradley model AB MPL-B320P-MJ22AA, connected to a PLC 132 via a servo driver and an absolute encoder. This servo driver could be an Allen-Bradley model AB 2094-BM01-S. The left-hand servo motor 761 can be coupled to the drive wheel of the belt via an APEX GEARBOX model AE070-005.

[0135] The PLC 132 can control the rotation of the drive wheel driven by the left-hand servo motor 761 using an encoder (which can be an absolute encoder). Therefore, the movement of the continuous drive belt 757 can be controlled, and the PLC 132 can determine the position of the left-hand actuator arm 711 in real time. Consequently, the PLC 132 can determine the position of the left-hand compression plate 720 in real time. Depending on the type and thickness of the material forming the carton blank 111, the positioning of the left-hand compression plate 720 relative to the plate of the right-hand compression device 706 can be adjusted by the PLC 132 to ensure appropriate compression of the folded plates of the carton blank 111 positioned therebetween.

[0136] Each of the upper pneumatic actuator 704a, lower pneumatic actuator 704b, and central pneumatic actuator 710 can be a double-acting cylinder, and they can be supplied with pressurized air controlled by an electronic valve device (not shown). The electronic valve device can be a valve unit of model CPE14-M1Bh-5J-1 / 8, which can communicate with and be controlled by PLC 132. Therefore, PLC 132 can cause the piston arm to extend and retract during the processing of the carton blank 111 to achieve the closure and sealing of the folding plate.

[0137] The upper pneumatic actuator device 704a and the upper plow-shaped member 708a can be suitably positioned and tilted downward (e.g., at approximately 45 degrees relative to the vertical) to fully fold the main fold plate F downward, thereby enabling engagement by the right-hand compression device 706. Similarly, the lower pneumatic actuator device 704b and the lower plow-shaped member 708b can be suitably positioned and tilted upward (e.g., at approximately 45 degrees relative to the vertical) to fully fold the main fold plate G, thereby enabling engagement by the right-hand compression device 706 substantially simultaneously, or at least allowing the right-hand compression device 706 to simultaneously compress both fold plates F and G toward the secondary fold plates J and K, which have upper surfaces containing some adhesive.

[0138] The glue applicator 709 has a properly positioned nozzle, and the operation of the nozzle can be controlled by a PLC 132. Once folds such as the preceding fold J and the following fold K have been folded inward to form part of the bottom of the carton, the glue applicator 709 can apply suitable adhesive to such folds. An example of a suitable known applicator that can be used for the glue applicator 709 is the ProBlue10 applicator manufactured by Nordson. An example of a suitable adhesive that can be used on the carton blank 111 made of cardboard is Cool-Lok 034250A-790 adhesive sold by Lanco Adhesives. The glue applicator 709 can communicate electronically with the PLC 132, which can be operated to signal the glue applicator 709 to apply adhesive at the appropriate time during the positioning of the erector heads 120a, 120b.

[0139] The left-hand compression device 704 can be used to enter the carton from the left and compress the folds F, G, J, and K between the left-hand compression plate 720, the upper guide rail 717a of the right-hand compression device 706, and the lower guide rail 717b of the right-hand compression device 706. This compression can be shown to help ensure that the individual panels are compressed together to allow the adhesive to properly bond the folds together, thereby creating a sturdy bottom for the carton.

[0140] In some embodiments, once the left-hand compression device 704 and the right-hand compression device 706 have completed the compression of the folding plate, the PLC 132 can send a signal to the solenoid valve device, causing the left-hand compression device 704 and the right-hand compression device 706 to retract. The carton blank 111 can be shown as fully opened to form an upright carton suitable for loading one or more items. The second erector head 120b can then carry the upright carton to the unloading chute 750 and then release the upright carton so that it falls onto the unloading conveyor 117, which can then remove the upright carton for further processing. In other embodiments, such as the illustrated embodiment, the upright carton 111 can be released and fall onto support plate 703, and remain on support plate 703 until a next carton blank 111 carried by another upright head (such as a first upright head 120a moved by a first mobile device 115a) moves the next carton blank 111 to a position where the next carton blank 111 is to be folded, sealed, and compressed. In this way, the next carton blank 111 pushes the previous upright carton downstream, where the previous upright carton falls onto unloading conveyor 117. Carton unloading conveyors are well known in the art, and any suitable known carton conveyor can be used for unloading conveyor 117.

[0141] Other examples of transfer devices that can be used to transfer upright cartons from the folding and sealing device 130 to the carton unloading conveyor include a “blow-away” system, which may employ one or more of the following: compressed air nozzles, suction cup systems, push arms, or simply allowing the upright cartons to fall freely.

[0142] Such as the unloading sensor 243 of the electronic eye, model 42KL-P2LB-F4 manufactured by Allen-Bradley (see Figure 2 The unloading sensor 243 can be located near the bottom of the unloading chute 750. The unloading sensor 243 can be positioned and operated to detect the presence of an upright carton at the input of the unloading conveyor 117. In this way, a digital signal can be used to notify the PLC 132 that an upright carton is in the correct position at the bottom of the unloading chute 750, preventing another upright carton from being unloaded into the unloading chute 750. If an upright carton is in the correct position at the bottom of the unloading chute 750, the carton forming system 100 can be stopped by the PLC 132 until any malfunction of the unloading conveyor 117 can be corrected.

[0143] The overall operation of the carton forming system 100 will now be described in further detail.

[0144] As an initial step, the operator can access the PLC 132 via the HMI 133 to activate the carton forming system 100. In response to activation, the carton forming system 100 can be initialized by the PLC 132 such that all components are placed in their “start” positions. Stacked carton blanks 111 can be placed at the input end of the feed conveyor 204, and then the carton forming system 100 can be instructed by the PLC 132, such as via the HMI 133, to begin processing the stacked carton blanks 111.

[0145] The PLC 132 can then send a command to the drive motor of the feed conveyor 204 to begin driving the feed conveyor belt 214, causing the stacked carton blanks 111 to move downstream. Sometime before the stacked carton blanks 111 reach the alignment conveyor 206, under the control of the PLC 132, the right-hand side guide wall 201 can be shown being extended wide enough by the drive mechanism 260 to allow the stacked carton blanks 111 to enter the alignment conveyor 206 even if the stack is misaligned and / or the carton blanks 111 in the stack are not perfectly aligned with each other. The stacked carton blanks 111 can then move downstream until the leading edge of the stacked blanks passes the downstream edge of the feed conveyor 204, at which point the gap sensor 242 can be shown sending a signal to the PLC 132 indicating that the leading edge of the stack has reached the input of the alignment conveyor 206. In response to receiving this signal, PLC 132 can send a command to the drive motor of feed conveyor 204 to begin driving the alignment conveyor belt 216, causing the stacked carton blanks 111 to move downstream toward the front wall 218 of hopper 110. Once the front edge of the stacked carton blanks 111 reaches the front wall 218, presence sensor 240 can be indicated to send a signal to PLC 132, indicating that the front edge of the stacked carton blanks has reached the front wall 218. In response to receiving the signal, PLC 132 can initiate a compaction sequence to "align" the stacked carton blanks 111, as detailed above.

[0146] To recap, the compaction sequence used to ensure that the carton blank 111 is correctly positioned in the pick-up position may include the following steps. When activated by pressurized air controlled by PLC 132 and associated valves, the compaction actuator 276 extends. The right-hand side guide wall 201 can then retract to contact the sides of the stacked carton blanks 111, thereby pressing the stacked carton blanks 111 against the left-hand side guide wall 200. This compression can be shown as aligning the carton blanks 111 such that their side edges are aligned with each other and with the corresponding longitudinal sidewalls of the left-hand side guide wall 200 and the right-hand side guide wall 201. The tamping actuator 276 can then retract, and the vertical tamping plate 280 can press the stacked carton blanks 111 forward, aligning the carton blanks 111 in the stack so that their front and rear edges are vertically aligned with each other and with the inner surfaces of the vertical tamping plate 280 and the front end wall 218. The stacked blanks 111 are then correctly positioned so that the erector heads 120a and 120b can begin picking up blanks from the stack.

[0147] One of the erector heads, such as the second erector head 120b, can be shown positioned at a zero position calibrated for the second erector head 120b by control of a PLC 132 on a second mobile device 115b. The PLC 132 can then cause the left belt drive motor 150 and the right belt drive motor 154 to operate in a sequence of operations.

[0148] First, the second erector head 120b can be moved to, for example... Figure 17 The location to pick up is shown in the middle diagram.

[0149] As the second erector head 120b is moved vertically downward to remove the top carton blank 111 from the stacked carton blanks 111 in the hopper 110, the movement of the second erector head can be shown as generally vertically downward, just before the suction cup 312 contacts the upper surface of the carton blank 111. Before the suction cup 312 contacts the surface of the panel A of the carton blank 111, the sensor rod 380 can be shown as engaging the surface of panel A, causing the sensor rod 380 to be pushed upward. This upward movement of the sensor rod 380 relative to the bottom suction cup 327 can be shown as physically activating the sensor rod 380 and sending a signal to the PLC 132 in response. In response to receiving this signal, the PLC 132 slows down the left belt drive motor 150 and the right belt drive motor 154, causing the final few centimeters (e.g., 3.5 cm) of downward movement toward contact between the suction cup 312 and the upper surface of panel A to occur at a much slower rate. Furthermore, PLC 132 knows how much further vertically the second erector head 120b will be lowered to establish proper contact between the suction cup 312 and panel A. It should also be clear that sensor rod 380 and associated sensor devices can also be used to ensure that PLC 132 knows whether the given carton blank 111 remains engaged with the second erector head 120b until the appropriate release position is reached, such as once the carton blank 111 has been erected in hopper 110.

[0150] PLC 132 can also be shown as operating a solenoid valve device 340 on the second erector head 120b to cause suction at the suction plate 312, and optionally, also at the piston arm 320 (although the suction at the piston arm 320 can be delayed).

[0151] like Figure 17 As shown in the diagram, when the second erector head 120b is in the pick-up position and suction is applied to the suction cup 312, the second erector head 120b can engage panel A (see Figure 1). Figure 10A (the position of the suction cup outline), and then begin to lift the given carton blank 111 upwards, as shown. Figure 18 The diagram shows that PLC 132 can be shown as knowing how high to raise the upper surface of a given carton blank 111, such that once opened, the first reference line W1 will be properly vertically positioned, enabling the components of the folding and sealing device 130 to perform their respective functions as described above.

[0152] Preferably, when the second erector head 120b has reached a predetermined vertical position, and more preferably, when the second erector head 120b has not moved longitudinally toward the folding and sealing device 130, the PLC 132 sends a signal to cause the servo motor 364 to rotate. The rotation of the servo motor 364 can be represented as causing the laterally mounted shaft 342 to rotate at a specific desired speed in a specific desired direction for a desired time. The PLC 132 can control the rotational position of the laterally mounted shaft 342 so that a rotator device 350, fixedly attached to the laterally mounted shaft 342, rotates together with the laterally mounted shaft 342. Therefore, the rotator device 350 can rotate to... Figure 19 The position shown in the figure, and at this position, the piston arm suction cup 320 with suction engagement can be shown as being attached to the underside of the given carton blank 111, and in particular to the panel D.

[0153] In the next operation, under the control of PLC 132, the "blank opening" operation can be represented as the opposing forces provided by the upward-acting suction cup 312 at the top and the piston arm suction cup 320 acting in the opposite downward direction initiating the pulling apart of the flat, given carton blank 111. Then, as the rotator device 350 rotates back 90 degrees, the upper suction cup 312 and the lower piston arm suction cup 320 continue to apply force to move the given carton blank 111 to... Figure 20 The location shown in the diagram.

[0154] During the reversal of the rotator assembly 350, pressurized air can be supplied to the mounting block pneumatic actuator assembly 325 via the solenoid valve assembly 340. The PLC 132 can send a signal to the solenoid valve assembly 340 to operate the mounting block pneumatic actuator assembly 325, thereby extending the piston arm 326 at a specific angular position of the rotating arm 351 and / or at a specific angular position of the second erector head 120b provided by the encoder associated with the servo motor 364. The PLC 342 can actuate the mounting block pneumatic actuator assembly 325 approximately simultaneously with the action of the solenoid valve assembly 340, when the piston arm suction cup 320 has contacted the downward-facing panel D and the rotation of the rotating arm 351 is about to begin or has already begun. When the rotating arm 351 has rotated approximately 45 degrees, the piston arm 326 can be fully extended. Figure 20 As shown in the diagram, when the rotator device 350 is in the 90-degree position, the piston arm 326 can continue to extend and remain in the extended state.

[0155] Once the given carton blank 111 has been opened, the second upright head 120b can firmly hold the blank by the suction applied to panel A by suction cup 312 and to panel D by piston arm suction cup 320. Furthermore, once opened, folding plates K and J need to fold inward toward the bottom opening of the given carton blank 111. Figure 21 In the embodiment illustrated, the secondary fold K is closed by actuation of the paddle 310. Therefore, the PLC 132 can send a signal to the solenoid valve device 340. This signal causes the rotary actuator 399 to rotate the paddle shaft 316, and thus the paddle 310. The paddle 310 can then engage the secondary fold K of the given carton blank 111, causing the secondary fold K to fold around its fold line, at which it connects to the panel D. Thus, the secondary fold K can fold inward toward the bottom opening of the given carton blank 111.

[0156] The front bottom fold J can also fold around its fold line, which connects the front bottom fold J to the panel B, through engagement with the upper folding guide / plow-shaped element 700 and the lower folding guide / plow-shaped element 701, which form part of the folding and sealing device 130. This folding can occur as the second erector head 120b moves longitudinally downstream toward the folding and sealing device 130. As the given carton blank 111, held by the second erector head 120b, moves longitudinally downstream into the folding and sealing device 130, the front bottom fold J can fold inward through the upper folding guide / plow-shaped element 700 and the lower folding guide / plow-shaped element 701, such that both bottom folds K and J are folded inward to begin forming the bottom of the carton, as... Figure 22 The diagram is shown in the image.

[0157] Furthermore, when folding plates K and J have been folded inward, under the control of PLC 132, or according to another controller or trigger, adhesive applicator 709 can apply suitable adhesive at appropriate positions on folding plates K and J through appropriately positioned nozzles. Adhesive can be applied before, during, or after PLC 132 causes the second moving device 115b to move the second erector head 120b to a downstream position, where the main folding plates F and G can be folded and compressed onto the secondary folding plates K and J. Figure 23 As shown in the diagram, glue can be applied while the second mobile device 115b moves the second erector head 120b to a downstream position so as to close the bottom opening by folding and compression.

[0158] Next, the upper pleated actuator device 705 is activated by the PLC 132, which acts via a valve mechanism to cause the upper pneumatic actuator device 704a to extend its piston arm connected to the upper plowshare 708a. Similarly, the lower pleated actuator device 707 can be activated by the PLC 132, causing the lower pneumatic actuator device 704b to extend its piston arm connected to the lower plowshare 708b, as in sequence. Figure 24 and Figure 25 As shown in the image.

[0159] Next, as Figure 26 As shown, the right-hand compression device 706, with a central pneumatic actuator 710, extends the piston arm such that a longitudinally extending sealing plate 716, attached to an upper guide rail 717a and a lower guide rail 717b, engages the upper main folding plate F and the lower main folding plate J. When the piston arm of the actuator device 710 extends horizontally and laterally inward to push the main folding plates F and G into engagement with the lower secondary folding plates K and J, the upper guide rail 717a can be positioned to engage the upper main folding plate F, and the lower guide rail 717b can be positioned to engage the lower main folding plate G. Once the compression device 706 has engaged the main folding plates F and G, the upper folding plate actuator 705 and the lower folding plate actuator 707 can be retracted by the PLC 132.

[0160] Next, as Figure 27 As shown in the diagram, the left-hand compression device 704 can be used to enter the carton blank 111 from the left side and compress the folds F, G, J, and K between the left-hand compression plate 720 of the left-hand compression device 704 and the upper guide rail 717a and lower guide rail 717b of the right-hand compression device 706. This compression can be shown to help ensure that each panel is compressed together to ensure that the adhesive properly binds the folds together to form a strong carton bottom.

[0161] Once the compression has been held for a short period (e.g., approximately 0.5 seconds) to allow the glue to fully solidify / harden and bond the folded panels together, as... Figure 28 As illustrated in the diagram, compression can be released by retracting the left-hand compression device 704 and the right-hand compression device 706. The carton can then be viewed as a fully upright carton and released from the folding and sealing device 130 and the second erector head 120b. This release can be shown as occurring in response to the PLC 132 causing the piston arm suction cup 320 and the suction plate suction cup 312 to close their suction via the solenoid valve device 340. Additionally, the PLC 132 can cause the rotator device 350 to rotate further rearward by 90 degrees. Figure 29 The horizontal preparation position is shown in the diagram.

[0162] Subsequently, the second erector head 120b can release the erected carton, which can then fall onto and remain on the support plate 703 until another erector head (such as the first erector head 120a moved by the first mobile device 115a) carries the next carton blank 111 and moves the next carton blank 111 to a position where the next carton blank 111 will be folded, sealed and compressed, and thus the fully erected carton is pushed downstream to the unloading chute 750, where the erected carton can fall onto the unloading conveyor 117.

[0163] When a given carton blank 111 is processed by the carton forming system 100, the entire sequence of movement of the given carton blank 111 is as follows: Figure 10A , Figure 10B , Figure 10C , Figure 10D and Figures 11 to 16 A separate map is shown in the image. Figure 10A , Figure 10B , Figure 10C , Figure 10D In the diagram, the given carton blank 111 is shown as a flat tubular configuration. Figure 11 In the illustration, a given carton blank 111 is shown in its open configuration after being opened by an erector head, such as a second erector head 120b. Figure 12 In the illustration, the given carton blank 111 has an inwardly folded rear fold K, and... Figure 13 In the illustration, the given carton blank 111 has a front fold J that is also folded inward. Figure 14 In the illustration, the given carton blank 111 has inwardly folded main bottom folds F and G. Figure 15 The diagram illustrates a given carton blank 111 when folds J, K, F, and G are being compressed or have already been compressed to seal the bottom of an upright carton. Finally, in Figure 16 The image shows an upright cardboard box with its opening facing upwards, allowing it to hold one or more items.

[0164] Although the aforementioned processing of the carton blank 111 by the second erector head 120b has already occurred, the first erector head 120a, supported and moved by the first moving device 115a, can perform the same process in a different phase than the second erector head 120b. For example, the cyclic movement and operation of the first erector head 120a can differ from the movement and operation of the second erector head 120b by 180 degrees. By operating the first erector head 120a and the second erector head 120b simultaneously but in a different phase, it can be shown that one erector head does not interfere with the other. Therefore, the carton forming system 100's capacity to process the carton blank 111 is significantly increased compared to a system with only a single erector head. It is worth noting that the processing capacity of the carton forming system 100 can still be considered relatively high even using only a single erector head. Part of the relatively high processing capacity is also due to the relatively short “stroke” (i.e., longitudinal distance) traveled by the erector head when performing the removal, erection, folding, sealing, and compression of the blanks. This relatively short stroke means that the parts do not travel as long a distance as those in a conventional carton erector. When using two erector heads with moving parts, the carton forming system 100 is able to process approximately 35 carton blanks per minute.

[0165] It will be understood that by making relatively minor changes to the components of the carton forming system 100, the carton forming system 100 can be changed from being able to handle blanks that can be processed into open-top cartons to being able to handle blanks that can be processed into open-top pallets. Figure 46 The illustration shows a plan view of a pallet blank that can be processed according to some embodiments. Figure 47 , Figure 48 and Figure 49 The illustration shows other blanks that can be processed, examples of cartons that can be formed, and these examples include blanks for wrapping around a so-called half-slotted carton (HSC) and HSC blanks, as well as blanks for wrapping around an RSC.

[0166] It should be clear that carton forming systems can be used in different ways than Figure 1A The carton forming system 100 is arranged in a manner described above. For example, several arrangements of carton forming systems are disclosed in U.S. Patent Application No. 16 / 230,979, filed December 21, 2018 and published February 11, 2020 as U.S. Patent No. 10,556,713, and U.S. Patent Application No. 16 / 808,140, ​​filed March 3, 2020 and published May 13, 2021 as U.S. Patent Publication No. US 2021 / 0138756 A1, all of which are incorporated herein by reference in their entirety.

[0167] refer to Figure 50 In summary, as Figure 1A An alternative to the carton forming system 100, the carton forming system 6000, has a hopper 6110 adapted to receive and hold a plurality of removable carton blanks 111, and an end effector 6120 for removing the removable carton blanks 111 from a pick-up area and placing the removable carton blanks 111 on a reciprocating conveyor 6140. As will be described below, the end effector 6120 and the reciprocating conveyor 6140 cooperate to manipulate the removable carton blanks 111, thereby erecting the removable carton blanks 111 into a sleeve.

[0168] The carton forming system 6000 may also include a folding device 6130 and a sealing station 6135, the folding device generally indicated by 6130 and configured to fold one or more folds of each sleeve, and the folds of the carton blank 111 are sealed at the sealing station 6135. The carton forming system 6000 may also include a carton reorientation station 6116 and a carton unloading conveyor 6117 for receiving and removing the carton after it has been fully erected.

[0169] The operation of the components of the carton forming system 6000 can be controlled by a PLC. The PLC can be accessed by a human operator through a Human Machine Interface (HMI) module mounted on the frame 6109 of the carton forming system 6000. The HMI module can communicate electronically with the PLC. The PLC can be any suitable PLC, and can include units such as the ControlLogix 5561 unit, which incorporates devices from the Logix 5000 series manufactured by Allen-Bradley / Rockwell Automation. The HMI module can be a Panelview part number 2711P-T15C4D1 module, also manufactured by Allen-Bradley / Rockwell Automation.

[0170] Now let's move on to the various parts of the carton forming system 6000, refer to... Figure 50 The hopper 6110 can be configured to hold a plurality of vertically stacked, detachably stacked carton blanks 111, and can be operated to move the stacked carton blanks 111 in a horizontal direction generally parallel to the horizontal axis X under the control of a PLC to a pick-up position, in which the end effector 6120 can remove the carton from the hopper 6110.

[0171] The hopper 6110 may include a single conveyor or other blank feeding device to deliver carton blanks 111 to a pick-up position. In the illustrated embodiment, two conveyors are disclosed: a feed conveyor 6204 and an alignment conveyor 6206. The feed conveyor 6204 may be configured and operable to move stacked carton blanks 111 from a stacking input position (where stacked carton blanks may be loaded onto the feed conveyor 6204, for example, by manual or robotic placement) to a position where the stacked carton blanks 111 are transferred to the alignment conveyor 6206 for horizontal and lateral alignment. The alignment conveyor 6206 may be positioned downstream of the feed conveyor 6204 and may be used to move stacked carton blanks 111 to the pick-up position. The hopper 6110 may load and initially hold a large number of vertically stacked carton blanks 111, which rest on the feed conveyor 6204. The rear wall 6202, mounted to the frame 6109, can be configured to prevent the stack from falling backward when initially loaded onto the feed conveyor 6204. The rear wall 6202 can have a generally flat, vertically and laterally oriented surface facing the stacked carton blanks 111. The feed conveyor 6204 can have an appropriate length to continuously store a satisfactory number of stacked carton blanks 111. A PLC can control the operation of the feed conveyor 6204 to move one stack at a time to the alignment conveyor 6206.

[0172] In the case of one or more stacks of carton blanks 111 arranged longitudinally on the feed conveyor 604, these stacks can be sequentially fed onto the alignment conveyor 6206. A sensor (not shown) can be provided near the feed conveyor 6204 to monitor whether there are stacks waiting on the feed conveyor 6204, and the sensor can be operable to send a warning signal to the PLC, which can warn the operator that the hopper 6110 is low and needs to be replenished. The sensor can be a sensor with part number 42GRP-9000-QD manufactured by Allen Bradley.

[0173] Of particular note is that multiple stacks of blanks can be provided on the feed conveyor 6204, and each stack of blanks can have associated information that can be read by an information reader 6205, such as an electronic or optical reading device. For example, barcodes can be provided on each stack of carton blanks 111, such as on the top or bottom carton blanks 111 of the stack. The barcodes can be read by a barcode reader associated with the feed conveyor 6204. The barcode reader can communicate with a PLC. The barcodes can provide information indicating the characteristics of the carton blanks 111 in the stack. For example, the barcode can identify the size and / or type of carton blanks 111 in a particular stack. Other information indicators, such as, for example, RFID tags / chips and RFID readers, can be used. The information can then be automatically provided by the information reader to the PLC, which can determine whether the current configuration of the carton forming system 100 is capable of handling blanks of a particular type / size without requiring manual adjustments to any components. It is taken into consideration that, within a certain type / size range of the cardboard box blank 111, Figure 50 The 6000 carton forming system can handle different types and sizes of carton blanks 111 without requiring manual adjustment. Figure 50 Any component of the carton forming system 6000. As discussed above, barcode / RFID tags can provide information about the dimensions of the carton blank 111, and the PLC can then determine the necessary adjustments (if required) to be made to be able to handle a particular carton blank 111 or a particular stack of carton blanks 111: (a) components of the hopper 6110; (b) movement of the end effector 6120; (c) movement of the reciprocating motion device 6140; and (d) at least some of the components of the folding device 6130 and some of the components at the sealing site 6135. As a result, Figure 50 The carton forming system 6000 can automatically process at least some different types of carton blanks 111 to form different upright cartons without requiring manual adjustment of any part of the carton forming system 6000 by the operator.

[0174] The belt of the feed conveyor 6204 can be driven by a suitable motor, such as a DC motor or a frequency converter motor controlled by a PLC via a DC motor driver (all sold by Oriental, model AXH-5100-KC-30).

[0175] Once the PLC has given instructions (e.g., by a human operator via an HMI module), the feed conveyor 6204 can be activated to move the stacked carton blanks 111 horizontally downstream. The PLC can control the motor via a motor driver, and thus control the feed conveyor 6204 to move and transfer the stack toward and onto the alignment conveyor 6206.

[0176] The alignment conveyor 6206 can be driven by a motor with a corresponding motor driver. The motor for the alignment conveyor 6206 can also be controlled by a PLC. The alignment conveyor 6206 can be operated to further move the stacked carton blanks 111 horizontally until the front of the stack abuts against the flat front stop wall 6218.

[0177] The respective belts of the feed conveyor 6204 and the alignment conveyor 6206 can be made of any suitable material, such as Ropanyl.

[0178] During the horizontal movement of the stacked carton blanks 111 via the feed conveyor 6204 and the alignment conveyor 6206, the left side of the stacked carton blanks 111 can be supported and guided by a left sidewall 6200 that can be fixed to the frame 6109. The left sidewall 6200 can be oriented substantially vertically and can extend horizontally for substantially the entire length of the feed conveyor 6204 and the alignment conveyor 6206.

[0179] The outer side of the hopper 6110 adjacent to the feed conveyor 6204 can remain open; however, the outer side of the alignment conveyor 6206 is illustrated as having a movable outer guide wall 6201.

[0180] exist Figure 50 During operation of the carton forming system 6000, the left-hand sidewall 6200 is fixed, and the outer guide wall 6201 can be laterally moved as part of the blank stacking alignment process to provide a generally longitudinal alignment of the end edges of the stacked carton blanks 111 in preparation for processing, while the stack of blanks is held between the left-hand sidewall 6200 and the outer guide wall 6201. Specifically, the PLC can position the outer guide wall 6201 based on information previously read by the information reader 6205, based on the height dimension of the removable carton blanks 111 in the stack ready for processing.

[0181] To pick up the blank, the end effector 6120 may have one or more suction cups that provide suction to the panel generally perpendicular to the surface of the panel to be joined. Other suitable types of joining devices may also be used.

[0182] The end effector 6120 is illustrated as having a dedicated, independently driven and controlled mobile device 6115, which allows the end effector 6120 to move within a plane defined by both the vertical axis Z and the horizontal axis Y. Therefore, the end effector 6120 can only move in the vertical direction Z and the horizontal direction Y; it cannot move in the horizontal direction X. If the movement of the end effector 6120 is restricted to only the Z and Y directions, a relatively less complex mobile device can be constructed compared to the desired movement in all three directions.

[0183] The mobile device 6115 includes a vertically oriented support tube, the cross-section of which may be generally rectangular, and an end effector 6120 may be mounted to the support tube by a mounting block, such that the end effector 6120 moves in space together with the support tube.

[0184] The folding device 6130 is illustrated as having opposing horizontally reciprocating finned plowshares, namely an upstream finned plowshare and a downstream finned plowshare. These finned plowshares are slidably supported on a horizontal track 6512 extending in the X direction.

[0185] The finned plow-shaped member is attached to the base of the L-shaped support at either end of a horizontal guide rail 6512 on which it runs. One of the L-shaped supports is associated with reference numeral 6560a. The L-shaped support straddles the channel 6562 of the vertical ribs 6109a, 6109b of the frame 6109. A servo motor 6568 meshes with a common drive shaft 6570 to rotate a pinion (not shown) within hubs 6572a, 6572b. This pinion meshes with a ring gear portion of shafts 6574a, 6574b to rotate and thus adjust the vertical position of shafts 6574a, 6574b. Shafts 6574a, 6574b are rotatably connected to the top of the L-shaped support. As a result, operation of the servo motor 6568 in one direction of rotation raises the L-shaped support—and thus the finned plow-shaped member—and operation of the servo motor 6568 in the opposite direction of rotation lowers the L-shaped support.

[0186] Similarly, the folding plow-shaped member runs on a vertical guide rail via a support arm and carriage, which is attached to a linear support member in a channel straddling the vertical ribs of the frame 6109. A common drive shaft also rotates a pinion (not shown) within hub 6572c, which meshes with a ring gear portion of shaft 6574c to rotate and thus adjust the vertical position of shaft 6574c. Shaft 6574c is rotatably connected to the top of the linear support member. As a result, operation of servo motor 6568 in one rotational direction raises the linear support member—and thus the folding plow-shaped member—and operation of servo motor 6568 in the opposite rotational direction lowers the linear support member. Furthermore, since all supports are adjusted by common drive shaft 6570, all these supports are adjusted to the same vertical height by operation of the servo motors.

[0187] Sealing station 6135 includes a tape sealer 6640 and a folding bar 6632, which are supported by finned support rails 6512 and move vertically together with the finned plowshare. Sealing station 6135 also includes a pair of opposing conveyor belts: an upper conveyor belt driven by an upper conveyor belt servo motor 6602 and a lower conveyor belt 6610 driven by a lower conveyor belt servo motor 6612, with the tape sealer 6640 positioned between the upper and lower conveyor belts. The lower conveyor belt 6610 and support platform 6614 are supported by the factory floor. The upper conveyor belt is mounted to a subframe 6622. The servo motor 6568 has a second drive shaft operatively associated with a transmission system (not shown), such that the operation of the servo motor 6568 adjusts the vertical position of the subframe 6622, and thus adjusts the vertical position of the upper conveyor belt relative to the lower conveyor belt 6610. Furthermore, it should be noted that the drive shaft and the common drive shaft 6570 are driven by the same servo motor 6568, such that the vertical adjustment of the upper conveyor belt is mirror-symmetrical to the vertical adjustment of the finned plowshare. However, the transmission system is configured with a 2:1 gear ratio, such that for any rotation of the common drive shaft 6570, the drive shaft rotates twice. As a result, a vertical adjustment of n cm for the finned plowshare, folding plowshare, tape sealer, and folding support rod leads to a 2n cm vertical adjustment of the upper conveyor belt. This ensures that, for any position of the upper conveyor belt, the centerline of the carton sleeve remains at the height of the finned plowshare and tape sealer.

[0188] Sealing station 6135 terminates at carton reorientation station 6116. Carton reorientation station 6116 has a pair of deflecting plates 6650, 6652 that, as the upright carton falls from the end of the sealing station onto the unloading conveyor 6117, deflecting plates 6650, 6652 reorient the upright carton from a sideways position at sealing station 6135 to a vertical position on the unloading conveyor 6117, with the top opening of the upright carton facing upwards. Unloading conveyor 6117 can be implemented as a simple annular belt conveyor driven by an unloading conveyor servo motor 6648.

[0189] exist Figure 51 In another aspect of this application, as schematically illustrated, in addition to what is described below, the carton forming system 5100 and Figure 50 The 6000 carton forming system is constructed in essentially the same way. Figure 51 In the carton forming system 5100, multiple hoppers M1-M5 can be supported by one or more frame structures located above a common feed conveyor 6204', which can generally be as follows: Figure 50 The feed conveyor 6204 is constructed as described above. The hoppers M1-M5 can be arranged longitudinally spaced apart from each other vertically above the feed conveyor 6204'. The feed conveyor 6204' feeds the alignment conveyor 6206', which can be configured as follows: Figure 50 Alignment conveyor 6206. In addition to the description below, Figure 51 The remainder of the carton forming system 5100 can be combined with Figure 50 The same as the 6000 carton forming system.

[0190] Each hopper M1-M15 can hold one or more stacks of product packaging, such as each being generally composed of... Figure 50 The carton forming system 6000 processes carton blanks 111, wherein at least some of the hoppers M1-M15, and possibly each of the hoppers M1-M15, contains packaging / carton blanks of different types / sizes and / or configurations compared to the other hoppers. The size, configuration, and type of the carton blanks (and the cartons that can be formed therefrom) can vary to provide packaging / carton blanks that can be formed by… Figure 51 The 5100 carton forming system automatically handles a range of carton sizes, configurations, and types without any manual intervention. Figure 51 Any component of the 5100 carton forming system. For use with Figure 51 The PLC of the carton forming system 5100 can be programmed so that the specific size / overall size / configuration (e.g., regular slotted carton or "RSC") / type of each of the carton blanks held in each of the hoppers M1-M5 is stored in the PLC's memory.

[0191] Each hopper M1-M5 can provide vertical stacking of box blanks above feed conveyor 6204', and can distribute individual box blanks onto feed conveyor 6204' as needed in a flattened orientation under PLC control. An example arrangement of a suitable type of vertical box distribution hopper is the hopper that forms part of the 310E box erector manufactured by Wepackit Corporation of Orangeville, Ontario, Canada (see www.wepackitmachinery.com / 310E / 310E.pdf).

[0192] The PLC can issue instructions to form cartons, and if necessary, the PLC can cause one of the hoppers M1-M5 to distribute appropriately configured / sized carton blanks onto the feed conveyor 6204' for delivery to the alignment conveyor 6206'. The PLC is intended to selectively move and transfer individual carton blanks from any of the hoppers M1 to M5 onto the feed conveyor 6204' at a time. Therefore, individual carton blanks can be continuously and longitudinally fed by the feed conveyor 6204' into the alignment conveyor 6206' in a desired sequence. Figure 51 The specific sequence / order of carton blanks on the feed conveyor 6204' of the carton forming system 5100 can be determined and selected by a PLC or another control system, so that the carton blanks can arrive at the alignment conveyor 6206' in a desired sequence, in which it is expected that... Figure 51 The 5100 carton forming system internally processes blanks.

[0193] The PLC can store a record in its memory of the sequence of box blanks already placed on the feed conveyor 6204'. For example, this information may include the type / size / configuration of the box blanks, and... Figure 51 In the case of a carton forming system 5100 that includes a labeling machine, this information may include some labeling information for the labels to be applied to the carton blanks. Each time a new carton request is received, a new record can be added, and optionally, once the carton is formed (and labeled), the record can be removed. Therefore, such records can be organized and maintained sequentially in the PLC's memory using conventional shift register techniques. In this way, when a carton blank arrives, a record of the next carton blank scheduled to arrive at the alignment conveyor 6206' can be provided at the output of the shift register, and the type / configuration / size of this carton blank and its labeling information can be determined based on the provided output.

[0194] Additional features that can be used in a carton forming system 6000 are provided in U.S. Patent Publication No. US2021 / 0138756 A1, published on May 13, 2021, in the name of HJ Paul Langen, the entire contents of which are incorporated herein by reference.

[0195] Figure 52 The order fulfillment location 5200 is illustrated in a floor plan. Order fulfillment location 5200 can be considered as being logically or physically organized into areas or zones associated with various functions. Order fulfillment location 5200 includes a product storage and introduction area 5202, a tower storage area 5204, a transport container introduction area 5206, a product introduction area 5208, an autonomous mobile robot movement area 5210, and a route distribution and accumulation area 5212. In practice, depending on the size of order fulfillment location 5200, it may include... Figure 52 The diagram shows multiple areas, and in some cases, one or more areas may be omitted. The product introduction area 5208 may be enclosed by multiple walls and a top.

[0196] At the product storage introduction area 5202, various products can be shown arriving at the order fulfillment location 5200 in, for example, multiple delivery trailers.

[0197] Arrived products, typically arranged in an orderly fashion on pallets, can be stored in multiple towers located at tower storage area 5204. Personnel and / or robots 5999 can unload delivered products (such as those delivered by transport trailers, and these products can be delivered on pallets) into order fulfillment system 5200. Personnel and / or robots 5999 can then store the unloaded products in the towers. When full, a given tower can then be moved by a tower transport mechanism (AMR) (discussed below) so that the given tower is located within tower storage area 5204. The process of storing products that have arrived at order fulfillment location 5200 into multiple towers will be described in more detail below.

[0198] The transport container introduction area 5206 can be filled with multiple carton forming systems that may follow the design of the previously disclosed carton forming system 100.

[0199] According to various aspects of this application, multiple autonomous mobile robots (AMRs) can be deployed to move within the autonomous mobile robot movement area 5210.

[0200] As will be discussed in detail below, AMR can be controlled to access transport container introduction area 5206 to obtain the transport container.

[0201] The combination of the AMR and the transport container can then be controlled to access one or more sites in product entry area 5208. At a given site in product entry area 5208, one or more products can be received within a transport container carried by the AMR. Sites in product entry area 5208 can be associated with the supply of products stored in tower storage area 5204.

[0202] Upon receiving the completed order, the AMR can then be controlled to move within the autonomous mobile robot's movement area 5210, enabling further order fulfillment functions. For example, the AMR can then be controlled to move the transport container to a location within the autonomous mobile robot's movement area 5210 where the weight of the transport container can be verified. The transport container can then be sealed and labeled.

[0203] Then, at route distribution accumulation area 5212, the transport container, which has been weight verified, sealed and labeled, can be received, and at route distribution accumulation area 5212, the transport container can be loaded onto the delivery vehicle by personnel and / or robot 5998.

[0204] Figure 53 The AMR 5300 according to this application is illustrated in a top-right perspective view.

[0205] Figure 53A The diagram shows... Figure 53 A top-right perspective view of the AMR 5300, with the transport container 5309 added.

[0206] The AMR 5300 may have a base forming part of a mobile cart 5304. Other components may be attached to or interconnected with the base of the cart 5304. The AMR 5300 may include an outer casing 5302 carried by the cart 5304. The cart 5304 may be similar in features to known autonomous mobile robots. In practice, the cart 5304 is expected to include a rechargeable power source, such as a battery (not explicitly shown), and a transmission (not explicitly shown). The transmission or drive motor may be configured to cause a set of drive wheels (not shown) to move the cart 5304. The rechargeable power source, transmission, and drive wheels may be mounted to the base of the cart 5304. The typical charging interval for a modern AMR can be up to three hours. The AMR 5300 may be configured to return to a designated charging station as needed. At the designated charging station, the AMR 5300 may establish a connection between a charging circuit (not shown) and an external power source such as a wall outlet.

[0207] In addition to the set of drive wheels, the trolley 5304 may also have a set of stabilizing wheels 5306S, which may be casters to allow the trolley 5304 to easily rotate and move during operation. There may be at least three wheels in total, including drive wheels and stabilizing wheels 5306S, which together support and drive the movement of the trolley 5304 on the surface. The trolley 5304 may also be intended to include a control system (not explicitly shown), which may be implemented as a processor communicating with memory. The AMR 5300 may include a transceiver for establishing a wireless connection with a controller that forms part of the overall system, which will be discussed in detail below.

[0208] Details of the example design for AMR 5300 can be found in U.S. Provisional Patent Application Serial No. 63 / 424676, the contents of which are incorporated herein by reference. The details of the example design include a description of multiple suction cups mounted to the outer casing 5302. Figure 53A As shown in the diagram, the suction cup can be used to hold the transport container 5309 on the AMR 5300.

[0209] Figure 54 A cross-sectional perspective view of the AMR 5300 is illustrated. The outer casing 5302 can be made of a suitable material such as molded plastic, fiberglass, aluminum, or other metals. The contents of the outer casing 5302, held within its inner cavity, are illustrated using dashed lines. The contents of the outer casing 5302 may include a vacuum reservoir 5402 and a plurality of suction cups 5404 mounted to the outer casing 5302. The suction cups 5404 may be mounted in a generally vertically upward direction and have an upward contact surface. In other embodiments, the suction cups 5404 may additionally or alternatively be oriented in other orientations, such as lateral.

[0210] Preferably, the multiple suction cups 5404 are mounted to the outer casing 5302 with their contact surfaces facing upwards, maintaining a flush top surface 5412 of the outer casing 5302. In practice, the top surface 5412 of the outer casing 5302 may appear to have multiple recesses corresponding to the multiple suction cups 5404. The suction cups 5404 can be implemented using, for example, 2-inch pigrip suction cups manufactured by PIAB of Toby, Sweden. A vacuum pump 5406, pneumatically connected to the vacuum reservoir 5402, can be mounted to the trolley 5304 of the AMR 5300. The vacuum pump 5406 can be driven by an integrated electric motor (not shown). Examples of suitable electric vacuum pumps for use as the vacuum pump 5406 are those available from McMaster-Carr of Cleveland, Ohio, and Thomas of Sheboygan, Wisconsin. The vacuum reservoir 5402 is also pneumatically connected to the multiple suction cups 5404 via corresponding multiple holes / openings in the vacuum reservoir 5402. A sliding plate 5408 is positioned between an opening / hole in the vacuum reservoir 5402 and each of a plurality of suction cups 5404 (and a corresponding valve 5502 as described below). The sliding plate 5408 may be made of a suitable material, such as molded plastic, fiberglass, aluminum, or other metal, and may be configured with perforations / openings corresponding to each opening in the vacuum reservoir 5402. The sliding plate 5408 is movable between a closed position / state and an open position / state, in which the opening in the vacuum reservoir and the opening of each corresponding valve 5502 / suction cup 5404 combination (as further described below) are blocked, and in the open position / state, the opening in the vacuum reservoir and the opening of each corresponding valve 5502 / suction cup 5404 combination (as further described below) are not blocked, thereby allowing suction to be generated at the top contact surface of each corresponding valve 5502 / suction cup 5404 combination.

[0211] The sliding plate 5408 can be moved between an open and closed position by actuation of the electric actuator 5410. An example of an actuator type that can be used as the electric actuator 5410 is a solenoid valve type actuator, such as the A14092600ux0438 open-frame actuator linear mini push-pull solenoid electromagnet manufactured by uxcell in Hong Kong, China, DC 4.5V, 40 g / 2mm. Another example of an electric actuator type that can be used as the electric actuator 5410 is a linear stepper motor type actuator, such as the VSM0632 6mm miniature linear stepper motor with bracket manufactured by VicTech Motor Co., Ltd. in Changzhou, Jiangsu, China. Yet another example of an electric actuator type that can be used as the electric actuator 5410 is a linear potentiometer type actuator, such as a model from the LMCR8 series from P3 Americas in San Diego, California.

[0212] Figure 55A A cross-sectional view shows a portion of the outer casing 5302, as well as multiple suction cups 5404, a vacuum reservoir 5402, and a sliding plate 5408. Figure 55A The cross-sectional view illustrates each suction cup 5404 combined with a one-way valve 5502. The one-way valve 5502 can be implemented, for example, using a piSave sensing flow control / check valve manufactured by PIAB of Täby, Sweden.

[0213] exist Figure 55A In the first open position, the sliding plate 5408 is in the first open position. In the first open position, the perforation in the sliding plate 5408 is aligned with the hole in the vacuum reservoir 5402. Figure 55A The alignment shown in the diagram can be illustrated as allowing airflow through each suction cup 5404, into and through the one-way valve 5502 of the suction cup 5404, and into the negative pressure vacuum reservoir 5402. It is noteworthy that when the sliding plate 5408 is in the first open position, the airflow through the suction cups 5404 is controlled by the one-way valve 5502.

[0214] Figure 55B The cross-sectional view is shown. Figure 55A The same part as the outer box 5302 shown in the diagram. Figure 55B In the middle, the sliding plate 5408 is in the second closed position. In the second closed position, the perforation in the sliding plate 5408 is not aligned with the hole in the vacuum reservoir 5402. Figure 55B The misalignment shown in the diagram can be illustrated as preventing or blocking air from flowing into the suction cup 5404 through the one-way valve 5502 and into the vacuum reservoir 5402.

[0215] During operation, the pressure within the vacuum reservoir 5402 is reduced by an action performed by the vacuum pump 5406. In effect, in response to commands received from the control system, the vacuum pump 5406 can cause the integrated electric motor to create negative pressure within the vacuum reservoir 5402. When the control system controls the drive wheel 5306D to operate the AMR 5300, the sliding plate 5408 can be maintained in a second position, thereby reducing vacuum pressure leakage.

[0216] Figure 56A The illustration shows an embodiment of the basic concept of a fulfillment center 7000, which utilizes, for example... Figure 53 AMR 5300 and / or Figure 58 The AMR device of the AMR 5800 is illustrated in the figure and described below.

[0217] Each of the multiple AMRs in the system, such as AMR 5800 (and / or AMR 5300), can be programmed to move from one station to another along the following path 7680: 1. Each AMR 5300 / 5800 moves to one of several carton entry stations 7628, where a carton erector transfers the upright, bottom-sealed carton onto the AMR 5300 / 5800.

[0218] 2. Each AMR 5300 / 5800 then moves to one or more product introduction stations in product introduction area 7608, which can be manual product introduction stations and / or robotic product introduction stations, where the operator and / or robot places one or more ordered products into upright cartons. Robotic product introduction stations may also be referred to as product transfer devices.

[0219] 3. Each AMR 5300 / 5800 is then moved to one of the multiple order verification sites 7630 to verify whether the contents of the box correspond to the product in the order.

[0220] 4. Each AMR 5300 / 5800 then moves and passes through the top sealer 7620 and the box labeler 7624.

[0221] 5. Each AMR 5300 / 5800 then moves to the finished product box unloading conveyor 7626.

[0222] 6. Each AMR 5300 / 5800 can then be moved to one of the charging stations 7622 or returned to one of the box entry stations 7628, where the box erector can transfer the upright, bottom-sealed box to the AMR 5300 / 5800 to allow the cycle to be repeated.

[0223] The container erector at container entry station 7628 may be a container erector of model MC-17169 manufactured by AFA Systems, Inc., Ontario, Canada, or it may be another container erector described herein. Container entry station 7628 may also be referred to as a transport container delivery system. The container top sealer 7620 and the container labeling machine 7624 may also be devices available from AFA Systems, Inc. The container erector at container entry station 7628 may be the container erector disclosed in U.S. Patent Publication No. 2021 / 0138756 A1, published May 13, 2021, the entire contents of which are incorporated herein by reference.

[0224] Figure 68 An example arrangement of the box top seal 7620 is illustrated in a left front perspective view (and example box top seals may also be provided for other order fulfillment systems described herein). Figure 68 The example box top seal 7620 can be understood as having many of the same features and components as known box top seals. However, Figure 68The difference between the example box top sealer 7620 and known box top sealers is that when the upright carton is... Figure 68 When the components of the example carton top seal 7620 are in operation, the upright cartons are maintained on the AMR 5300 / 5800. That is to say, Figure 68 The example box top seal 7620 can be considered a "drive-thru" sealing device. The AMR 5300 / 5800 can move the sealing device 7620 using only its own drive mechanism and is powered by the sealing device 7620.

[0225] Figure 68 The components of the example carton top sealer 7620 may include a pair of laterally spaced, longitudinally extending guide strips 6802. These laterally spaced, longitudinally extending guide strips 6802 may be made of a suitable material such as rubber. Each guide strip 6802 may be arranged around a pair of freely rotatable pulleys that can rotate about a generally vertically oriented axis. The guide strips 6802 may be shown as being operable to guide upright cartons through the example carton top sealer 7620 during longitudinal movement of an AMR 5300 / 5800 having upright cartons thereon. The guide strips may be shown as guiding cartons through the carton during longitudinal movement of the AMR 5300 / 5800. Figure 68 The example carton top seal 7620 contacts the corresponding opposite side surface of the upright carton fixed to the AMR5300 / 5800.

[0226] In various aspects of this application, the movement and positioning of the guide belt 6802 can be sensed by a guide belt movement sensor (not shown). The output from the guide belt movement sensor, which can be transmitted to the order fulfillment processor, can be shown as indicating the movement of the AMR 5300 / 5800 and the upright cartons through the carton top seal 7620, the operation of which will be discussed in more detail below. Conveniently, the position of the pulleys can be adjusted laterally to change the distance between the guide belts 6802 to accommodate upright cartons of different sizes.

[0227] Similar to known box top seals, Figure 68The components of the example carton top sealer 7620 may include one or more folding guides 6806, one or more folding kickers such as a rear folding kicker 6808, and a sealing system 6804. In operation, as the guide belt 6802 guides the upright carton through the example carton top sealer 7620 during longitudinal movement of the AMR 5300 / 5800 carrying the upright carton, the rear folding kicker 6808 can be used to close the rear top fold, and the folding guides 6806 (and / or one or more other folding kickers) can be used to close the front top fold and the side top folds. As with known carton top sealers, after or simultaneously with the top fold being closed, the sealing system 6804 can seal the carton by applying tape or other adhesive to hold the top fold in the closed position.

[0228] With similar Figure 68 The example carton top sealer 7620 can be considered a "drive-thru" sealing device, and the carton labeler 7624 can be considered a "drive-thru" carton labeler, allowing the AMR 5300 / 5800 to move entirely under its own power through the carton labeler 7624. In fact, the carton top sealer 7620 and the top labeler 7624 can be located in the same position, so that when the AMR 5300 / 5800 transfers upright cartons through the carton top sealer 7620 and the top labeler 7624 located in the same position, the open, upright cartons can be closed, sealed, and labeled.

[0229] Figure 56 A floor plan of part 5600 of the order fulfillment center is shown. Part 5600 of the fulfillment center includes a charging station 5602, a transport container entry station 5604, multiple cargo loading stations 5606A, 5606B, 5606C (common or individual 5606), a padding entry station (not shown), an inspection station (not shown), a rework station (not shown), and an order verification station (not shown). Figure 56 (As shown in the diagram), closed station 5616 and route transfer station 5618. Transport container introduction station 5604 can also be referred to as transport container delivery system.

[0230] Figure 57 The illustration shows example steps in the method of fulfilling an order.

[0231] Given Figure 56 The control system can control the drive wheels 5306D to move the AMR 5300 from the charging station 5602 (step 5702). Figure 57The AMR 5300 arrives at the transport container inlet station 5604. When the AMR 5300 arrives at the transport container inlet station 5604, the control system can control the electric actuator 5410 to move the sliding plate 5408 to a first position. Minimizing vacuum leakage in the reservoir can be considered an important step towards minimizing the number of activations and duration of the vacuum pump 5406. Frequent activation of the onboard vacuum pump 5406 can reduce the cycle time (charging period) of the AMR 5300.

[0232] At the transport container entry site 5604, it can be received on the top surface 5412 of the outer casing 5302 (step 5704). Figure 57 ) Transport containers of appropriate size to fulfill customer orders (see 5309) Figure 53A When the transport container 5309 does not completely cover the top surface 5412 of the outer casing 5302, a subset of the one-way valves 5502 senses that it is covered by the transport container. In response to this sensing, this subset of the one-way valves 5502 can actuate autonomously to open. The remaining one-way valves 5502 can remain closed. The transport container 5309 can be a flexible (e.g., plastic) type of bag, sleeve, pallet, carton, box, or container. When the transport container 5309 is not full, it may have a relatively low mass / weight and therefore may be prone to displacement, especially during operation when the trolley 5304 is moving, if it is not secured to the top surface 5412 with suction(s).

[0233] AMR 5300 can generate suction at each of at least some of the multiple suction cups 5404 (step 5706). Figure 57 This keeps transport container 5309 on AMR 5300.

[0234] The combination of the sliding plate 5408, which has been moved to the first position, and the subset of the one-way valve 5502 that has been autonomously opened can be shown as such that the suction cup 5404 acts on the transport container 5309 to hold the transport container 5309 in proper position on the top surface 5412 of the outer casing 5302. In some embodiments, when placed and held on the top surface 5412, the coverage area of ​​the transport container 5309 will ensure that the boundary of the transport container 5309 does not extend beyond the perimeter of the top surface 5412.

[0235] When the transport container does not completely cover the top surface 5412 of the outer casing 5302, only a subset of the plurality of suction cups 5404 corresponding to a subset of the autonomously opened one-way valves 5502 act on the transport container 5309. The one-way valves 5502 can be configured and operated such that the corresponding state of the valve changes from a substantially inactive mode (which may only allow very low levels of airflow into the combination of suction cups 5404 / valve 5502) to an active mode only when the surface area of ​​the object (e.g., a portion of the lower surface of the transport container 5309) covers the corresponding suction cup 5404. In the active mode, the significantly increased (e.g., maximum) airflow into the combination of suction cups 5404 / valve 5502 results in a significantly increased (e.g., full) suction force generated by the suction cups. By activating only the suction cups 5404 that cover a portion of the surface of the transport container, compared to an embodiment where all one-way valves 5502 open simultaneously and all suction cups 5404 are activated regardless of whether the contact surface of the transport container 5309 covers all or only some of the contact surface of the suction cups 5404, this can result in a reduction in the energy consumed by the AMR 5300. For example, a relatively small vacuum pump can be used, thereby reducing pump investment and energy consumption.

[0236] As can be seen, for transport containers of various sizes and shapes, the one-way valve 5502 allows the AMR 5300 to be adapted to hold the transport container in place on the top surface 5412 of the outer carton 5302. That is, to name just four examples, the AMR 5300 can be adapted to hold the transport container 5309 in place when the transport container is a box with a regularly slotted bottom standing upright, a carton with an open top or open sides, a cardboard box with an open top or open sides, a flexible bag with an open end, or a sleeve with an open top or side. In general, for transport containers of various sizes, such as any type of transport container having a bottom surface portion that can cover one or more suction cups, and when the transport container can have openings at the top, sides, or ends, the AMR 5300 can be considered to be efficiently adapted to hold these transport containers in place.

[0237] Because the transport container 5309 is held in place on the top surface 5412 of the outer casing 5302, the transport container 5309 can remain secured to the AMR 5300. In other words, when the AMR 5300 transports the transport container 5309 to and from various sites around the fulfillment center (see...), the container remains securely attached to the AMR 5300. Figure 56This prevents the transport container 5309 from moving or falling when performing actions such as loading goods into the transport container 5309, closing the transport container, and labeling the transport container 5309. It will be understood that the embodiments disclosed herein may be particularly advantageous when the transport container 5309 is empty or contains lightweight goods, making it more likely that the transport container 5309 will move back and forth on or fall from the top surface 5412, especially when the trolley 5304 is moved during operation.

[0238] In some embodiments, when suction is generated at each of at least some of the suction cups 5404 to hold the transport container 5309 on the AMR 5300, the control system of the trolley 5304 can subsequently execute instructions to cause the set of drive wheels 5306D to move appropriately via a guide transmission to move the AMR 5300 from the transport container into the station 5604 (step 5708). Figure 57 ) to one or more cargo loading stations 5606.

[0239] Therefore, AMR 5300 can be shown as moving transport container 5309 from transport container introduction station 5604 (step 5708, Figure 57 (To the first cargo loading station 5606A, AMR 5300 can be maintained at the first cargo loading station 5606A (step 5710,) Figure 57 The AMR 5300 controls the transport container 5309, which receives goods loaded into it. Loading goods into the transport container 5309 can be done autonomously, for example, by a product loading robot (not shown) receiving instructions, or, for example, manually. The AMR 5300 can transport the transport container 5309 from a first cargo loading station 5606A to a second cargo loading station 5606B, where more goods can be loaded into the transport container 5309.

[0240] In determining (step 5712), Figure 57 Before AMR 5300 has visited a complete set of cargo loading sites 5606 for a specific customer order, the control system can move (step 5714). Figure 57 AMR 5300 transports transport container 5309 to another cargo loading site 5606.

[0241] In determining (step 5712), Figure 57 When AMR 100 has visited a complete set of cargo loading sites 5606 for a specific customer order, the control system can move (step 5714). Figure 57AMR 5300 is used to transport transport container 5309 from the final cargo loading station 5606 to the top sealing and marking system (not shown) at the closed station 5616.

[0242] The top closure and labeling system can be designed to accept regular slotted boxes, sleeves or bags, and other transport containers. Transport container 5309 can be closed and labeled by the top closure and labeling system without leaving its fixed position on the top surface 5412 of the outer casing 5302.

[0243] Conveniently, it can be seen that when goods are directly loaded into transport containers 5309 fixed to the AMR 5300, the number of multiple fulfillment operations proposed in this paper is significantly reduced compared to the number of fulfillment operations that are currently required in routine fulfillment operations.

[0244] Once closed site 5616 has been visited, the control system can move (step 5716). Figure 57 The AMR 5300 is used to transport the transport container 5309 from the closed site 5616 to the appropriate route transfer station 5618. At the route transfer station 5618, the control system of the AMR 5300 can control the electric actuator 5410 to move the sliding plate 5408 to a second position. It should be understood that when the sliding plate 5408 is in the second position, the vacuum suction cups 5404 do not function to maintain their grip on the transport container 5309, and thus the transport container 5309 is released from the AMR 5300 (step 5718). Figure 57 Therefore, transport container 5309 can be removed from AMR 5300 and placed at route transfer station 5618, for example, onto the appropriate route transfer conveyor.

[0245] In addition to the cargo loading station 5606, the closed station 5616 and the route transfer station 5618 described above, the AMR 5300 can be shown as transporting the transport container 5309 to or from various other stations or areas such as a padding introduction station, an inspection station, a rework station and an order verification station.

[0246] Once transport container 5309 has been removed from AMR 5300, AMR 5300 can be controlled to return to transport container introduction station 5604 to obtain a new transport container, which is suitable for fulfilling the next customer order.

[0247] Conveniently, the one-way valves 5502 and their ability to open autonomously in response to sensing that the transport container 5309 covers them can be shown to minimize vacuum loss when any part of the suction cup 5404 is not covered by the transport container, thus giving the AMR 5300 the characteristic of versatility.

[0248] Furthermore, the sliding plate 5408 can be shown as being used to cut off the vacuum, thereby establishing that any size transport container fixed to the AMR 5300 can be released at any time during the process without losing the vacuum in the vacuum reservoir 5402.

[0249] It is worth noting that the combination of the outer casing 5302 and the vacuum pump 5406 can be used to modify the existing version of the trolley 5304. Of course, for proper operation, the control system for the trolley will undergo appropriate software updates. Alternatively, the AMR 5300 can be formed as a single unit. That is, there may be no discernible difference between the trolley 5304 and the components previously described as being housed in the outer casing 5302.

[0250] Figure 53 The features of the cart 5304 are likely similar to those of known autonomous mobile robots. In fact, the cart 5304 is expected to include a rechargeable power source, such as a battery (not explicitly shown), and a transmission mechanism (not explicitly shown). The transmission mechanism or drive motor can be configured to cause the set of drive wheels 5306D to move the cart 5304. The rechargeable power source, transmission mechanism, and drive wheels 5306D can be mounted to the base of the cart 5304. Typical modern AMRs have charging intervals of up to three hours. The AMR 5300 can be configured to return to a designated charging station 5602 as needed. At the designated charging station 5602, the AMR 5300 can establish a connection between a charging circuit (not shown) and an external power source such as a wall outlet.

[0251] It should be clear that other mechanisms can also be used to keep transport containers on the AMR. Figure 58 The illustrations depict various aspects of the actions according to this application. Figure 53 The AMR 5800 is an alternative to the AMR 5300.

[0252] The AMR 5800 has a base that forms part of the mobile trolley 5804. Other components can be attached to or interconnected with the base of the trolley 5804. Figure 53 The same as the AMR 5300, Figure 58The AMR 5800 may have an onboard control system (not shown). The AMR 5800 may include a first belt 5802A and a second belt 5802B carried by a trolley 5804. The first belt 5802A may be controlled, for example, by the onboard control system (not shown) in a manner independent of controlling the second belt 5802B. A first lug 5812A may be attached to the first belt 5802A. A second lug 5812B may be attached to the second belt 5802B.

[0253] By controlling the onboard control system of the first belt 5802A, the first lug 5812A can be actuated in a direction toward or away from the second lug 5812B. Similarly, by controlling the onboard control system of the second belt 5802B, the second lug 5812B can be actuated in a direction toward or away from the first lug 5812A. In this way, by manipulating the position of the first lug 5812A and the second lug 5812B relative to each other, the onboard control system can control the first belt 5802A and the second belt 5802B to prepare a gap between the first lug 5812A and the second lug 5812B, a gap suitable for easy loading of upright transport containers of selected dimensions (e.g., selected length and / or selected width of the bottom surface of the upright carton). By further manipulating the positions of the first lug 5812A and the second lug 5812B relative to each other, the onboard control system can control the first belt 5802A and the second belt 5802B to close the gap between the first lug 5812A and the second lug 5812B, thereby securing the upright carton between the first lug 5812A and the second lug 5812B. The action of the first lug 5812A and the second lug 5812B can be shown as preventing the upright carton from accidentally falling off the AMR 5800. For example, in Figure 58 In the embodiment illustrated in the figure, the transport container 5809 is maintained on the AMR 5800 and simultaneously acted upon by a first lug 5812A and a second lug 5812B. When reaching the position where an upright carton containing goods will be unloaded from the AMR 5800, the onboard control system can control the second belt 5802B to move the second lug 5812B so that it is no longer engaged with the upright carton. The onboard control system can also control the first belt 5802A, and thus the first lug 5812A, to actuate the upright carton containing one or more goods onto an input conveyor for further processing of the upright carton phase. For example, as will be discussed below, the input conveyor may be associated with a carton sealer. In another aspect of this application, a robotic arm (not shown) can pick up an upright carton from the AMR 5800 and place the upright carton onto an input conveyor for further processing of the upright carton phase.

[0254] Therefore, the AMR 5800 can be used to transport a transport container and may include: a mobile trolley; a control system for controlling the operation of an autonomous mobile robot; a first belt having an upper surface including a first lug; and a second belt having an upper surface including a second lug. The control system is operable to control and adjust the spacing between the first lug and the second lug for movement between a first position and a second position, wherein in the first position the spacing between the first lug and the second lug is adapted to allow the transport container to be positioned between or removed from the first lug and the second lug on the upper surfaces of the first and second belts, and in the second position the spacing between the first lug and the second lug is such that the first lug and the second lug engage the side surfaces of the transport container to secure the transport container between the first lug and the second lug above the first and second surfaces of the belts. The upper surfaces of the first and second belts may be configured to support the transport container thereon, such that when the transport container is secured between the first lug and the second lug, the transport container is supported on the first and second surfaces of the belts. Figure 58 The movement of the AMR 5800 shown in the diagram can be similar to... Figure 53 The movement of the AMR 5300 is shown in the middle diagram (reference). Figure 56 discuss).

[0255] See Figure 57 When using Figure 58 The AMR 5800 shown in the middle diagram is replaced by Figure 53 In the AMR 5300 illustrated in the diagram, some steps differ. Specifically, step 5706 indicates the step of generating suction at each of at least some of the suction cups 5404 to hold the transport container 5309 on the AMR 5300. Figure 58 In the context of the AMR 5800 illustrated in the middle diagram, step 5704 may involve holding the transport container 5809 on the AMR 5800 by the action of lugs 5812A and 5812B. The details have already been discussed. Figure 57 Step 5718 involves releasing the transport container 5309 from the AMR 5300 by reducing the suction force provided by multiple suction cups 5404. In the scenario of releasing the transport container 5809 from the AMR 5800, the onboard control system can control the first belt 5802A and the second belt 5802B to eject the transport container 5809 from the AMR 5800 to the route transfer station 5618. Figure 53 AMR 5300 and Figure 58 In the context of both AMR 5800 and AMR 5300, step 5714 of moving the AMR 5300 / 5800 to the closed site may involve the AMR 5300 / 5800 driving the transport container through the box top sealer 7620 and the box labeling machine 7624 (see [link to documentation]). Figure 56AThis closes the open flaps, seals the transport container, and marks the transport container.

[0256] exist Figure 56 In the example loop illustrated in section 5600 of the fulfillment center, AMR 5800 can move to transport container entry station 5604, where upright, bottom-sealed cartons can be transferred onto AMR 5800. AMR 5800 can then move to one or more cargo loading stations 5606, where a human operator or robot can place one or more products into the upright, bottom-sealed cartons. AMR 5800 can then move to order verification station 7630 (see...). Figure 56A The AMR 5800 can then verify the contents of the upright, bottom-sealed cartons. The AMR 5800 can then move further to and through a sealing station 5616. Sealing station 5616 can be implemented with a top sealer and a labeling system. Therefore, at sealing station 5616, the upright, bottom-sealed cartons can be top-sealed and labeled. The AMR 5800 can then move the top-sealed and labeled cartons to a route transfer station 5618. Route transfer station 5618 can be implemented with a finished carton unloading conveyor. The AMR 5800 can release the top-sealed and labeled cartons at route transfer station 5618. The AMR 5800 can then move to a charging station 5602. Alternatively, the AMR 5800 can return to a transport container entry station 5604, where another upright, bottom-sealed carton can be transferred to the AMR 5800, allowing the cycle outlined above to be repeated.

[0257] Figure 64 The diagram illustrates the order fulfillment system 1000. Figure 64 The order fulfillment system 1000 can be understood as... Figure 52 This is performed in the scenario where the order fulfillment position is 5200. Figure 64 In this diagram, the order fulfillment system 1000 is shown to include several components, including an order fulfillment processor 1300. The order fulfillment system 1000 may include, for example, multiple carton forming systems 1100A, 1100B, and 1100C located in the transport container introduction area 5206. The carton forming systems 1100A, 1100B, and 1100C may also be referred to as transport container delivery systems.

[0258] A single fulfillment system 1000 can include multiple AMR 1400A, 1400B, and 1400C. Figure 64In the diagram, the order fulfillment system 1000 is illustrated as including multiple carton sealers 1500A, 1500B, and 1500C. Multiple customer order devices may also be provided, including a first customer order device 1200A, a second customer order device 1200B, and a third customer order device 1200C. Customer order devices 1200A, 1200B, and 1200C can be linked to an order fulfillment processor 1300. The first customer order device 1200A may, for example, be a telephone capable of communicating with a call center 1250. The call center 1250 may be adapted to receive orders from customers that operate the first customer order device 1200A, and then, using call center software, a call center operator can enter orders for one or more products. Orders can be transmitted to the order fulfillment processor 1300 via a communication link. The second customer order device 1200B and the third customer order device 1200C may be personal computing devices, such as mobile phones or personal computers, capable of communicating directly with the order fulfillment processor 1300 via wireless and / or terrestrial communication networks. This communication network may, for example, be an IPv4, IPv6, X.25, IPX-compatible, or similar network. Therefore, this network may be the public Internet. Through the operation of appropriate software on the customer order devices 1200B, 1200C and the order fulfillment processor 1300, the customer order devices 1200B, 1200C may be adapted to input orders for one or more products into the order fulfillment processor 1300. For example, the customer order devices 1200B, 1200C may be adapted to run a suitable browser supporting the Hypertext Transfer Protocol (HTTP) to access data and services provided by an HTTP server application run by the order fulfillment processor 1300. By using an HTTP-enabled browser, the customer order devices 1200B, 1200C can input orders for one or more products into the order fulfillment processor 1300.

[0259] The order fulfillment processor 1300 may be a mainframe computer, server, or other computing device capable of processing customer orders received directly or indirectly from customer order devices 1200A, 1200B, 1200C. The order fulfillment processor 1300 may include a database containing information that can be stored in suitable memory, including information associated with: (a) information / details of all products that a customer may order through the order fulfillment system 1000, containing one or more characteristics of each product, such as the physical volume and / or actual physical dimensions (e.g., height, width, length, and / or diameter) of the space occupied (e.g., the dimensions of the box holding one or more items), optionally, the weight of each product, and further optionally, the product code associated with each product, such as a Universal Product Code (UPC), or, if the product is a book, an International Standard Book Number (ISBN); (b) information / details of the dimensions of each type of carton / carton blank that can be or is being used in the order fulfillment system 1000 to package the customer's carton / carton blank. (c) Information / details of each carton forming system (e.g., carton forming systems 1100A, 1100B, 1100C), including information / details of the cartons that each carton forming system can form (such as type, size, and / or configuration), and optionally, when the carton forming system includes multiple hoppers, the type, size, and / or configuration of carton blanks provided in each of these hoppers, and the corresponding type, size, and / or configuration of upright cartons that can be formed from each type of carton blank, and further optionally, the quantity of carton blanks provided in each of these hoppers; (d) Information / details about each customer, including the name of the entity and the shipping address to which the order to be fulfilled by the order fulfillment system 1000 is to be delivered; and (e) Information / details about where each product is located in the product storage facility, such as the warehouse building where the products that may be ordered are stored. The database may be continuously updated to include new data. For example, new data may include data related to information / details about new inventory items, such as new items introduced into product storage introduction area 5202 of order fulfillment location 5200, or information / details about new types / sizes / configurations of cartons / carton blanks that can be used in order fulfillment system 1000 to package one or more products ordered by customers.

[0260] As described above, the order fulfillment processor 1300 may also include an HTTP server application adapted to provide database information to and receive orders from customer order devices 1200B and 1200C. Some or all of the above information / details may be manually entered into the order fulfillment processor 1300 by the operator of the order fulfillment system 1000. Alternatively or additionally, the information / details of each available carton may be updated periodically or continuously. The PLC 132 of each carton forming system 1100A, 1100B, and 1100C may be adapted to monitor the status of carton blanks in its(one or more) hoppers during operation and provide information related to that status to the order fulfillment processor 1300. In this way, the order fulfillment processor 1300 may be continuously provided with up-to-date information on the available carton blanks in the hoppers of each of the carton forming systems.

[0261] The order fulfillment processor 1300 may also include a product packaging utility / software module that identifies from a variety of available carton types the appropriate carton type (or multiple carton types) for packaging the products in a customer's order. An example of such a product packaging utility is disclosed in U.S. Patent No. 6,876,958 to Chowdhury et al., granted April 5, 2005, to assignee New Breed Corporation (“Chowdhury”), the entire contents of which are incorporated herein by reference. Specifically, Chowdhury's product packaging utility processes each customer order to automatically identify from available carton types / sizes / configurations the appropriate carton type / size / configuration for packaging the products in the order. Chowdhury's product packaging utility identifies / determines (one or more) suitable cartons based on an algorithm / function that accesses and uses one or more electronically stored features (e.g., size, weight, etc.) for each product in an order and one or more electronically stored features (e.g., size, dimensions, configuration, type, maximum volume that can be held, maximum weight that can be held, etc.) for available carton types. This algorithm identifies suitable cartons such that the minimum number and minimum size of cartons suitable for packaging the products in the order can be provided. Therefore, the identification of suitable carton types / sizes / configurations can be optimized to provide the optimal carton type / size / configuration that optimizes the packaging materials used and optimizes the free space within the carton, and the carton identified as suitable can be called the "optimal" carton. It will be understood that the identification of suitable carton types / sizes / configurations can also be based on other predefined criteria. Chowdhury's product packaging utility's carton identification algorithm can also consider other factors and constraints, such as the availability of each type / size / configuration of cartons, the maximum fill rate of each type / size / configuration of cartons, the maximum number of products that can be placed in each type / size / configuration of cartons, and whether certain products are pre-packaged together and therefore must be placed in the same carton. Therefore, when the order fulfillment processor 1300 includes a product packaging utility such as the one disclosed by Chowdhury, the order fulfillment processor 1300 can process a customer order for a specific product by accessing information in memory and utilizing algorithms / functions to identify suitable cartons (or multiple cartons) for packaging such products from among multiple available cartons.

[0262] It should be noted that the size of a carton can refer to the overall internal usable volume that can hold the item / item within the carton. Size can also refer to the specific dimensions of the carton. Information about the carton type may include a reference to the material used to manufacture the carton blank (e.g., cardboard or corrugated cardboard). Information about the carton type may also include a reference to a configuration that indicates whether the carton is a top-opening carton that is generally rectangular when closed, or another configuration such as a regularly slotted carton.

[0263] The product packaging utility disclosed by Chowdhury can generate a packing list for each carton identified as being fulfilled for a specific type / size / configuration of order. This packing list indicates the order in which each product should be placed in the carton, and information indicating where each product should be placed within the carton. For example, placement information can be expressed using three-dimensional coordinates (e.g., 0, 0, 0) in a coordinate system defined for the carton and / or position descriptors within the carton (e.g., front, right-hand side, second layer, etc.). Therefore, when the order fulfillment processor 1300 includes a product packaging utility, such as the one disclosed by Chowdhury, the order fulfillment processor 1300 can generate a packing list and / or placement information for each identified carton. The order fulfillment processor 1300 can also generate a diagram illustrating the desired optimal physical arrangement of the products in each carton. Such a diagram can be easily generated using the placement coordinates of each product, as provided by the product packaging utility disclosed in Chowdhury.

[0264] For each carton identified as belonging to a specific type of order to be fulfilled, the order fulfillment processor 1300 may be further configured to select one of carton forming systems 1100A, 1100B, and 1100C (1100 individually or collectively) to form a suitable carton of the type / size / configuration identified by the order fulfillment processor 1300. The order fulfillment processor 1300 may access and use information stored in its memory regarding the suitability of the carton forming system to process the identified suitable carton. For example, the suitability of the carton forming system may be determined by the order fulfillment processor 1300 based on information regarding whether the carton forming system contains boxes of the type / size / configuration required to hold the carton blanks needed to form the identified carton. The suitability of the carton forming system may also be determined based on stored information regarding the required type / size / configuration quantity of carton blanks in the hopper of the carton forming system. Such quantities may be measured using appropriate sensors placed at each carton forming system and updated during operation. Alternatively, the order fulfillment processor 1300 can simply select a carton forming system randomly or according to a predefined sequence.

[0265] Once the order fulfillment processor 1300 has selected a suitable carton forming system (e.g., ...), Figure 64 In one of the carton forming systems 1100, the order fulfillment processor 1300 can generate a fulfillment order data structure (e.g., file, object, message, etc.) containing information or instructions for the selected carton forming system 1100 to form a suitable carton blank into an upright carton. The generated fulfillment order data structure can be transmitted to the PLC 132 of the selected carton forming system 1100 via a communication link.

[0266] The fulfillment order data structure may include indicators that indicate (i) the type / size / configuration of cartons to be formed by the selected carton forming system 1100, as determined by the product packaging utilities; (ii) a specific hopper of the selected carton forming system 1100 containing carton blanks for forming suitable cartons; (iii) a list of one or more specific products from the customer order being fulfilled, which, once formed, will be loaded into upright cartons, optionally identifying the products by associated product codes and optionally arranged in the order in which the products will be loaded into upright cartons once formed; (iv) the site in the product introduction area 5208 for each specific product from the customer order being fulfilled; and (v) customer shipping information for the carton indicating the destination name and address. In some cases, the fulfillment order data structure may include information on multiple cartons processed by the selected carton forming system 1100.

[0267] The fulfillment order data structure can be received and processed by the PLC 132 of the selected carton forming system 1100. Specifically, the PLC 132 of the selected carton forming system 1100 processes the fulfillment order data configuration to identify the requested type / size / configuration of the carton (or multiple cartons) to be formed, and the specific compartment of the carton forming system containing the carton blanks for forming each desired carton. Once the suitable carton and the specific compartment containing the carton blanks for forming the suitable carton have been identified, the PLC 132 of the selected carton forming system 1100 can then cause the suitable carton blanks to be formed into the required carton type / size / configuration.

[0268] Alternatively, the data structure may be stored in the memory of the PLC 132 of the carton forming system, or in the memory of the order fulfillment processor 1300 for later retrieval when the order is picked up and packaged, as described below.

[0269] Once the cartons are erected for a specific customer's product order, the erected cartons can then be physically transferred to the AMR (commonly or separately, referred to as 1400).

[0270] like Figure 67 The illustration shows an upright carton, formed from a carton blank and having dimensions of width W, height H, and length L, capable of loading items numbered 1 to 6 (i.e., products) arranged in a specific configuration. It may also contain additional padding or packaging materials (e.g., bubble wrap) that can be inserted to maintain the stability and integrity of the items in the package arrangement during transport to the customer. Given the specific arrangement of items specified for the order, the AMR can be controlled to access sites in a specific order (e.g., the site holding the largest item can be accessed first), allowing the upright carton to be loaded in a manner consistent with the specified arrangement.

[0271] Now go to Figure 59 , 60 Except for the differences described below, the carton forming system 1100 may include the same components as described above (60A, 61, 62, and 63). Figure 1A The cardboard box forming system has 100 identical or substantially identical components. For example... Figure 1A The structural / mechanical components of the carton forming system 100 and 1100 can be made of any suitable material. The carton forming system 1100 is particularly useful as part of a customer order fulfillment system 1000 capable of fulfilling product orders issued or initiated by customers as described above. However, the carton forming system 1100 can also be used in other applications.

[0272] As described above Figure 1A An alternative to the hopper of the carton forming system 1100 is that the carton forming system 1100 may include or utilize multiple hoppers, such as... Figure 60 The hoppers are labeled M1 to M16. Each hopper M1-M16 can each hold one or more stacks of product packaging such as carton blanks 111 generally processed by system 100, wherein at least some of hoppers M1-M16 hold packaging / carton blanks of different types / sizes and / or configurations than those in other hoppers. The size, configuration, and type of the carton blanks (and the cartons that can be formed therefrom) can be varied to provide a range of carton sizes, configurations, and types that can be automatically processed by carton forming system 1100 without any manual intervention to modify any part of carton forming system 1100. The PLC 132 of carton forming system 1100 can be programmed such that a specific size / overall size / configuration (e.g., such as a regular slotted carton or "RSC") / type of each of the carton blanks held in each of hoppers M1-M16 is stored in the memory of PLC 132. Recall that alternatives to the RSC configuration include envelope configurations and pallet configurations. When using such alternatives, some components of the carton forming system 1100 can be replaced by a sleeve feeder or a pallet feeder.

[0273] It should also be noted that the carton forming system 1100 can be configured with bins having settings / selections for carton blanks of different sizes / configurations / types than other boxes, so that each of the carton forming systems 1100 is operable to handle different carton blanks. The carton forming system 1100 can be configured with bins, such that they collectively handle a set of predefined carton blank types, thereby providing a range of carton sizes, configurations, and types.

[0274] Each of the hoppers M1-M16 may have its own carton blank transfer device, which may accordingly include transversely oriented carton transferors 1203(1) to 1203(16) (referred to individually or collectively by reference numeral 1203). Each of the hopper conveyors 1203 may be controlled by a PLC 132 of the carton forming system 1100 such that the stack of carton blanks in each of the hoppers M1-M16 can be moved to a position adjacent to a longitudinally oriented central carton blank feed conveyor 1204. Each hopper M1-M16 may have a conveying device controlled by the PLC 132, operable to remove and move carton blanks from the stacks adjacent to the feed conveyors 1204 in the hoppers M1-M16 and feed the carton blanks onto the central feed conveyor 1204, so that the carton blanks can be conveyed in the manner described above in conjunction with system 100.

[0275] Now for reference Figure 60A As a representative example of a silo construction, the silo conveyor 1203 may include a frame 1215 supporting five generally parallel and spaced continuous belts 1213, which may be made of any suitable flexible material such as Ropanyl. Each of the continuous belts 1213 may extend between a plurality of rotatable idler pulleys 1221 mounted on a freely rotatable shaft and a plurality of rotatable drive wheels 1223. The drive wheels 1223 may be mounted to rotate together with a common drive shaft 1225 of a silo conveyor servo motor 1219, which can be interconnected and communicated with a PLC 132 of the carton forming system 1100 via a servo drive. Each of the continuous belts 1213 may have an upper belt portion on which one or more stacks of carton blanks 1211 can be supported together. The PLC 132 can issue instructions (such as via the order fulfillment processor 1300) to form cartons, and if needed, the PLC 132 can move the upper portion of the feed conveyor belt 214 toward the feed conveyor belt 1204 by operating the servo motor 1219 of the drive wheel 1223. In this way, if needed, the feed conveyor belt 214 can move the stack of carton blanks 1211 to a position adjacent to the feed conveyor belt 1204.

[0276] Vertically and longitudinally oriented plates 1230 can be positioned close to the end of each bin conveyor 1203 adjacent to the feed conveyor 1204. Each plate 1230 can be supported by a plurality of plate support members 1235, which may be part of a frame 1215. The lower longitudinally extending edge 1233 of the plate 1230 can be positioned such that only the bottom carton blank 1211 in the stack of carton blanks (i.e., the blank immediately above the upper part of the belt) can pass through a slot provided below the lower edge 1233 of the plate 1230 and the horizontal plane formed by the upper surface of the upper part of the continuous belt 1213. In this way, a slot 1231 can be provided that allows a single carton blank 1211 from the bottom of the stack to be pushed laterally through the slot 1231 and onto the feed conveyor 1204 at a time.

[0277] A pushing mechanism may be provided in response to a signal from the PLC 132 of the carton forming system 1100 to push the carton blanks 1211 in the hopper from the bottom of the stack through the slot 1231 onto the feed conveyor 1204. The pushing mechanism can be any suitable type of device and may, for example, include a plurality of lugs 1217 located in the space between the continuous belts 1213. The lugs 1217 may be driven along a circulating path by a common type of crank mechanism (not shown), which may include a common pneumatic or hydraulic cylinder having a piston controlled by the PLC 132 to appropriately control the flow of pressurized air / hydraulic fluid to the cylinder by activating appropriate valves. The cylinder may have a piston arm attached to a longitudinally oriented rod member that can be mounted for rotation. The crank mechanism can be configured to provide a path for lug 1217 starting from a position behind the bottom carton blank in the stack; then moving laterally between continuous belts 1213 while engaging the rear edge of the bottom carton blank, thereby pushing the bottom carton blank through slot 1231. Once the crank mechanism reaches the end of the stroke, lug 1271 can be shown descending below the stack of carton blanks and moving laterally in the opposite direction back to the starting position, while simultaneously not engaging with the next bottom carton blank on the stack and passing under the stack. This path returns lug 1217 to the starting position such that when signaled by PLC 132, another carton blank is loaded onto feed conveyor 1204, and this operation can be repeated.

[0278] In summary, PLC 132 can therefore control the servo motor 1219 of the hopper conveyor, and thus control the movement of each conveyor 1203, and thus control the movement of the lug 1271. Therefore, PLC 132 can selectively move any one of the individual carton blanks from M1 to M16 and transfer them onto the feed conveyor 1204 in one go.

[0279] Therefore, unlike in system 100 where stacked carton blanks can be fed to alignment conveyor 206 by feed conveyor 204, in order fulfillment system 1000, individual carton blanks can be continuously fed longitudinally to alignment conveyor 1206 by feed conveyor 1204. The specific sequence / order of carton blanks placed on feed conveyor 1204 in each carton forming system 1100 can be determined and selected by PLC 132, such that carton blanks arrive at alignment conveyor 1206 in a manner that allows for desired processing of carton blanks at least within carton forming system 1100.

[0280] Furthermore, each PLC 132 can store a record in its memory of carton blanks already placed on the feed conveyor 1204 to be formed. Each record can contain information received by the PLC 132 from the order fulfillment processor 1300 (e.g., via an order fulfillment data structure) for the specific carton blank to be formed. For example, this information can include the type / size / configuration of the carton blank. Whenever a request for a new carton is received from the order fulfillment processor 1300, a new record can be added, and optionally, a record can be removed once the carton has been formed. Thus, such records can be organized and maintained sequentially in the memory of the PLC 132 using conventional shift register techniques. In this way, when the next carton blank arrives, a record of the next carton blank scheduled to arrive at the alignment conveyor 1206 can be provided at the output of the shift register. Furthermore, the type / configuration / size of the next carton blank can be determined based on the provided output.

[0281] Once a given carton blank has been transferred from the feed conveyor 1204 to the alignment conveyor 1206, the alignment conveyor 1206 can then, under the control of the PLC 132, move the given carton blank to the pick-up position. As the carton blank is moved longitudinally downstream by the alignment conveyor 1206, it can be partially propelled by a pair of adjacent spaced vertical plates 1218 (see...). Figure 63 The front edge of each carton blank on the surface is used to determine the pick-up position.

[0282] The feed conveyor belt 1204 can be used with Figure 7 The feed conveyor 204 is constructed in a substantially similar manner to include a pair of spaced feed conveyor belts 214 that can be driven by a suitable motor, such as a DC motor or a variable frequency drive motor. In the case where the motor is a DC motor, the motor can be controlled by a PLC 132 via a DC motor driver device (such as all of which are sold by Oriental as model AXH-5100-KC-30).

[0283] The feed conveyor belt 214 may have an upper belt portion supported on rollers (not shown). The PLC 132 can cause the upper portion of the feed conveyor belt 214 to move longitudinally downstream toward the alignment conveyor 1206 as needed. In this way, the feed conveyor belt 214 can move a series of spaced-apart carton blanks longitudinally downstream. The PLC 132 can control the motor driving the feed conveyor 1204 via a motor driver device, and therefore, the feed conveyor 1204 can be operated to move and transfer a series of carton blanks obtained from multiple hoppers M1 to M16 toward and to the alignment conveyor 1206.

[0284] like Figure 7 The alignment conveyor 206, and the alignment conveyor 1206 may also include a series of laterally oriented rollers 1208, which can be mounted to rotate freely to the lower part of the hopper frame 202. The alignment conveyor belt 1216 may be driven by a motor with a corresponding motor driver. The motor and motor driver for the alignment conveyor 1206 may also be controlled by a PLC 132. The alignment conveyor belt 1216 may provide an upper belt portion supported on the rollers 1208, on which one or more carton blanks may be supported. The alignment conveyor belt 1216 may be operated to further longitudinally and sequentially move each carton blank until the front of the carton blank abuts the generally flat, vertically and laterally oriented inward-facing surface of the upright spacer 1218, such that each carton blank is sequentially placed in a pick-up position.

[0285] The feed conveyor belt 1214 of the feed conveyor belt 1204 and the alignment conveyor belt 1216 of the alignment conveyor belt 1206 can be made of any suitable material such as, for example, polypropylene.

[0286] A sensor (not shown), such as an Allen-Bradley model 42KL-D1LB-F4, can be located within the horizontal gap between the feed conveyor belt 1214 and the alignment conveyor belt 1216. The sensor can be positioned and operable to detect the presence of the leading edge of the blank as each blank sequentially begins to move across the gap between the feed conveyor belt 1214 and the alignment conveyor belt 1216. When the leading edge is detected, the sensor can send a digital signal to the PLC 132 indicating that a specific carton blank (its size / configuration / type known to the PLC 132) has moved to a position where the conveyor 1206 can begin to move. The PLC 132 can then cause the motor of the conveyor 1206 to be activated, causing the top portion of the alignment conveyor belt 1216 to begin moving the carton blank downstream. In this way, each carton blank can be "transferred" from the feed conveyor 1204 to the alignment conveyor 1206.

[0287] Once the rear edge of each carton blank passes the sensor, a signal can be sent to PLC 132. PLC 132 can then respond by sending a signal to shut down the motor driving feeder belt 1214 of feeder belt 1204. Feeder belt 1204 then enters a state awaiting further signals, after which the next carton blank in the series on feeder belt 1204 is fed to alignment conveyor 1206. Simultaneously, alignment conveyor 1206 can be operated to move the carton blank placed on it to the pick-up position.

[0288] The presence of the carton blank on the alignment conveyor 1206 at the pickup position can be due to [various factors]. Figure 7 The presence sensor 240 and gap sensor 242 are detected by another sensor of the same type. This sensor can detect the presence of the leading edge of the blank at the pick-up position and can send a digital signal to the PLC 132, thereby emitting a signal indicating that the carton blank is in the pick-up position. At the pick-up position, the carton blank can also be longitudinally centered by a pair of movable, longitudinally oriented sidewall guides 1201, 1202.

[0289] Each carton blank can be correctly positioned and oriented longitudinally and laterally at the pick-up position so as to properly engage with one of the erector heads of system 100, such as erector heads 120a and 120b. Side guide walls 1201 and 1202 can be mounted on rails to the lower part of the lower frame, and both side guide walls 1201 and 1202 can be oriented substantially vertically and can extend longitudinally over substantially the entire length of the alignment conveyor 1206. Side guide walls 1201 and 1202 can be mounted in a manner similar to the left-hand side guide wall 200 and right-hand side guide wall 201 in system 100.

[0290] A drive mechanism can be provided to drive each of the sidewalls 1201 and 1202 on the corresponding tracks. For sidewalls 1201 and 1202, one or more drive mechanisms that communicate electronically with the PLC 132 can be provided. For example, a servo motor 258 with a geared head (see...) can be provided. Figure 1B It communicates electronically with PLC 132 via a servo drive. An example that can be used is a servo motor MPL-B1530U-VJ42AA manufactured by Allen-Bradley, combined with a servo drive 2094-BC01-MP5-S also manufactured by Allen-Bradley and a gear head AE050-010 manufactured by Apex for MPL-A1520.

[0291] For example, in carton forming system 100, and in carton forming system 1100, lead screws can be interconnected to servo motors / gear heads. The lead screws can pass through nuts, which can be securely fixed to plates. These plates can be interconnected to spaced-apart, generally vertically oriented rod members. The rod members can be interconnected to support frames (not shown) forming part of the sidewalls. By activating the servo motor / gear head, the rotation of the servo motor can rotate the lead screw. As the rod passes through the nut, the nut can move inward or outward, causing the sidewalls 1201, 1202 to slide inward or outward on their tracks according to the direction of rotation of the lead screw. Encoders can be provided within or associated with the servo drive motor, and the encoders can rotate with respect to the rotation of the corresponding drive shaft of the servo drive. The encoders can communicate with and provide signals to the servo drive, which can then transmit the information to PLC 132. Therefore, PLC 132 is able to determine the longitudinal position of the lead screw in real time, and thus the lateral position of the sidewalls 1201, 1202. Therefore, PLC 132 can operate the servo drive to adjust the position of side walls 1201 and 1202. A specific type of encoder that can be used is called an "absolute" encoder. Therefore, once the encoder is calibrated so that the position of each screw is "zeroed," the encoder can maintain its zero-position calibration even if the order fulfillment system 1000 is powered off. With the lateral alignment mechanism of the side guide walls 1201 and 1202 adjacent to the left and right edges of the carton blank, the guide walls can ensure that when the carton blank is flattened, the baseline is correctly laterally aligned for labeling by the labeling device 1281 (only when...). Figure 63 (As shown in the figure) A label is affixed and picked up by the erector head 120 of the carton forming system 1100, and moved through the folding and sealing device 130, as described above, to achieve proper folding and sealing of the carton blank.

[0292] Optionally, the PLC 132 can verify that the type / size / configuration of the carton blank at the pick-up position matches the expected type / size / configuration of the carton blank. For example, the top surface of each carton blank may contain a barcode for identifying its type / size / configuration, and this barcode can be read at the pick-up position by a properly positioned barcode reader. The type / size / configuration of the carton blank read from this barcode can be compared with the expected type / size / configuration of the carton blank, which can be determined based on the record of the next planned carton blank stored in the memory of the PLC 132, as described above. Verification is successful when a match exists. When a mismatch occurs, the PLC 132 can signal for manual operator intervention.

[0293] As indicated above, each carton blank in each hopper can generally be initially formed and provided as such through Figures 10A to 10E The illustration shows an example of a flattened tubular configuration. Each carton blank has a height dimension "H"; a length dimension "L"; and a main panel length "Q" (see Figure 1). Figure 10B Each carton forming system 1100's PLC 132 can store in its memory each of the three dimensions of the carton blank to be processed by the carton forming system 1100, and using these stored dimensions, the PLC 132 can determine the necessary positions and / or movements of at least some of the components of the carton forming system 1100, including the paths of movement of the erector heads 120a, 120b as they move and cycle through their processing sequence.

[0294] In this regard, for each carton blank in each of the hoppers M1 to M16, PLC 132 can have the information necessary to fully process each selected carton blank.

[0295] As indicated above, regarding such Figure 11The indicative carton blanks shown are indicated by a first reference line "W1" passing through the midpoint of the fold line between panel D and fold plate K, and passing through the midpoint of the fold line between panel B and fold plate j. This first reference line W1 can be determined by PLC 132 based on the dimensions H, L, and Q of the blanks stored or obtained by PLC 132 for the carton blanks to be processed. The carton blanks can also be indicated by a second reference line "W2", which can be determined by PLC 132 and extends along the fold line between panel A and fold plate F and is generally parallel to the fold line between panel A and fold plate F. The first reference line W1 will be parallel to the second reference line W2. Since PLC 132 will be aligned with a vertical reference plane passing through the first reference line W1 and the second reference line W2, PLC 132 can also determine the relative position of the upright bottom of the carton blank in each bin. The positions of the second reference line W2 and the reference plane can be shown to align with other components in the carton forming system 1100 to ensure that the carton is correctly positioned during processing. Furthermore, the vertical distance R between the first reference line W1 and the second reference line W2 can be calculated by the PLC 132. This ensures that the PLC 132 knows where it needs to position the erector head so that the top plate A and the corresponding first reference line W1 are correctly positioned throughout the carton forming system 1100's processing of the carton blank.

[0296] The carton forming system 1100 can be shown as being able to track and modify the position of each carton blank as it is being processed, particularly as the carton blank moves longitudinally through the carton forming system 1100 and as the various components of the carton forming system 1100 engage the carton blank during its movement, tracking and modifying the vertical position of the first reference line W1 of the carton blank. This can be shown as establishing that the carton blank being processed is properly positioned relative to the system components such that the system components engage the carton blank at the appropriate position on the carton blank during processing. For carton blanks that may have a different configuration than carton blank 111, appropriate adjustments may be needed to the dimensions and data maintained by the PLC 132 so that the carton forming system 1100 can process carton blanks of a specific size / configuration / type.

[0297] Once the carton blank has been formed and sealed to form a partially sealed, upright carton, it can be placed in, for example... Figure 16 The configuration shown allows upright cartons to be unloaded from unloading conveyor 117 (see, for example, see...). Figure 8The carton is delivered and can be placed on an accumulator conveyor, which can be part of a corresponding carton loader, such as a specific AMR 1400 that can be associated with a specific carton forming system 1100 that forms an upright carton. In fact, in various aspects of this application, in response to the arrival of a specific AMR 1400 at a specific carton forming system 1100, a robotic arm (not shown) can be controlled to pick up the upright carton from the unloading conveyor 117 and place the upright carton on the specific AMR 1400.

[0298] An order fulfillment process can be considered initiated when empty, upright cartons are moved from the accumulator conveyor and placed on the AMR 1400. The AMR 1400 can autonomously move around the warehouse where product positioning is handled by system 1100. The AMR 1400 can be controlled to access one or more loading stations in the product introduction area 5208.

[0299] Once an order (or a portion of an order for a particular carton) has been received in an upright carton carried by the AMR 1400, and all products have been loaded into the upright carton, the AMR can carry the upright carton to one of the final carton sealing devices 1500. For example, the AMR 1400 can transfer the upright carton containing all products to a predetermined Random Top Carton Sealing (RTCS) feed conveyor that can feed the upright carton to a suitable top sealing device. The RTCS can be adapted to receive information provided by the order fulfillment processor 1300, so that the RTCS can automatically adjust the sealing components of the device so that the device can close and seal the top of the upright and loaded carton. The sealed carton can then be conveyed to the route distribution accumulation area 5212 for further sorting and processing. An example of a suitable type of RTCS device that can be used as part of the order fulfillment system 1000 is a random carton sealer manufactured by Marq Packaging Systems.

[0300] In the operation of the order fulfillment system 1000, each of multiple customers can use a customer order device, such as an order placement device 1200, which may have access to the call center 1250. By operating appropriate software on the order placement device 1200, the order placement device 1200 can communicate directly or indirectly with the order placement processor 1300, enabling customers to place multiple orders with the order fulfillment processor 1300, each order targeting one or more products.

[0301] The order fulfillment processor 1300 can process customer orders received directly or indirectly from the customer order device 1200. For each order, the order fulfillment processor 1300 can utilize its database, which contains information that can be stored therein, including information associated with: (a) details of all products that the customer can order through the order fulfillment system 1000, including the actual physical dimensions of each product (such as the dimensions of the packaged item), optionally, the weight of each product, and further optionally, the product code associated with each product; (b) details of each of the various types / sizes / configurations of carton blanks that can be used in the order fulfillment system 1000 for packaging one or more products ordered by the customer, including the dimensions of each carton / carton blank; (c) each carton forming system Details of the system (e.g., carton forming systems 1100A, 1100B, 1100C), including the type of upright cartons that each carton forming system can form, and optionally, when the carton forming system includes multiple hoppers, the type of carton blanks provided in each of these hoppers and the corresponding type of upright cartons that can be formed from each type of carton blank, and further optionally, the quantity of carton blanks provided in each of these hoppers; (d) information about each customer, including the name of the entity and the shipping address to which the order to be fulfilled by the order fulfillment system 1000 is to be delivered; and (e) information about the location of each product in the warehouse building that may contain the products that may be ordered.

[0302] For each order, the order fulfillment processor 1300 can also use product packaging utilities to identify suitable cartons from a limited and predetermined number of packing kits of cartons of a certain type / size / configuration, and may identify the optimal cartons (e.g., those with a specific type / size / configuration). Therefore, when each order for a specific product is entered into the order fulfillment processor 1300, the product packaging utilities can determine one or more optimal cartons that can be used to pack the products in each order (e.g., determining the minimum number of cartons and / or the minimum size cartons required to pack all products in a customer's order).

[0303] The order fulfillment processor 1300 can then generate a fulfillment order data structure for each order, which can be transmitted via a communication link to a PLC 132 in one of the carton forming systems 1100. The order fulfillment processor 1300 may have determined which carton forming system 1100 to send each fulfillment order data configuration to, randomly or based on availability and / or suitability, for processing the carton type / size / configuration determined for a particular customer order. The order fulfillment data configuration may include information including: (i) the type / size / configuration of the upright cartons determined by the desired product packaging facility formed by the carton forming system 1100; (ii) the specific hoppers of the carton forming system for carton blanks used to form cartons of the desired type / size / configuration; (iii) a list of one or more specific products from the customer order being fulfilled, which are expected to be loaded into the desired upright cartons once formed, optionally arranged in the order in which the products should be loaded into the cartons once formed; (iv) optionally, a diagram illustrating the desired optimal physical arrangement of one or more products when loading the upright cartons; (v) optionally, the location of each specific product from the customer order being fulfilled in the warehouse building; and (vi) the customer shipping information for the cartons, indicating the destination name and address of the cartons.

[0304] Each fulfillment order data structure can then be received and processed by the PLC 132 of the carton forming system to which the data structure is sent. Specifically, the PLC 132 of the carton forming system processes the fulfillment order data configuration to identify the type / size / configuration of the desired upright carton, the specific hopper of the carton forming system containing each desired type / size / configuration carton blank for forming the upright carton, and the contents of the label (or multiple labels) to be applied. Once the desired type / size / configuration carton blank and the specific hopper for containing the carton blank for forming the desired type / size / configuration upright carton have been identified, the PLC 132 of the carton forming system can cause the carton blank from the identified hopper to be formed substantially as outlined above.

[0305] Specifically, if it is necessary to move a stack of carton blanks of the identified type to an adjacent feed conveyor 1204, PLC 132 activates the appropriate conveyor corresponding to the hopper conveyors 1203(1) to 1203(16) of the identified hopper. Under the control of PLC 132, the transfer device can then transfer the desired carton blank from the identified hopper to the feed conveyor 1204. The feed conveyor 1204 can then be shown moving the carton blank longitudinally under the control of PLC 132, and then, when signaled by PLC 132, transferring the carton blank to the alignment conveyor 1206.

[0306] The alignment conveyor 1206, also under the control of PLC 132, can then move the carton blank to the pick-up position, and PLC 132 can then cause the sidewalls 1201, 1202 to laterally align the carton blank so that the carton blank is in the correct pick-up position. PLC 132 can then cause the carton forming components of the carton forming system (including the erector head 120) to be moved by the moving subsystem to pick up the carton blank 111 from the pick-up position, and to erect and partially seal the erected carton from the carton blank 111. PLC 132 can, on a continuous basis, cause any adjustments to the components of the folding and sealing device 130 as each carton blank is processed to accommodate each carton blank 111 when multiple carton blanks 111 are processed.

[0307] Once upright cartons are formed for a specific customer's product order, the upright cartons can then be physically transferred to the AMR 1400. The AMR 1400 can then be controlled to access a site in product entry area 5208, where the product can be received inside the upright cartons.

[0308] As briefly discussed above, the sites in product introduction area 5208 can be associated with the supply of products stored in tower storage area 5204. Similarly, as briefly discussed above, in some embodiments, multiple towers that can be used to store products can be located in tower storage area 5204, although... Figure 52 There are no towers specifically depicted in tower storage area 5204.

[0309] Figure 75 The illustration shows a perspective view of a tower 7510 among multiple towers that can be used to store products according to an example embodiment of this application. As shown, the tower 7510 may have compartments 7512 for storing individual products within the compartments 7512. Some compartments of the tower 7510, such as a first compartment 7512A, may be filled with individual products corresponding to the same stock unit (SKU). Some other compartments of the tower 7510, such as a second compartment 7512B, may be filled with individual products corresponding to at least two different SKUs. Each compartment 7512 may have one or more openings, such as a first opening 7514 or a second opening 7516, through which individual products can be stored in and retrieved from the tower 7510.

[0310] Storing products across multiple towers 7510 generally involves the following steps. When products arrive at order fulfillment location 5200, typically organized on pallets, any packaging surrounding the products can be removed first, allowing individual product items to be accessed. In some embodiments, obvious defects in individual product items can also be inspected. Assuming no defects are found, personnel can pick up individual products and store them in compartments 7512 of the multiple towers 7510. Once a specific product item has been stored in a specific compartment 7512, personnel can scan the barcode on the specific product item and / or the barcode located on the tower 7510 (e.g., the barcode associated with the specific compartment 7512 where the specific product item is stored), allowing the order fulfillment processor 1300 to know the location of the specific product item. This process can also be automated. For example, there may be one or more robots for removing packaging, one or more robots for picking up individual products and storing them in compartments 7512 of multiple towers 7510, and one or more robots for ensuring that the order execution processor 1300 knows information about the location of each stored individual product (e.g., a specific part 7512 of a specific tower 7510).

[0311] Each opening of compartment 7512, such as first opening 7514 or second opening 7516, may be covered by one or more flexible straps 7520, which prevents individual products stored in compartment 7512 from falling out of the respective compartment 7512, for example, during the transport of tower 7510 via tower transport AMR 7518.

[0312] In operation, the tower transport AMR 7518 can engage with tower 7510 and transport tower 7510 to product storage introduction area 5202. As discussed above, personnel and / or robots 5999 can unload products delivered to order fulfillment system 5200 (such as by transport trailer, and the products may be on pallets) at product storage introduction area 5202 and store the products in tower 7510. Once tower 7510 is filled with sufficient products, the tower transport AMR 7518 can transport tower 7510 to an available location within tower storage area 5204.

[0313] When one or more products need to be stored in tower 7510 to fulfill an order, order fulfillment processor 1300 can instruct tower delivery AMR 7518 to transport tower 7510 between a first position in the middle of tower storage area 5204 and a second position in product introduction area 5208. Tower delivery AMR 7518 may be a device manufactured by Amazon Robotics, Inc., formerly Kiva Systems, North Redding, Massachusetts. Tower delivery AMR 7518 can navigate around tower storage area 5204. When tower delivery AMR 7518 reaches the first position, it can slide under tower 7510 and lift tower 7510 off the ground by, for example, a helical motion. Tower delivery AMR 7518 can then carry tower 7510 to the second position in product introduction area 5208.

[0314] Conventional AMRs are known to navigate in several ways. A conventional AMR may include an upward-facing camera for reading barcodes on the underside of tower 7510. Alternatively, a conventional AMR may include a downward-facing camera for reading barcodes on the floor of tower storage area 5204. The barcodes can be understood as allowing the AMR to determine its instantaneous position information and navigate accordingly. The position information can be combined with readings from other navigation sensors such as encoders, accelerometers, and rate gyroscopes. It is also known that conventional AMRs include a collision detection system, which can be implemented as an infrared sensor and a touch-sensitive buffer that can stop the AMR in response to a person or object obstructing its navigation.

[0315] In some embodiments, for example, the order fulfillment processor 1300 may identify a tower 7510 in tower storage area 5204 as storing one or more products for fulfilling an order. The tower 7510, storing one or more products for fulfilling an order, or simply one or more products, can be transported from tower storage area 5204 to a specific site in product introduction area 5208. This transport can be performed manually or automatically. For example, multiple tower transport AMRs 7518 (not shown) can generally be designated for transporting tower 7510 between tower storage area 5204 and product introduction area 5208. The fulfillment order data structure generated by the order fulfillment processor 1300 may contain a tower transport AMR instruction for one of the multiple tower transport AMRs 7518 to engage with tower 7510 and transport tower 7510 to an upright carton that can receive one or more products at a specific site in product introduction area 5208 to fulfill the order. In practice, loading one or more products into the upright carton can be done manually or robotically. A station in product inbound area 5208 where one or more products are manually loaded into upright cartons can be referred to as a "manual product inbound station". A station in product inbound area 5208 where one or more products are robotically loaded into upright cartons can be referred to as a "robotic product inbound station" or "product transfer equipment". For example, a loading robot (not shown) may be located near and / or assigned to a robotic product inbound station in transport container inbound area 5208. When a tower storing one or more products for fulfilling an order (e.g., see...) Figure 75 When a tower (7510) is transported to a robotic product inbound station, the order fulfillment processor 1300 can instruct a loading robot to remove one or more products from one or more compartments of the tower 7510 and load them into appropriate boxes or cartons. For example, the loading robot may include an extendable arm capable of reaching a specific product within one or more compartments of the tower 7510 and loading that specific product into a box. The product inbound area 5208 may contain one or more loading robots for loading products from the tower 7510 into boxes; for example, one loading robot may serve one or more robotic product inbound stations in the product inbound area 5208. In this manner, the AMR 1400 supporting the upright cartons can travel to one or more stations in the product introduction area 5208, and at each station, receive one or more products from the corresponding tower 7510 to fulfill the order. After the corresponding tower transport AMR 7518 receives the tower transport AMR instruction through the order fulfillment processor 1300, each tower 7510 has been transported from the first position in the tower storage area 5204 to the corresponding station by the corresponding tower transport AMR 7518.

[0316] Once an order (or a portion of an order for a specific carton) has been received by the AMR 1400, and all products have been loaded into upright cartons at either a manual or robotic product inlet station, the AMR 1400 can carry the loaded cartons to one of the final carton sealing devices 1500A, 1500B, or 1500C. For example, the AMR 1400 can carry upright cartons loaded with all products via a predetermined Random Top Carton Sealing (RTCS) feeder conveyor that feeds the upright cartons to a suitable top sealing device. The RTCS can be adapted to receive information from the order fulfillment processor 1300, thus automatically adjusting the sealing components of the device so that the device can close and seal the top of the upright and loaded cartons. The finished cartons can then be conveyed to a central carton distribution system for further sorting and processing.

[0317] Further sorting and processing may include labeling the finished cartons. Figure 63 The marking device 1281 shown in the figure can be considered as being configured to mark the carton blank 111 before it is formed by the carton forming system 1100. Alternatively, a marking device (not shown) can be used to mark the finished carton at the output end of the final carton sealing devices 1500A, 1500B, 1500C.

[0318] When labeling upright cartons, while the cartons remain under the control of the carton forming system 1100, the labeling device 1281 can be mounted near the alignment conveyor 1206 to the frame of the carton forming system 1100. For example (although for simplicity, in Figure 63(Not depicted in the text) The marking device 1281 can be mounted to a frame portion of the carton forming system 1100, which is generally positioned above the location where the carton blank 111 is positioned when it is in the pick-up position. The marking device 1281 is operable to print and apply one or more labels to one or more panels of the carton blank 111 in the pick-up position, preferably the upward-facing panels. The marking device 1281 can be any suitable device, such as the PLS-500 label application system manufactured by Paragon Labeling Systems, White Bear Lake, MN, combined with an integrated printing engine, such as the Lt408 printing engine or the S84 series printing engine (e.g., models S8408, S8412, or S8424) manufactured by SATO USA, Charlotte, NC. Although in some embodiments the marking device may apply physically separate markings to the finished carton or carton blank 111, in other embodiments the marking device may apply printing to the finished carton or carton blank 111 without providing printing on physically separate markings.

[0319] As described above, one or more marks applied by the marking device 1281 to the upward-facing panel of each carton blank 111 can be specifically configured for that particular carton blank 111 and can contain various types of information related to the product order to be fulfilled, and are placed in the upright carton to be formed from that particular carton blank 111. One or more marks may contain information providing certain order information, including the type of products to be loaded into the upright carton to be formed from that blank, and optionally include the product codes of these products, the customer to whom the carton is to be shipped, and the customer's address. The marks may also contain a unique carton identifier. Some or all of the information may be provided in barcode format.

[0320] In various aspects of this application, a mark is printed and applied to the carton blank 111 when it is in a flattened configuration at the pick-up position and before it is erected and bottom-sealed. This makes the mark application process more reliable and provides a unique identification for the carton blank 111.

[0321] exist Figure 65 The diagram illustrates a first example mark 1283a that can be applied by the marking device 1281. Figure 66 The figure shows a second example mark 1283b that can be applied by the marking device 1281.

[0322] In some embodiments, various modifications are also possible. For example, instead of providing hopper conveyors 1203(1) to 1203(N) for hoppers M1 to M(N), it may be possible to provide a robotic system that can extract carton blanks from any of the stacks of carton blanks in each hopper according to the requirements of PLC 132. The robotic system may place specific carton blanks that may be needed onto the feed conveyor. In other embodiments, the feed conveyor may be omitted, and the robotic system may place each desired carton blank at a pick-up position.

[0323] Other fulfillment systems were also considered. For example, Figure 69 A schematic floor plan of an order fulfillment center 6900 is shown. Order fulfillment center 6900 may share similarities with the order fulfillment center 5200 described in detail above. In this example embodiment, order fulfillment center 6900 includes a product storage introduction area 6902, a product storage area 6904, a transport container introduction area 6906, an order verification and sealing area 6910, and a route distribution accumulation area 6912. Depending on the size of order fulfillment center 6900, it may include... Figure 69 Multiple regions are shown in one or more regions in the diagram, and in some cases, one or more regions may be omitted.

[0324] As described above, transport container introduction area 5206, Figure 69 The transport container introduction area 6906 can be filled with multiple receiving component forming systems, which may also be referred to as transport container delivery systems, and perhaps one or more of such systems follow the design of the carton forming system 100 disclosed above. In some embodiments, one or more of the multiple receiving component forming / delivery systems may only produce / deliver a single size / configuration / type of receiving component to the AMR.

[0325] According to various aspects of this application, as will be described in further detail below, multiple AMRs (e.g., AMR 5300 and / or 5800) can be deployed for movement between the various illustrated areas within a warehouse. For example, an AMR can be controlled to access a transport container introduction area 6906 to obtain a transport box (or other transport container), and subsequently controlled, with the transport container attached thereto, to access a product storage area 6904 to receive one or more products within the transport container for order fulfillment.

[0326] At the product storage introduction area 6902, various products may be shown arriving at the order fulfillment center 6900, for example, in multiple delivery trailers. Multiple units of a single SKU may be grouped into a container, and multiple containers may be grouped into pallets. In some cases, the term "pallet" may refer to a stacked structure of containers resting on a pallet base for handling using machinery such as a forklift 6999. In some other cases, the term "pallet" may refer to a pallet base. In some embodiments, multiple pallets may arrive as a unit, and this unit may have to be separated into individual pallets by personnel and / or machinery. For example, multiple pallets may be bundled or wrapped together and then untied or unfolded before storage.

[0327] Pallets can be transported to specific corresponding locations within the product storage area 6904. Such transport can be accomplished using a forklift 6999, which can be operated manually by an operator or, in other cases, automatically. In a preferred embodiment, the forklift 6999 can be implemented as an automated guided vehicle (AGV).

[0328] Product storage area 6904 may include multiple product storage racks 7100. In product storage area 6904, each pallet can be placed in its corresponding storage location. For example, for a specific pallet, forklift 6999 can receive a set of coordinates or orientations associated with a specific storage rack located within product storage area 6904 and a specific area within that rack where the specific pallet should be stored. In this way, each product storage rack 7100 can be filled with pallets corresponding to various products.

[0329] Figure 70 The illustration shows a perspective view of a portion of a product unloading system in an order fulfillment center according to an example embodiment of this application. Figure 70 The product uninstallation system section is illustrated as containing Figure 69 The system includes a product storage rack 7100 and an AMR lift 7110. The product storage rack 7100 may include multiple storage layers 7102 for storing pallets containing products, such as a first pallet 7120. As described above, each pallet may hold a single product of a specific SKU. In some embodiments, each pallet may hold a set of structured identical containers, such as container 7122, each container 7122 holding one or more specific SKUs (e.g., a container may be a box holding one or more sets of three books sold as a unit). In some embodiments, one or more pallets may hold a variety of different products instead of a specific SKU.

[0330] The product storage rack 7100 may also include a plurality of raised platforms 7104, each of which is adjacent to a corresponding location among the plurality of storage layers 7102. Each of the raised platforms 7104 may be configured for the AMR 5800 to travel upon.

[0331] The product storage rack 7100 may also include one or more product retrieval robots, such as robotic pickup arms 7106. In some embodiments, as illustrated, the robotic pickup arm 7106 may be associated with a corresponding storage layer 7102 of the product storage rack 7100. In some embodiments, the robotic pickup arm 7106 may serve multiple storage layers 7102 of the product storage rack 7100. Each robotic pickup arm 7106 may be configured to retrieve a single product from a pallet and load the product into a suitable transport container carried by the AMR 5800.

[0332] Specifically, each robotic pickup arm 7106 may be equipped with an end effector adapted to selectively remove individual items from a transport container within a pallet and release the items into a suitable transport container carried by the AMR 5800. The configuration of the end effector of the robotic pickup arm 7106 can depend on the characteristics of the items to be moved. For example, an end effector with one or more vacuum suction cups can effectively engage items with flat surfaces and relatively light weight. Other items, such as those with curved or irregular surfaces or relatively heavy weight, can be gripped with a claw or a clamping device of corresponding size and shape.

[0333] In some embodiments, multiple interchangeable end effectors may be used. For example, one or more robotic picker arms 7106 may be equipped with a releasable linkage mechanism configured to engage or disengage with one of the multiple end effectors picked up. Figure 77 An example robotic pickup arm 7106 is shown with a connector 7710 that can be used to engage multiple end effectors. The connector 7710 may include physical linkage mechanisms, such as quick-connects for electrical and pneumatic connections. Available end effectors (not shown) can be positioned in one or more rest positions accessible to the robotic pickup arm 7106. When needed, the robotic pickup arm 7106 can move to engage a suitable end effector via the connector 7710 and employ the end effector to perform a specific task. After the task has been performed, or when a different end effector is required, the robotic pickup arm 7106 can return to the rest position and release the connector 7710 to return the end effector.

[0334] The robotic pickup arm 7106 can be further configured to perform pallet removal operations. For example, the robotic pickup arm 7106 can be configured to remove packaging material from a pallet such as cable ties 7702, or to open or remove containers within a pallet to retrieve individual items held within the containers. The robotic pickup arm 7106 can be further configured to dispose of any removed packaging material. For example, the robotic pickup arm 7106 can grasp packaging material and transfer it to a disposal site, such as a chute (not shown).

[0335] To perform pallet removal operations, the robotic picker arm 7106 can engage with an end effector configured for pallet removal operations. In some embodiments, such an end effector may be a tape unstripper.

[0336] For example, Figure 78A and Figure 78B The illustration shows a tape unwinder / stripper 7800. The tape unwinder / stripper 7800 may include one or more of a motor 7804, a roller (not shown), scissors 7807, and a clamp containing a clamp top 7806 and a clamp bottom 7805. In operation, a cycle can begin when the robotic picker arm 7106 approaches and positions the tape unwinder / stripper 7800 towards the strapping 7702. The clamping parts 7805 / 7806 of the clamping mechanism hold the strapping 7702 in place. Once the strapping 7702 is held in place, the scissors 7807 can cut the strapping 7702. Because the clamping parts 7805 / 7806 hold the strapping 7702 in place, the strapping 7702 can maintain its position when the tension is released, thus avoiding unwanted and unpredictable movement. Once the strapping 7702 is cut, the motor 7804 can rotate the unbundling / stripping machine 7800 to wind the strapping 7702 around the entire unbundling / stripping machine 7800. A roller (not shown) may be a spring-loaded roller used to maintain the position of the strapping 7702 on the unbundling / stripping machine 7800 as the strapping 7702 forms a winding reel around the unbundling / stripping machine 7800.

[0337] Once the strapping 7702 is fully wound, the robotic pickup arm 7106 can place the strapping 7702 into a padding drop section or chute (not shown). Specifically, the robotic pickup arm 7106 can move the unwinder-stripper 7800 above the padding drop section or chute. There, the gripper parts 7805 / 7806 can disengage from holding the strapping 7702, allowing the winding reel of the strapping 7702 to fall from the chute. Alternatively, a mechanism (n...

Claims

1. An execution system comprising: The first product introduction area includes: Multiple product storage devices, wherein each product storage device holds multiple products; as well as A first product transfer device is operable to transfer a first product of a first plurality of products held by a first product storage device among the plurality of storage devices into a transport container; Autonomous Mobile Robot (AMR) for Transport Containers; A transport container delivery system operable to deliver the transport container to the transport container AMR; The transport container AMR is operable to: According to the transport container AMR instructions, proceed to the transport container delivery system; Waiting to receive the transport container at the transport container delivery system; While maintaining the transport container, proceed to the first product transfer device according to the transport container AMR command; At the first product transfer device, according to the transport container AMR instruction, the first product is waiting to be transferred from the product storage device into the transport container by the first product transfer device. as well as While maintaining the transport container containing the first product inside, and in accordance with the transport container AMR instructions, the container is moved to at least one location for further processing.

2. The execution system according to claim 212, further comprising: A control system including a processor, the processor being operable to: Generate transport container delivery system instructions; and Generate the AMR command for the transport container; The transport container delivery system is configured as follows: Receive the delivery instruction for the transport container from the processor; and According to the transport container delivery instruction, the transport container is delivered to the transport container AMR; The transport container AMR is configured to receive transport container AMR instructions from the processor.

3. The fulfillment system of claim 2, wherein the plurality of product storage devices includes a plurality of pallets in the first product introduction area, each of the plurality of pallets holding a plurality of products, and wherein the first product storage device includes a selected pallet selected by the processor from the plurality of pallets.

4. The fulfillment system of claim 3, wherein the selected pallet is located at a first pallet storage location in the first product introduction area.

5. The fulfillment system of claim 1, wherein the selected pallet holds multiple products corresponding to a single inventory unit.

6. The fulfillment system according to claim 4 or 5, wherein the first product introduction area comprises the plurality of pallets located at the respective plurality of pallet storage locations.

7. The fulfillment system of claim 6, wherein the plurality of pallet storage locations are positioned in a row.

8. The fulfillment system of claim 7, wherein the first pallet storage location is located at a first end position of the pallet storage location of the row.

9. The fulfillment system according to any one of claims 3 to 8, wherein the first product transfer device comprises a robotic picking device controlled by the processor.

10. The fulfillment system of claim 9, wherein the first product is held directly on the selected pallet.

11. The fulfillment system of claim 9, wherein the first product is held in a container and the container is supported on the selected pallet.

12. The fulfillment system of claim 11, wherein the cargo box comprises a first cargo box of a plurality of cargo boxes, and wherein the plurality of cargo boxes are stacked vertically on top of each other in a cargo box stack supported on the selected pallet.

13. The fulfillment system of claim 12, wherein at least some of the plurality of containers contain at least one of the plurality of products.

14. The fulfillment system of claim 13, wherein each of the plurality of containers contains at least one of the plurality of products.

15. The fulfillment system according to claim 12, 13 or 14, wherein the plurality of cartons are stacked vertically in a nested arrangement.

16. The fulfillment system according to any one of claims 12 to 15, further comprising a cargo box lifting device controlled by the processor and operable to lift all the cargo boxes above the first cargo box to expose a top opening of the first cargo box, thereby allowing the robotic picking device to pick up the first product and transfer the first product to the transport container.

17. The fulfillment system of claim 16, further comprising a cover covering the top of the opening of the top container in the container stack.

18. The fulfillment system of claim 17, wherein the weight of the cover is sufficient to stabilize the stack of cargo boxes.

19. The fulfillment system of claim 17 or 18, wherein the container lifting device is further operable to lift the cover only from the top container in the container stack to expose the top opening of the top container.

20. The performance system according to any one of claims 3 to 19, further comprising: A second product introduction area, wherein the second product introduction area includes a product tower, the product tower including a plurality of compartments for storing products, and wherein at least one of the plurality of compartments contains one or more products, the one or more products corresponding to at least one inventory unit; as well as A second product transfer device is operable to transfer a second product from the product tower to the transport container; The transport container AMR is further operable to: While maintaining the transport container containing the first product inside, and in accordance with the transport container AMR instructions, proceed to the second product transfer device; At the second product transfer device, the second product is awaited to be transferred from the product tower to the transport container by the second product transfer device. as well as While maintaining the transport container containing the first product and the second product inside, and in accordance with the transport container AMR instructions, the container is moved to at least one further location for further processing.

21. The fulfillment system of claim 20, further comprising a tower transport AMR, wherein the processor is further operable to generate instructions to cause the tower transport AMR to move the product tower to the second product transfer device in the second product introduction area.

22. The fulfillment system of claim 20 or 21, wherein each of the plurality of compartments contains one or more products, the one or more products corresponding to a plurality of inventory units.

23. The fulfillment system according to claim 20, 21 or 22, wherein the product tower includes a selected product tower, and wherein the second product introduction area includes a plurality of product towers.

24. The fulfillment system of claim 23, wherein the processor is further operable to generate instructions to cause the plurality of tower transport AMRs to independently move the plurality of product towers to a plurality of product transfer devices in the second product introduction area.

25. The fulfillment system of claim 24, wherein the plurality of product towers represent more than 500,000 inventory units of products.

26. The fulfillment system according to any one of claims 20 to 25, wherein the second product transfer device comprises a single unit.

27. The execution system according to any one of claims 20 to 26, further comprising: The third product introduction area includes a third area pallet, which holds multiple products and corresponds to multiple inventory units. A third product transfer device is operable to transfer a third product from the third area pallet to the transport container; The transport container AMR is further configured as follows: While maintaining the transport container and in accordance with the transport container AMR instructions, proceed to the third product transfer equipment where the third area pallet is located; At the third product transfer device and in accordance with the transport container AMR instruction, wait to transfer the third product from the third area pallet into the transport container; as well as While maintaining the transport container containing the first product, the second product, and the third product, the transport container proceeds to a location for further processing in accordance with the transport container AMR command.

28. The fulfillment system of claim 27, wherein the third area pallet is located at the second pallet storage location in the third product introduction area.

29. The fulfillment system according to claim 27 or 28, wherein the third product introduction area comprises a plurality of pallets, wherein the plurality of pallets store a plurality of products on each of a plurality of pallets at a plurality of third area pallet storage locations.

30. The fulfillment system of claim 29, wherein the selected pallet includes a first selected pallet, and wherein the second selected pallet is selected by the processor from the plurality of third area pallets.

31. The fulfillment system of claim 30, further comprising a pallet AMR, and wherein the processor is further operable to generate pallet AMR instructions, wherein the pallet AMR is operable to: Receive the AMR command for the pallet from the processor; According to the pallet AMR instruction, proceed to the selected pallet in the first product introduction area, and move the selected pallet to the vicinity of the transport container AMR holding the transport container.

32. The fulfillment system of claim 31, wherein after the first product has been transferred from the first selected pallet to the transport container, the pallet AMR is operable according to the pallet AMR instructions to move the selected pallet away from the transport container AMR holding the transport container.

33. The fulfillment system of claim 32, wherein after the first product has been transferred from the first selected pallet to the transport container, the pallet AMR is operable according to the pallet AMR instructions to move the selected pallet to a second pallet storage location in the first introduction area.

34. The fulfillment system of claim 33, further comprising a second pallet AMR, and wherein the processor is further operable to generate second pallet AMR instructions, wherein the second pallet AMR is configured to: Receive the second pallet AMR command from the processor; According to the second pallet AMR instruction, proceed to the second selected pallet in the third product introduction area, and move the second selected pallet to the vicinity of the transport container AMR holding the transport container; According to the second pallet AMR instruction, after the second product has been transferred from the second selected pallet to the transport container, the second selected pallet is moved to the first pallet storage location or the second pallet storage location in the third product introduction area.

35. The fulfillment system of claim 1, wherein the selected pallet holds multiple products corresponding to multiple inventory units.

36. The fulfillment system of claim 3, wherein the selected pallet includes a first area pallet, and the fulfillment system further includes: The second product introduction area includes a second area pallet, which holds multiple products and the multiple products correspond to multiple inventory units. A second product transfer device is operable to transfer a second product from the second area pallet to the transport container; The transport container AMR is further configured as follows: While maintaining the selected transport container and in accordance with the transport container AMR instructions, proceed to the second product transfer equipment where the third area pallet is located; At the second product transfer device, according to the transport container AMR instruction, the second product is waited to be transferred from the second area pallet into the transport container; as well as While maintaining the transport container containing the first product and the second product inside, and in accordance with the transport container AMR directive, the container is moved to at least one further location for further processing of the selected transport container.

37. The fulfillment system of claim 4, wherein the selected pallet includes a first selected pallet, and the processor is further operable to generate a first pallet AMR instruction, and wherein the fulfillment system further comprises: The first pallet AMR is configured as follows: Receive the first pallet AMR command from the processor; According to the first pallet AMR instruction, proceed to the pallet receiving position and engage the second selected pallet at the pallet receiving position; According to the AMR instruction of the first pallet: While engaging the second selected pallet, proceed to the second pallet storage location in the first product introduction area; as well as Release the second selected pallet at the second pallet storage location, wherein the second selected pallet holds at least one product, the at least one product corresponding to at least one inventory unit.

38. The fulfillment system of claim 37, wherein the pallet receiving location includes the location of the selected delivery trailer within the storage area.

39. The fulfillment system of claim 38, wherein the at least one product is held in a container and the container is supported on the second selected pallet.

40. The fulfillment system of claim 37, 38, or 39, further comprising a second pallet AMR, and wherein the processor is further operable to generate second pallet AMR instructions, wherein the second pallet AMR is configured to: Receive the second pallet AMR command from the processor; According to the second pallet AMR instruction, proceed to the first selected pallet in the first product introduction area, and move the first selected pallet to the vicinity of the transport container AMR holding the transport container; According to the second pallet AMR instruction, after the first product has been transferred from the first selected pallet to the transport container, the first selected pallet is moved to the first pallet storage location or the second pallet storage location in the first product introduction area.

41. The fulfillment system of claim 4, further comprising a pallet AMR, and wherein the processor is further operable to generate pallet AMR instructions, wherein the pallet AMR is operable to: Receive the AMR command for the pallet from the processor; According to the pallet AMR instruction, proceed to the selected pallet in the first product introduction area, and move the selected pallet to the vicinity of the transport container AMR holding the transport container.

42. The fulfillment system of claim 41, wherein the selected pallet includes a first area pallet, and the fulfillment system further includes: The second product introduction area includes a second area pallet, which holds multiple products and the multiple products correspond to multiple inventory units. A second product transfer device is operable to transfer a second product from the second area pallet to the transport container; Second pallet AMR; The processor is further operable to generate a second pallet AMR instruction; The second pallet AMR is configured as follows: Receive the second pallet AMR command from the processor; According to the AMR instruction for the second pallet: The pallet proceeds to the second product introduction area; and Move the second area pallet to the vicinity of the transport container AMR that holds the transport container; as well as According to the second pallet AMR instruction, after the second product has been transferred from the second area pallet to the transport container, the second selected pallet is moved to the first pallet storage location or the second pallet storage location in the second product introduction area.

43. The fulfillment system of claim 41, wherein after the first product has been transferred from the first selected pallet to the transport container, the pallet AMR is operable according to the pallet AMR instructions to move the selected pallet away from the transport container AMR holding the transport container.

44. The fulfillment system of claim 43, wherein after the first product has been transferred from the first selected pallet to the transport container, the pallet AMR is operable according to the pallet AMR instructions to move the selected pallet to a second pallet storage location.

45. The fulfillment system according to any one of claims 41 to 44, wherein the first product transfer device includes a robotic picking device controlled by the processor, and the robotic picking device is operable to transfer the first product from the first selected pallet to the transport container.

46. ​​The fulfillment system of claim 45, wherein the first product is held in a container and the container is supported on the selected pallet.

47. The fulfillment system of claim 46, wherein the cargo box comprises a first cargo box of a plurality of cargo boxes, and wherein the plurality of cargo boxes are stacked vertically on top of each other in a cargo box stack.

48. The fulfillment system of claim 47, wherein at least some of the plurality of containers contain at least one product.

49. The fulfillment system of claim 47, wherein each of the plurality of containers contains at least one product.

50. The fulfillment system according to claim 47, 48 or 49, wherein the plurality of cartons are stacked vertically in a nested arrangement.

51. The fulfillment system according to any one of claims 47 to 50, further comprising a container lifting device controlled by the processor and operable to lift all containers in the container stack above the container holding the first product to expose a top opening in the container holding the first product, such that the robotic device is operable to pick up the first product and transfer the first product to the transport container.

52. The fulfillment system of claim 51, further comprising a cover covering the top of the opening of the top container in the container stack.

53. The fulfillment system of claim 52, wherein the weight of the cover is sufficient to stabilize the stack of cartons.

54. The fulfillment system of claim 52 or 53, wherein the container lifting device is further operable to lift only the lid from the top container in the container stack to expose the top opening of the top container.

55. The execution system according to claim 3, further comprising: Multiple first product transfer devices operable to transfer multiple products from the multiple pallets to the transport container; Multiple pallet AMRs, wherein the processor is further operable to generate pallet AMR instructions for controlling the multiple pallet AMRs; The plurality of pallet AMRs are configured as follows: Receive the AMR command for the pallet from the processor; According to the pallet AMR instruction, the pallet travels to a plurality of selected pallets in the first product introduction area and moves the plurality of selected pallets to the vicinity of the respective plurality of transport container AMRs holding the respective plurality of transport containers; as well as According to the pallet AMR instruction, after multiple products have been transferred from the multiple selected pallets to the multiple transport containers, the multiple selected pallets are moved to multiple corresponding pallet storage locations.

56. The execution system according to claim 34, further comprising: Multiple first product transfer devices operable to transfer multiple products from the multiple pallets to the transport container; Multiple pallet AMRs, wherein the processor is further operable to generate pallet AMR instructions for controlling the multiple pallet AMRs; Some of the plurality of pallet AMRs are configured as follows: Receive the AMR command for the pallet from the processor; According to the pallet AMR instruction, the pallet travels to a plurality of selected pallets in the first product introduction area and moves the plurality of selected pallets to the vicinity of the respective plurality of transport container AMRs holding the respective plurality of transport containers; as well as According to the pallet AMR instruction, after multiple products have been transferred from the multiple selected pallets to the multiple transport containers, the multiple selected pallets are moved to multiple corresponding pallet storage locations in the first product introduction area. The other pallet AMRs in the plurality of pallet AMRs are configured as follows: Receive the AMR command for the pallet from the processor; According to the pallet AMR instruction, the pallet is moved to one of the selected pallets in the third product introduction area and the selected pallets are moved to the vicinity of the corresponding multiple transport container AMRs holding the corresponding multiple transport containers. as well as According to the pallet AMR instruction, after multiple products have been transferred from the multiple selected pallets to the multiple transport containers, the multiple selected pallets are moved to multiple corresponding pallet storage locations in the third product introduction area.

57. The fulfillment system according to any one of claims 2 to 56, wherein the transport container selection instruction is generated by the processor based on a customer order received by the processor, and the transport container AMR instruction is generated by the processor based on a customer order received by the processor.

58. The fulfillment system of claim 1, wherein the first product introduction area comprises a plurality of partitions.

59. The fulfillment system of claim 58, wherein the plurality of zones includes a zone in which the product is maintained at a temperature below freezing.

60. The fulfillment system of claim 58 or 59, wherein the plurality of partitions includes the partition in which the product is maintained at ambient temperature.

61. The fulfillment system according to claim 58, 59 or 60, wherein the plurality of zones includes a zone in which the product is maintained at a temperature above freezing point and below ambient temperature.

62. The performance system according to any one of claims 1 to 61, further comprising a plurality of walls and a top that enclose the first product introduction area.

63. The performance system according to any one of claims 20 to 36, further comprising a plurality of walls and a top that enclose the first product introduction area and the second product introduction area.

64. The performance system according to any one of claims 27 to 30, further comprising a plurality of walls and a top that enclose the first product introduction area, the second product introduction area and the third product introduction area.

65. The fulfillment system of claim 64, further comprising an upper layer and a lower layer, wherein the first product introduction area is located on one of the upper layer and the lower layer, and the second product introduction area and the third product introduction area are located on the other of the upper layer and the lower layer.

66. The fulfillment system of claim 64, further comprising an upper layer and a lower layer, wherein the first product introduction area is located on the upper layer and the second product introduction area and the third product introduction area are located on the lower layer.

67. The fulfillment system of claim 65 or 66, further comprising an AMR layer changing device operable to move the transport container AMR between the upper layer and the lower layer.

68. The performance system of claim 67, wherein the AMR floor changing device includes an escalator device.

69. The fulfillment system according to claim 67 or 68, wherein the transport container delivery system is located on the upper layer.

70. The fulfillment system according to any one of claims 1 to 69, wherein the at least one location for further processing includes a flap sealing station, a sealing device positioned at the flap sealing station, the sealing device being operable to seal the open flap of the selected transport container, and the further processing includes sealing the open flap of the selected transport container.

71. The fulfillment system of claim 70, wherein as the transport container AMR moves through the sealing device, the sealing device seals the open flaps of the transport container.

72. The fulfillment system of claim 71, further comprising a transport container verification device, wherein the further processing includes using the transport container verification device to verify the transport container.

73. The fulfillment system of claim 70, wherein the transport container AMR further comprises a drive mechanism operable to drive movement of the transport container AMR, and wherein the transport container AMR is driven by the drive mechanism through the sealing device.

74. The fulfillment system of claim 73, further comprising a first guide belt and a second guide belt that are laterally spaced apart and extend longitudinally, the first guide belt and the second guide belt being operable to guide the selected transport container through the sealing device during longitudinal movement of the transport container AMR on which the transport container is located.

75. The fulfillment system according to any one of claims 70 to 74, further comprising a transport container marking device, wherein the further processing comprises using the transport container marking device to mark the transport container.

76. The fulfillment system according to any one of claims 70 to 75, further comprising a transport container radio frequency (RF) labeling device, wherein said further processing comprises labeling the transport container with an RF tag using the transport container RF labeling device.

77. The fulfillment system according to any one of claims 70 to 76, further comprising a padding insert device, wherein said further processing comprises inserting padding into the transport container using said padding insert device.

78. The fulfillment system according to any one of claims 70 to 77, further comprising a route distribution accumulation area operable to receive and form a plurality of full transport containers, the plurality of full transport containers being filled with one or more products, which together constitute a single customer order.

79. The fulfillment system of claim 78, further comprising an unloading conveyor operable to receive the group of multiple full shipping containers and move the group to a vehicle loading position.

80. The execution system according to any one of claims 70 to 79, further comprising a route distribution accumulation area, and wherein said further processing comprises: The destination of the transport container and / or the first product is determined at the processor; and The transport container is transferred using a transfer device to a station in the route distribution accumulation area, the station in the route distribution accumulation area corresponding to the destination.

81. The fulfillment system of claim 80, wherein the unloading position in the route distribution accumulation area corresponds to a delivery route of an ordered sequence representing a destination, and wherein generating the AMR instruction comprises: The location of the destination of the first product is determined in the ordered sequence of destinations; as well as The arrival time of the transport container AMR is arranged at the unloading position in the route distribution accumulation area, such that the arrival time corresponds to the position in the ordered sequence of the destination.

82. The fulfillment system according to any one of claims 64 to 69, wherein the first product introduction area comprises a plurality of partitions.

83. The fulfillment system of claim 82, wherein the plurality of partitions includes an environmental partition in which the product is maintained at an ambient temperature.

84. The fulfillment system of claim 83, wherein the plurality of zones includes a freezing zone in which the product is maintained at a temperature below freezing.

85. The execution system of claim 84, wherein the freezing partition is defined by a logical partition and / or a physical partition.

86. The fulfillment system according to claim 82, 83 or 84, wherein the plurality of zones includes a refrigerated zone in which the product is maintained at a temperature above freezing point and below ambient temperature.

87. The execution system of claim 86, wherein the refrigeration partition is defined by a logical partition and / or a physical partition.

88. The fulfillment system according to any one of claims 3 to 37, wherein the selected pallet includes a general pallet.

89. The fulfillment system according to any one of claims 38 to 40, wherein both the first selected pallet and the second selected pallet comprise general-purpose pallets.

90. The fulfillment system of claim 89, wherein the first universal pallet and the second universal pallet support a vertical stack of universal cartons thereon.

91. The fulfillment system according to any one of claims 1 to 90, wherein the transport container includes a selected transport container, and the transport container delivery system is operable to deliver the selected transport container from a plurality of transport containers of different sizes, and wherein the transport container AMR is configured to wait at the transport container delivery system to receive the selected transport container in accordance with the transport container AMR instructions.

92. The fulfillment system according to claims 1 to 13 or any one of claims, wherein the processor is further operable to generate an AMR instruction for the transport container, and wherein the fulfillment system further comprises: The transport container is introduced into an AMR, which is configured as follows: Receive the AMR instruction from the transport container from the processor; AMR directives are introduced based on the transport container: Proceed to the receiving position for the transport container pallet; and At the receiving position of the transport container pallet, the transport container pallet is engaged, and the transport container pallet holds multiple transport container blanks; as well as Proceeding to the blank transfer position close to the transport container delivery system; as well as A blank transfer device, located near the transport container delivery system and the blank transfer location, operable to transfer transport container blanks from the transport container pallet to the transport container delivery system.

93. The fulfillment system of claim 92, wherein the transport container delivery system includes the blank transfer device.

94. The fulfillment system according to claim 92 or 93, wherein the plurality of transport container blanks are held in a plurality of boxes supported on the transport container pallet.

95. The fulfillment system of claim 94, wherein the plurality of cartons are stacked vertically on top of each other in a carton stack.

96. The fulfillment system of claim 95, wherein the plurality of cartons are stacked vertically in a nested arrangement.

97. The fulfillment system according to any one of claims 1 to 15 or 36 to 50, wherein the blank transfer device comprises both a container lifting device and a robotic device controlled by the processor, the container lifting device being operable to lift all containers in the container stack above the container holding at least one transport container blank to expose a top opening of the container holding at least one transport container blank, and the robotic device being operable to pick up the transport container blank from the container holding at least one transport container blank and transfer the at least one transport container blank to the transport container delivery system.

98. The fulfillment system of claim 98, wherein the transport container delivery system, according to a transport container delivery instruction received from the processor, erects the transport container blank into the selected transport container and delivers the selected transport container to the transport container AMR.

99. The fulfillment system of claim 98 or 99, further comprising a cover covering the top of the opening of the top container in the container stack, wherein the container lifting device is further operable to lift the cover only from the top container to expose the top of the opening of the top container.

100. A method for operating a system, the system comprising: A first product introduction area includes multiple product storage devices, each of which holds multiple products. A first product transfer device is operable to transfer a first product of a first plurality of products held by a first product storage device among the plurality of storage devices into a transport container; Autonomous Mobile Robot (AMR) for Transport Containers; and A transport container delivery system operable to deliver the transport container to the transport container AMR; The method includes the transport container AMR: Proceeding to the transport container delivery system; Waiting to receive the transport container from the transport container delivery system; While maintaining the transport container, proceed to the first product transfer device in the first product introduction area; At the first product transfer device, wait for the first product from the product storage device to be received into the transport container; and While keeping the transport container containing the first product inside, proceed to at least one location to further process the transport container.

101. An execution system comprising: The first product introduction area includes multiple pallets, each of which holds multiple products; Product transfer equipment, operable to transfer a first product from a pallet selected from the plurality of pallets; Autonomous Mobile Robot (AMR) for Transport Containers; and A transport container delivery system operable to deliver a selected transport container to the transport container AMR; The transport container AMR is operable to: Proceeding to the transport container delivery system; Waiting to receive the selected transport container at the transport container delivery system; While maintaining the selected transport container, proceed to the product transfer equipment in the product introduction area; Wait at the first product transfer location to receive the first product from the selected pallet into the selected transport container; as well as While maintaining the selected transport container containing the first product inside, the process proceeds to at least one location for further processing of the selected transport container.

102. The system of claim 101, wherein the selected transport container is selected by the processor from a variety of available types of transport containers.

103. The system of claim 102, wherein the multiple available types of transport containers comprise multiple transport containers of different sizes.

104. The system of claim 102 or 103, wherein the multiple available types of transport containers include both insulated transport containers and non-insulated transport containers.

105. The system according to any one of claims 102 to 104, wherein the selected transport container is selected by the processor based on a customer order received by the processor, and wherein the transport container AMR instruction for the transport container AMR is generated by the processor based on the customer order received by the processor.

106. The fulfillment system according to any one of claims 102 to 105, wherein the selected pallet includes a general pallet.

107. A method for operating a performance system, the performance system comprising: The first product introduction area includes multiple pallets, each of which holds multiple products; Product transfer equipment, operable to transfer a first product from a selected pallet, the selected pallet being chosen from a plurality of pallets; Autonomous Mobile Robot (AMR) for Transport Containers; and A transport container delivery system operable to deliver a selected transport container to the transport container AMR; The method includes the transport container AMR: Proceeding to the transport container delivery system; Waiting to receive the selected transport container at the transport container delivery system; While maintaining the selected transport container, proceed to the product transfer equipment in the product introduction area; At the first product transfer location, wait to receive the first product from the selected pallet into the selected transport container; and While maintaining the selected transport container containing the first product inside, the process proceeds to at least one location for further processing of the selected transport container.

108. An execution system comprising: A processor that is operable to generate instructions for an autonomous mobile robot (AMR) with pallets. The pallet AMR is configured as follows: Receive the AMR command for the pallet from the processor; According to the AMR instruction of the pallet: Proceed to the pallet receiving position; Receive the selected pallet at the pallet receiving location; While maintaining the selected pallet, proceed to the product storage area; as well as Release the selected pallet; The pallet holds at least one product, and the at least one product corresponds to at least one inventory unit.

109. The fulfillment system of claim 107, wherein the pallet AMR is configured to, upon the AMR instruction, travel to a pallet storage location in the product storage area while holding the selected pallet, and release the selected pallet at the pallet storage location.

110. The fulfillment system of claim 109, wherein the selected pallet is located at a first pallet storage location in the product introduction area.

111. The fulfillment system of claim 110, wherein the product introduction area comprises a plurality of pallets located at corresponding plurality of pallet storage locations.

112. The fulfillment system of claim 111, wherein the plurality of pallet storage locations are arranged in a row.

113. The fulfillment system of claim 112, wherein the first pallet storage location is located at a first end position of the row of the pallet storage location.

114. The fulfillment system according to any one of claims 108 to 113, wherein the pallet receiving location is a location within the storage area of ​​the selected transport trailer.

115. The fulfillment system of claim 114, wherein the at least one product is held in a container and the container is supported on the selected pallet.

116. The fulfillment system of claim 115, wherein the cargo box is a first cargo box of a plurality of general cargo boxes, wherein the plurality of general cargo boxes are stacked vertically on top of each other in a cargo box stack, and wherein each of the general cargo boxes holds at least one product.

117. The fulfillment system of claim 116, wherein each of the plurality of universal cargo boxes contains at least one product, and wherein all of the at least one product in all of the plurality of universal cargo boxes corresponds to the same inventory unit.

118. The fulfillment system of claim 117, wherein each of the plurality of universal containers contains at least one product.

119. The fulfillment system of claim 118, wherein each of the plurality of universal containers holds one or more products of the same inventory unit.

120. The fulfillment system of claim 118, wherein at least some of the plurality of universal containers hold one or more products from different inventory units.

121. A method of operating a performance system, the performance system comprising: A processor operable to generate instructions for a palletized autonomous mobile robot (AMR); AMR pallet; The method includes the AMR pallet: Receive the AMR command for the pallet from the processor; According to the AMR instruction of the pallet: Proceed to the pallet receiving position; Receive the selected pallet at the pallet receiving location; While maintaining the selected pallet, proceed to the product storage area; and Release the selected pallet, wherein the selected pallet holds at least one product, the at least one product corresponding to at least one inventory unit.

122. A system comprising: A mobile device operable to move one or more of a plurality of stacked cartons, the stacked cartons being vertically stacked on a pallet in the carton stack positioned at the carton movement location, wherein at least some of the plurality of cartons contain at least one product in the cartons, and the carton stack is supported on the pallet. A processor that is operable to generate instructions for mobile devices; The mobile device described therein is operable to: Receive instructions from the mobile device from the processor; Joining selected containers from the plurality of containers in the container stack; and Move the selected container and any containers stacked on top of the selected container.

123. The system according to claim 122, wherein: The mobile device includes a lifting device operable to vertically lift one or more of the plurality of boxes in the box stack, the box stack being positioned at a box movement position serving as a first box lifting position; The processor is operable to generate boosting device instructions; The lifting device is further operable to: Receive the boosting device instruction from the processor; Join a selected container from the plurality of containers in the container stack; as well as Vertically lift the selected container and any containers stacked on top of the selected container in the container stack.

124. The system of claim 123, wherein the lifting device is further operable to receive lifting device instructions from the processor to vertically lift the selected container and any container stacked above the selected container, thereby exposing a top opening in the selected container located in the container stack immediately below the container below it.

125. The system of claim 123 or 124, wherein the lifting device includes at least one vertically movable lifting arm operable to releasably engage a selected container of each of the plurality of containers in the container stack, and to lift and lower the selected container and all containers stacked above the selected container in the container stack.

126. The system of claim 125, wherein the at least one lifting arm comprises a first robotic lifting arm and a second robotic lifting arm positioned on opposite sides of the stack of containers in the vertical direction.

127. The system of claim 124, wherein the processor is operable to generate pick-up instructions, and the system further comprises: A robotic pickup device is operable such that, after the lifting device has lifted the selected container and all containers stacked above the selected container to expose the top opening immediately adjacent to the container below, the robotic pickup device is operable to pick up the container according to the pickup instruction: Pick up the product; as well as The product is transferred from the adjacent lower cargo box into the transport container.

128. The system according to any one of claims 123 to 127, wherein the plurality of cartons are arranged in a vertically nested configuration in the carton stack.

129. The system of claim 123 or 124, wherein the cargo boxes are stacked and supported on a cargo box support structure.

130. The system of claim 129, wherein the cargo box support structure comprises a pallet.

131. The system of claim 130, wherein the pallet comprises a general-purpose pallet.

132. The system according to any one of claims 125 to 128, wherein the cargo boxes are stacked and supported on a cargo box support structure.

133. The system of claim 132, wherein the cargo box support structure comprises a pallet.

134. The system of claim 133, further comprising an autonomous pallet moving robot (AMR), wherein the processor is configured to generate pallet AMR instructions, and wherein the pallet AMR is configured to engage the pallet at the first box lifting position and move the pallet and a stack of boxes on the pallet or a portion thereof from the first box lifting position, according to the pallet AMR instructions.

135. The system of claim 134, wherein after the lifting device lifts the selected container together with all containers stacked above the selected container from the plurality of containers to expose the top opening of the adjacent lower container, the pallet AMR is operable to move the pallet together with the adjacent lower container and any container supported on the pallet AMR below the adjacent lower container from the first container lifting position to a pick-up position, in which the robotic pick-up device is operable to pick up the product and transfer the product from the adjacent lower container to the transport container.

136. The system of claim 135, wherein the transport container is supported on the transport container AMR.

137. The system according to claim 135 or 136, wherein the system is operable such that: Following the AMR command on the pallet, the robotic pickup device picks up the product and transfers it from the adjacent lower container to the transport container: The pallet AMR is operable to move the pallet, along with the adjacent lower container and any container supported on the pallet AMR below the adjacent lower container, from the pickup position to a second container lifting position; and The lifting device is operable to lower the selected cargo box, along with all cargo boxes stacked above the selected cargo box, in the cargo box lifting position and according to the lifting device command, such that the selected cargo box is supported on the adjacent cargo box below it to reconstruct the cargo box stack.

138. The system of claim 137, wherein the first cargo box lifting position and the second cargo box lifting position are substantially at the same physical position.

139. The system of claim 137 or 138, wherein the pallet AMR is operable according to the pallet AMR command to engage with the pallet supporting the box stack at a pallet storage location and to move the pallet supporting the box stack from the pallet storage location to the first box lifting location.

140. The system of claim 139, wherein the pallet storage location is located in a refrigerated or frozen compartment.

141. The system of claim 140, wherein the cargo box lifting position is located in the refrigerated compartment or the frozen compartment.

142. The system of claim 141, wherein the pickup location is located in an environmental partition.

143. The system of claim 141 or 142, wherein the pickup device is located in an environmental partition.

144. The system of claim 143, wherein the processor is operable to generate a roller shutter instruction such that when the pallet AMR, together with the immediately below cargo box and any of the plurality of cargo boxes supported on the pallet AMR below the immediately below cargo box, travels from the lifting position through a roller shutter that moves up and down under the control of the roller shutter instruction to the pickup position, in order to reduce the amount of air traveling from the environmental zone to the refrigerated zone or the frozen zone to heat its air.

145. The system according to any one of claims 141 to 144, wherein the lifting device further comprises one or more of the actuator and the control device, and wherein at least one of the actuator and the control device is located in the environmental partition, and at least a portion of the at least one pickup arm extends into the refrigeration partition or the freezing partition.

146. The system of claim 145, wherein the freezing compartment and the refrigeration compartment are defined by a physical separation zone, wherein both the actuator and the control device are located on the environmental partition side of the physical separation zone, and wherein at least a portion of the at least one pickup arm is located on the refrigeration partition side or the freezing partition side of the physical separation zone.

147. The system according to any one of claims 137 to 146, wherein the pallet supporting the stack of cartons comprises a plurality of pallets, each of the plurality of pallets supporting a corresponding stack of cartons, wherein at least some of the cartons in each of the plurality of cartons stacked on the plurality of pallets contain at least one product in each carton.

148. The system of claim 147, wherein the plurality of pallets are arranged in one or more rows of pallets.

149. The system of claim 148, wherein the first set of multiple rows of the plurality of pallets is arranged in a laterally spaced relationship relative to the second set of multiple rows of the plurality of pallets.

150. The system of claim 148, wherein the first group and the second group are located in a refrigeration compartment or a freezing compartment.

151. The system of claim 150, wherein the first set of pallets is laterally spaced from the second set of pallets to provide a longitudinally oriented passage therebetween, the passage being configured to provide a physical path for the pallet AMR so that the pallet AMR can engage with the preceding pallet in each row of the multi-row pallets and move the preceding pallet to the first lifting position.

152. The system according to any one of claims 122 to 151, wherein each of the plurality of cartons holds one or more products of the same inventory unit.

153. The system according to any one of claims 122 to 151, wherein at least some of the plurality of cartons hold one or more products from different inventory units.

154. A method comprising: One or more of a plurality of stacked boxes are moved vertically on a pallet in a stack of boxes positioned at a moving location, wherein at least some of the boxes contain at least one product, and the stack of boxes is supported on the pallet. as well as Engage a selected container from the plurality of containers in the container stack, and optionally move the selected container and any containers stacked on top of the selected container by lifting.

155. A system for delivering products, comprising: A transport trailer configured to receive and store at least one pallet; Autonomous Mobile Palletizing Robot (AMR) is an operational tool for transporting pallets. as well as A processor operable to transmit instructions to the pallet AMR, the instructions causing the pallet AMR to: Navigate to the pallet receiving location outside the transport trailer and engage the pallet; Navigate to the storage location in the delivery trailer and release the pallet at the storage location; as well as Navigate away from the delivery trailer without the pallet in sight; The transport trailer includes an internal storage space defined by a ceiling surface, side wall surfaces, and a floor surface; and The configuration of the floor surface facilitates navigation by the pallet AMR within the transport trailer.

156. The system of claim 155, wherein the configuration includes a barcode on the floor surface, the barcode being detectable by the pallet AMR.

157. A method for delivering products using a pallet autonomous mobile robot (AMR) to load pallets onto a delivery trailer, the delivery trailer being configured to receive and store the pallets, the method comprising the pallet AMR: Navigate to the pallet receiving location outside the transport trailer and engage the pallet; Navigate to the storage location in the delivery trailer and release the pallet at the storage location; as well as Navigate away from the delivery trailer without the pallet in sight.

158. The method of claim 157, wherein the floor surface of the transport trailer is configured to facilitate navigation of the autonomous mobile robot (AMR) within the transport trailer.

159. A system for delivering products, comprising: A transport trailer configured to receive and store at least one pallet; Autonomous Mobile Palletizing Robot (AMR) is an operational tool for transporting pallets. as well as A processor operable to transmit instructions to a pallet AMR, the instructions causing the pallet AMR to: Navigate to the pallet receiving location inside the transport trailer and engage the given pallet; Navigate to the storage location outside the delivery trailer and release the given pallet at the storage location; as well as Navigate away from the given pallet.

160. The system according to claim 159, wherein: The transport trailer includes an internal storage space defined by a ceiling surface, side wall surfaces, and a floor surface; as well as The floor surface is configured to facilitate navigation by the given pallet AMR in the delivery trailer.

161. A method for delivering products using a pallet autonomous mobile robot (AMR) to unload a transport trailer, the transport trailer being capable of receiving and storing pallets, the method comprising the pallet AMR: Navigate to the pallet receiving location inside the transport trailer and engage the given pallet; Navigate to the storage location outside the delivery trailer and release the given pallet at the storage location; as well as Navigate away from the given pallet.

162. The method of claim 161, wherein the transport trailer includes an internal storage space defined by a ceiling surface, side wall surfaces and a floor surface, and the floor surface of the transport trailer facilitates navigation of the pallet AMR within the transport trailer.

163. A system for loading and transporting products, comprising: Sources of multiple products, wherein the system is operable to transfer the multiple products to a pallet located at a pallet loading location; A transport trailer configured to receive and store at least one pallet; Autonomous Mobile Robot (AMR) for pallets, which can be operated to move pallets; as well as A processor operable to transmit instructions to a pallet AMR, the instructions causing the pallet AMR to: Navigate to the pallet receiving location and engage a given pallet holding multiple products; Navigate to the storage location in the delivery trailer and release the given pallet at the storage location; as well as Navigate away from the delivery trailer without the given pallet.

164. The system of claim 163, further comprising a container sourcing system, wherein the system is further operable to transfer the plurality of products onto a specific pallet, and the system further comprising: Product transfer equipment, operable to transfer at least one product to each of a plurality of cartons provided by the source of the cartons; A container stacking and forming device, operable to form a container stack from the plurality of containers; as well as A container stacking and loading device, operable to stack and load the containers onto the specific pallet; The aforementioned pallet AMR is operable to: Navigate to the pallet receiving location; Join the specific pallet; Navigate to the storage location within the transport trailer; as well as Release the specific pallet at the storage location.

165. The system of claim 163 or 164, wherein the source of the plurality of products includes a product delivery conveyor operable to transfer the plurality of products to a product transfer location, wherein at the product transfer location, the product transfer device is operable to transfer at least one product to each of a plurality of cartons provided by the source of the cartons.

166. The system of claim 165, wherein the product transfer device includes a robotic picking device controlled by the processor, and the robotic picking device is operable to pick up the at least one product and transfer the at least one product to each of the plurality of cartons.

167. The system of claim 166, wherein the robot picking device further comprises a vision sensing system.

168. A system for loading products onto a pallet, the system comprising: The source of the product; Product transfer equipment, operable to load at a loading site at least one product provided by the source of said product into each of a plurality of cargo boxes, thereby forming a plurality of loaded cargo boxes; Loaded container stacking forming equipment, operable to form a loaded container stack from the plurality of loaded containers; Equipment operable to stack the loaded containers onto a pallet to form a loaded pallet; An autonomous mobile robot (AMR) for pallets is operable to engage with loaded pallets and move the loaded pallets while supporting the stacking of loaded boxes. as well as A processor operable to transmit instructions to the pallet AMR, the instructions causing the pallet AMR to: Navigate to the pallet receiving location; Engage the unloaded pallet at the pallet receiving position; Navigate to the container stacking receiving location along with the unloaded pallets; Receive the stacked containers to form the loaded pallet; Navigate away from the container stacking receiving location along with the loaded pallets; as well as While engaging the loaded pallets, it proceeds to a location for further processing.

169. The system of claim 168, wherein the product transfer device includes a robotic picking device controlled by the processor, and the robotic picking device is operable to pick up the at least one product and transfer the at least one product to each of the plurality of cartons.

170. The system of claim 169, wherein the robot picking device further comprises a vision sensing system.

171. The system according to any one of claims 168 to 170, further comprising a container conveyor device operable to deliver the plurality of containers to the loading station.

172. The system of claim 171, wherein the container conveyor equipment is further operable to deliver the plurality of loaded containers to the loaded container stacking equipment.

173. The system according to any one of claims 168 to 172, wherein the system further comprises: Multiple unloaded pallets, each of the multiple unloaded pallets containing the multiple empty boxes, the empty boxes not containing any products; The equipment is operable to continuously remove each of the plurality of empty containers from each unloaded pallet at an empty container transfer station and to transfer the plurality of empty containers to the container conveyor equipment, wherein the container conveyor equipment delivers the plurality of empty containers to the loading station.

174. The system of claim 171, further comprising: An unloaded pallet AMR, operable to engage with a given unloaded pallet of the plurality of unloaded pallets and move the given unloaded pallet from the unloaded pallet storage location to the empty container transfer station. as well as A processor operable to transmit instructions to the unloaded pallet AMR, the instructions causing the unloaded pallet AMR to: Navigate to the location of the unloaded pallet storage; Engage the given unloaded pallet at the unloaded pallet storage location; Navigate to the empty container transfer station along with the given unloaded pallet; Navigate away from the container transfer station along with the unloaded pallets and without the containers stacked. as well as While engaging the unloaded pallets, proceed to the location for further processing.

175. A method for loading products onto a pallet, the method comprising: At least one product supplied by the source of the product is loaded into each of a plurality of empty containers to form a plurality of loaded containers; The multiple loaded containers are stacked together to form a loaded container stack; The loaded containers are stacked onto pallets to form loaded pallets; The pallet autonomous mobile robot (AMR) engages with the loaded pallet; as well as Move the loaded pallets while supporting the stacking of the loaded containers.

176. A system for delivering products to a performance operation, the system comprising: Production operations, including the source of the product; Product transfer equipment, which is operable in the production operation to transfer multiple products supplied by the source of the products onto a pallet located at a pallet loading position; A first delivery trailer is operable to receive and store at least one pallet, and the first delivery trailer enables an autonomous mobile robot (AMR) to navigate therein. The first production pallet AMR at the production operation site is operable to: Navigate to the pallet receiving location; At the pallet receiving position, a pallet for holding multiple products is engaged; Navigate to the storage location in the transport trailer; Release the loaded pallets at the storage location; as well as Navigate away from the transport trailer without the loaded pallet; The fulfillment operation includes a first fulfillment pallet AMR, which is operable to: Navigate to the storage location on the first delivery trailer; The loaded pallets are engaged at the storage location; Navigate to the pallet storage location within the execution operation; Release the loaded pallet at the pallet storage location; Navigate away from the pallet storage location without the loaded pallet; When the first transport trailer is loaded with the loaded pallets, the first transport trailer is operable to transport the loaded pallets from the production operation to the fulfillment operation.

177. The system of claim 176, further comprising: A second transport trailer is operable to receive and store at least one pallet, and the second transport trailer enables the AMR to navigate within it; The second fulfillment pallet AMR is operable as follows: Navigate to the fulfillment operation in the fulfillment operation to return to the pallet storage location; At the return pallet storage location of the operation, the return pallet is a pallet that no longer holds any products; Navigate from the pallet storage location to the return trailer storage location in the second transport trailer from the performed operation; Release the return pallet at the return trailer storage location; as well as Navigate away from the second transport trailer without the return pallet mentioned; The second production pallet AMR is operable as follows: Navigate to the aforementioned return trailer storage location; The return pallet is engaged at the return trailer storage location; Navigate away from the second transport trailer to the production operation return pallet storage location in the absence of the return pallet; Release the returned pallet at the production operation's return pallet storage location; as well as Navigate away from the production operation and return to the pallet storage location; When the second transport trailer is loaded with the return pallet, the second transport trailer is operable to transport the return pallet from the performance operation to the production operation.

178. The system of claim 177, further comprising a processing system operable to control the operation of the fulfillment pallet AMR, the first production pallet AMR, the second fulfillment pallet AMR, and the second production pallet AMR.

179. A method for delivering a product to a performance operation, the method comprising: In production operations: Multiple products supplied by the product's source are transferred onto a pallet to form a loaded pallet; The first production pallet is navigated to the loaded pallet by an autonomous mobile robot (AMR); The loaded pallet is engaged by the first production pallet AMR; The first production pallet is navigated by an AMR to the storage location in the transport trailer; When the transport trailer is in the production operation, the loaded pallet is released by the first production pallet AMR at the pallet storage location; as well as The first production pallet AMR navigates away from the transport trailer without the loaded pallet.

180. The method of claim 179, further comprising moving the transport trailer from the production operation to the fulfillment operation.

181. The method of claim 179 or 180, wherein the fulfillment operation further comprises a first fulfillment pallet AMR, and the method further comprises: The first fulfilling pallet AMR is navigated to the pallet storage location on the transport trailer; The loaded pallet is engaged by the first fulfilling pallet AMR; During the fulfillment operation, the first fulfilled pallet AMR navigates to the storage location of the second pallet; The loaded pallet is released by the first fulfilling pallet AMR at the second pallet storage location; as well as The first fulfilling pallet AMR navigates away from the second pallet storage location without carrying the loaded pallet.

182. A method for performing an operation, the method comprising: The first autonomous mobile robot (AMR) at the performance operation site navigates to the pallet storage location located on the first transport trailer at the performance operation site; The first AMR engages a loaded pallet, the loaded pallet holding multiple products; The first AMR moves the loaded pallet to the position where the operation is performed; The component performing the operation empties most or all of the products from the loaded pallet to form a return pallet; The second AMR at the execution point guides the return pallet. as well as The second AMR moves the returned pallet to the pallet storage location on the second transport trailer at the performance site.

183. A method for operating a production operation, the method comprising: Use multiple products to load pallets, thereby forming a loaded pallet; The first autonomous mobile robot (AMR) at the production operation site navigates to the loaded pallet; The loaded pallets are moved onto the first transport trailer by the first AMR; The second AMR at the production operation site navigates to the return pallet located on the second transport trailer at the production operation site; as well as The return pallet is removed from the second transport trailer by the second AMR.

184. A transport trailer including an internal storage space defined by a ceiling surface, side wall surfaces and a floor surface, the floor surface comprising a first configuration facilitating navigation of an autonomous mobile robot (AMR) within the transport trailer.

185. The transport trailer of claim 184, wherein the first configuration is consistent with a second configuration for performance operation, wherein the second configuration facilitates navigation by the AMR during the performance operation.

186. The transport trailer according to claim 184 or 185, wherein the first configuration is consistent with a third configuration for production operation, wherein the third configuration facilitates navigation by the AMR during the production operation.

187. The transport trailer according to any one of claims 184 to 186, wherein the first configuration includes a barcode on the interior floor surface of the transport trailer, the barcode being detectable by the AMR.

188. A system comprising: The transport trailer according to claim 187; AMR; as well as A processor operable to communicate with the AMR to receive barcode signals from the AMR, and in response to this, guides the movement of the AMR within the transport trailer.

189. A transport trailer comprising: Internal storage space, defined by the ceiling surface, side wall surface and floor surface; Multiple airbags are positioned on the sidewall surface, the multiple airbags having: In a first state, the airbag is inflated with pressurized air to engage the side surface of a cargo box supported on a pallet stored in the internal space; and In the second state, the airbag is depressurized and detaches from the side surface of the cargo box.

190. The transport trailer of claim 189, wherein the pallet supports the vertical stacking of a plurality of cartons, and wherein: The plurality of airbags in the first state are engaged and supported on the side surfaces of some of the plurality of cargo boxes stored on the pallet in the internal space; as well as The plurality of airbags in the second state detach from some of the plurality of cargo boxes.

191. The transport trailer according to claim 189 or 190, further comprising: An air pressure system operable to inflate and deflate the plurality of airbags; as well as A tractor unit that is operable to push the transport trailer.

192. A transport container blank delivery system for delivering transport container blanks to an upright transport container delivery system, the transport container blank delivery system comprising: A pallet for transporting container blanks, which holds multiple transport container blanks; An autonomous mobile robot (AMR) for transporting container blanks is configured as follows: Proceed to the receiving position for the transport container blank pallet; The transport container blank pallet is engaged at the receiving position of the transport container blank pallet; as well as Proceed to the blank transfer position, wherein the blank transfer position is close to the upright transport container delivery system; as well as A blank transfer device, located near the blank transfer location and the upright transport container delivery system, operable to transfer the plurality of transport container blanks from the transport container blank pallets to the upright transport container delivery system.

193. The system of claim 192, further comprising a processor operable to generate transport container blank AMR instructions, wherein the transport container blank AMR is configured to: Receive the AMR instruction from the transport container from the processor; According to the AMR command introduced by the transport container, it proceeds to the pallet receiving position of the transport container; At the transport container pallet receiving position and in accordance with the transport container introduction AMR command, the transport container pallet is engaged; and The transport container is instructed to initiate an AMR (Automatic Transport Response) procedure and proceed to the blank transfer location.

194. The system of claim 193, wherein the blank transfer device is part of the upright transport container delivery system.

195. The system of claim 193 or 194, wherein the blank transfer device comprises a robotic device and a computer vision device operable to jointly position and engage each of the plurality of transport container blanks, and to move each of the transport container blanks from the transport container blank pallet to the upright transport container delivery system.

196. The system according to any one of claims 193 to 195, wherein the plurality of transport container blanks are held in a plurality of boxes supported on the transport container pallet.

197. The system of claim 196, wherein the plurality of cartons are stacked vertically on top of each other in a carton stack.

198. The system of claim 197, wherein the plurality of containers are stacked vertically in a nested arrangement.

199. The system according to any one of claims 196 to 198, wherein the blank transfer device comprises: The cargo container lifting device is controlled by the processor; as well as The robotic device is controlled by the processor; The container lifting device is operable to lift all containers in the container stack above the container holding the selected transport container blank, thereby exposing the top opening of the container holding the selected transport container blank; The robotic device is operable to pick up the selected transport container blank from the cargo box holding the selected transport container blank and transfer the selected transport container blank to the upright transport container delivery system.

200. The system of claim 193, wherein the upright transport container delivery system is operable to erect the selected transport container blank into an upright transport container and deliver the upright transport container to a transport container AMR in accordance with a transport container delivery instruction received from the processor.

201. The system of claim 197 or 198, further comprising a cover covering the top of the opening of the top container in the container stack, wherein the container lifting device is further operable to lift the cover only from the top container, thereby exposing the top of the opening of the top container in the container stack.

202. A method for operating a fulfillment system, the fulfillment system comprising an autonomous mobile robot (AMR) for transporting container blanks, the method comprising: The transport container blank AMR travels to the transport container blank pallet receiving position; The transport container blank AMR is engaged with the transport container blank pallet at the receiving position of the transport container blank pallet, and the transport container blank pallet holds multiple transport container blanks; as well as The transport container blank AMR travels to the blank transfer position close to the transport container delivery system.

203. The method of claim 202, further comprising transferring the plurality of transport container blanks from the transport container blank pallet to the transport container delivery system.

204. A system for delivering a transport container blank to a performance operation, the system comprising: Production operations that are operable to provide a source of transport container blanks; Product transfer equipment, operable at the production operation location, to transfer multiple transport container blanks provided by the source of the transport container blanks to a transport container blank pallet located at the pallet loading position; The first transport trailer is configured to receive and store the transport container blank pallets; An autonomous mobile robot (AMR) for producing pallets is operable at the production operation site to move the transport container blank pallets. as well as A processing system operable to transmit production pallet AMR instructions to the production pallet AMR, the production pallet AMR instructions causing the production pallet AMR to: Navigate to the pallet receiving location; The transport container blank pallets are engaged to hold the plurality of transport container blanks; Navigate to the storage location in the transport trailer; Release the transport container blank pallet at the storage location; as well as Navigate away from the transport trailer in the absence of the transport container blank pallet; When the first transport trailer is loaded with the transport container blank pallet, the first transport trailer can be operated to transport the transport container blank pallet from the production operation to the fulfillment operation.

205. The system of claim 204, further comprising: A fulfillment system, which includes a transport container delivery system; as well as A fulfillment pallet AMR, operable at the fulfillment operation point to move the transport container blank pallet; The processing system is further operable to transmit fulfillment pallet AMR instructions to the fulfillment pallet AMR, the fulfillment pallet AMR instructions causing the fulfillment pallet AMR to: Navigate to the pallet storage location on the first transport trailer; Connect the transport container blank pallet; Navigate to the pallet storage location during the execution operation; Release the transport container blank pallet at the pallet storage location; as well as Navigate away from the pallet storage location in the absence of the transport container blank pallet.

206. The system of claim 205, further comprising: The first transport container blank AMR is configured as follows: During the execution operation, the vehicle travels to the pallet storage location; The transport container blank pallet is engaged at the pallet storage location; as well as Proceeding to the blank transfer position close to the transport container delivery system; as well as A blank transfer device is provided near the transport container delivery system and the blank transfer location. The blank transfer device is operable to transfer the plurality of transport container blanks from the transport container blank pallet to the transport container delivery system.

207. The system of claim 206, wherein the processing system is further operable to: The second fulfillment pallet AMR instruction is transmitted to the second fulfillment pallet AMR, and the second fulfillment pallet AMR instruction causes the second fulfillment pallet AMR to: The return pallet is joined together, the return pallet comprising the transport container blank pallet without any transport container blanks; Navigate from the blank transfer location to: The return to the pallet storage location during the execution operation; or The return trailer storage location in the second transport trailer; Release the transport container blank pallet; The second production pallet AMR instruction is transmitted to the second production pallet AMR, and the second production pallet AMR instruction causes the second production pallet AMR to: Navigate to the return trailer storage location in the second transport trailer; Join the returned pallet; Navigate together with the returned pallet from the second transport trailer to the returned pallet storage location in the production operation; Release the returned pallet; as well as Navigate away from the stated return pallet storage location; When the second transport trailer is loaded with the return pallet, the second transport trailer is operable to transport the return pallet from the performance operation to the production operation.

208. The system according to any one of claims 204 to 207, wherein the processing system comprises a first processor located at the production operation and a second processor located at the fulfillment operation.

209. The system of claim 208, wherein the first processor and the second processor communicate electronically with each other.

210. A method for delivering a transport container blank to a performance operation, the method comprising: Transfer multiple transport containers onto transport container blank pallets; The pallet is navigated to the transport container blank pallet by an autonomous mobile robot (AMR); The transport container blank pallet held by the pallet AMR engagement of the pallet; The pallet is navigated by the AMR to the storage location on the transport trailer; The transport container blank pallet is released by the pallet AMR at the storage location; as well as Navigate away from the transport trailer without the transport container blank pallet.

211. A combined production and fulfillment system, comprising: The system according to claim 177; as well as The system according to claim 205.

212. An execution system comprising: A processor that is operable to: Generate carton forming instructions; as well as Generate instructions for the Autonomous Mobile Robot (AMR). The carton forming system is configured as follows: Receive the carton forming instruction from the processor; According to the carton forming instruction, a carton blank is selected from a plurality of available carton blanks; and The cardboard box blank is formed into an upright cardboard box; AMR, which is configured as follows: Receive the AMR instruction from the processor; According to the AMR command, proceed to the carton forming system and receive the upright carton from the carton forming system; According to the AMR instructions, while maintaining the upright carton, proceed to the station in the product introduction area; The product is received into the upright carton at the site; as well as According to the AMR instruction, while maintaining the upright carton containing the product inside, the vehicle moves to a position for further processing of the upright carton.

213. The fulfillment system of claim 212, wherein the carton forming instruction is generated by the processor based on a customer order received by the processor, and the AMR instruction is generated by the processor based on the customer order received by the processor.

214. The fulfillment system of claim 212 or claim 213, wherein the product introduction area includes a product tower, the product tower including a plurality of compartments for storing products, and wherein at least one of the plurality of compartments contains one or more products, the one or more products corresponding to at least one storage unit.

215. The fulfillment system according to any one of claims 212 to 214, further comprising a scale, wherein said further processing includes confirming that the weight of the combination of the upright carton and the product, measured using the scale, is close to the expected weight of the combination of the upright carton and the product.

216. The fulfillment system according to any one of claims 212 to 215, further comprising a carton sealing device, wherein the further processing comprises sealing the upright carton at the carton sealing device.

217. The fulfillment system according to any one of claims 212 to 216, further comprising a carton labeling device, wherein the further processing includes using the carton labeling device to label the erected carton.

218. The execution system according to any one of claims 212 to 217, further comprising a route distribution accumulation area, and wherein said further processing comprises: Determine the destination of the product; as well as The upright cardboard box is transferred to a station in the route distribution accumulation area, the station in the route distribution accumulation area corresponding to the destination.

219. The fulfillment system of claim 218, wherein the unloading positions in the route distribution accumulation area correspond to delivery routes representing an ordered sequence of destinations, and wherein generating the AMR instruction comprises: The location of the product's destination is determined within the ordered sequence of each destination; as well as Arrange the arrival time sequence of the AMR at the unloading location in the route distribution accumulation area such that the arrival time sequence corresponds to the position in the ordered sequence of each destination.

220. The fulfillment system according to any one of claims 212 to 219, wherein the further processing includes using a suction cup to hold the upright carton.

221. The order fulfillment system according to any one of claims 212 to 220, wherein the further processing includes using lugs attached to an independently controlled belt to hold the upright carton.

222. The order fulfillment system according to any one of claims 212 to 221, wherein the product introduction area is adjacent to the storage area.

223. The order fulfillment system of claim 222, wherein the storage area comprises a plurality of towers storing products in compartments, wherein the towers are configured for transport by a tower-carrying autonomous mobile robot to the product introduction area.

224. The order fulfillment system of claim 222, wherein the storage area comprises a plurality of product storage racks for storing products in pallets.

225. The order fulfillment system according to any one of claims 212 to 224, wherein the plurality of available carton blanks are stored in a plurality of silos.

226. The order fulfillment system according to any one of claims 212 to 225, wherein the station in the product introduction area includes a robot product loading station, and wherein the AMR is configured to receive the product from the product removal robot at the robot product loading station into the upright carton.

227. The order fulfillment system according to any one of claims 212 to 225, wherein the station in the product introduction area includes a manual product loading station, and wherein the AMR is configured to receive the product from the manual product removal assistant into the upright carton at the manual product loading station.

228. An execution system comprising: A processor that is operable to: Generate transport container selection instructions; as well as Generate instructions for the Autonomous Mobile Robot (AMR). The transport container delivery system is configured as follows: Receive the transport container selection instruction from the processor; and According to the transport container selection instruction, select the desired transport container from a plurality of transport containers; AMR, which is configured as follows: Receive the AMR instruction from the processor; According to the AMR instructions, proceed to the transport container delivery system and receive the selected transport container from the transport container delivery system; According to the AMR instructions, while maintaining the selected transport container, proceed to the station in the product introduction area; At the site, the product is received into the selected shipping container; as well as According to the AMR directive, while keeping the selected transport container containing the product inside, proceed to a location for further processing of the selected transport container.

229. The fulfillment system of claim 228, wherein the transport container selection instruction is generated by the processor based on a customer order received by the processor, and the AMR instruction is generated by the processor based on the customer order received by the processor.

230. The fulfillment system of claim 228 or 229, wherein the product introduction area includes a product tower, the product tower including a plurality of compartments for storing products, and wherein at least one of the plurality of compartments contains one or more products, the one or more products corresponding to at least one inventory unit.

231. The performance system according to any one of claims 228 to 230, wherein the product is a first product, and wherein the AMR is further configured to: According to the AMR instruction, while holding the selected transport container, proceed to a given product storage rack in the storage area, wherein the storage area contains multiple product storage racks for storing products in pallets; At the given product storage rack, the second product is received into the selected transport container; and According to the AMR directive, while maintaining the selected transport container containing the first product and the second product inside, the transport container is moved to a different location for further processing of the selected transport container.

232. The fulfillment system according to any one of claims 228 to 231, wherein the AMR is further configured to, upon the AMR instruction, travel to a position in a second product introduction area while holding the selected transport container, wherein the second product introduction area includes a container storage structure that holds a plurality of containers for storing products, and wherein at least one of the plurality of containers contains one or more products, the one or more products corresponding to a single inventory unit.

233. The fulfillment system of claim 232, wherein the AMR is a transport container AMR, and the system further includes a cargo storage AMR, wherein the processor is further operable to generate a cargo storage AMR instruction that instructs the cargo storage AMR to transport the cargo storage structure to the second product introduction area to meet the transport container AMR.

234. The fulfillment system according to any one of claims 228 to 233, further comprising a sealing device operable to seal the open flap of the selected transport container.

235. The fulfillment system of claim 234, wherein as the AMR moves through the sealing device, the sealing device seals the open flaps of the selected transport container.

236. The execution system of claim 235, wherein the AMR further comprises a drive mechanism operable to drive movement of the AMR, and wherein the AMR is driven by the drive mechanism through the sealing device.

237. The fulfillment system of claim 236, further comprising a first guide belt and a second guide belt that are laterally spaced apart and extend longitudinally, the first guide belt and the second guide belt being operable to guide the selected transport container through the sealing device during longitudinal movement of the AMR on which the selected transport container is located.

238. The fulfillment system of claim 237, wherein the order fulfillment system is operable such that movement of the guide belt provides the processor with information instructing the AMR and the transport container to move through the sealing device.

239. The fulfillment system according to any one of claims 228 to 238, wherein the station in the product introduction area includes a robot product loading station, and wherein the AMR is configured to receive the product from the product removal robot into the transport container at the robot product loading station.

240. The fulfillment system according to any one of claims 228 to 238, wherein the station in the product introduction area includes a manual product loading station, and wherein the AMR is configured to receive the product from the manual product removal assistant into the transport container at the manual product loading station.

241. A carton closing and sealing system, comprising: Autonomous Mobile Robot (AMR) A processor that is operable to generate AMR instructions; A transport container delivery system configured and operable to deliver transport containers to the AMR; A sealing device operable such that when the AMR on which the transport container is located moves through the sealing device, the transport container is sealed. The AMR is configured and operable to: Receive the AMR instruction from the processor; as well as According to the AMR command, proceed to the sealing device and move through the sealing device to seal the transport container.

242. The system of claim 241, wherein the AMR further comprises a drive mechanism operable to drive movement of the AMR, and the AMR having the transport container thereon is driven by the drive mechanism through the sealing device.

243. The system of claim 241 or 242, further comprising a first guide belt and a second guide belt that are laterally spaced apart and extend longitudinally, the first guide belt and the second guide belt being operable to guide the transport container through the sealing device during longitudinal movement of the AMR on which the transport container is secured.

244. The system of claim 243, wherein during the longitudinal movement of the AMR, on which the transport container is fixed, through the sealing device, the guide belt contacts the respective opposite side surfaces of the transport container.

245. The system of claim 243 or 244, wherein the lateral spacing of the guide strips can be adjusted by the processor to correspond to the width of the transport container.

246. The system according to any one of claims 243 to 245, wherein the system is operable such that movement of the longitudinal guide belt provides the processor with information instructing the AMR and transport container to move through the sealing device.

247. The system according to any one of claims 241 to 246, wherein the sealing device includes a folding guide system operable to close at least one of an upper guide fold and opposing first and second side folds of the transport container during movement of the AMR and the transport container through the sealing device.

248. The system of claim 247, wherein the sealing device further comprises a flap kicking mechanism operable to close a rear flap of the transport container during movement of the AMR and the transport container through the sealing device.

249. The system according to any one of claims 241 to 248, further comprising a labeling device operable such that the transport container is labeled when the AMR having the transport container thereon moves past the labeling device.

250. The system of claim 249, wherein the AMR moves through the sealing device and the marking device according to the AMR command to seal the transport container and mark the transport container.

251. An autonomous mobile robot (AMR) for transporting receiving items, the AMR comprising: Mobile cart; A control system for controlling the operation of the AMR; The first belt has an upper surface; The first lug is fastened to the upper surface of the first strip; The second belt has an upper surface; as well as The second lug is fastened to the upper surface of the second band; The control system is operable to control and adjust the position of the first lug relative to the second lug to move between the following positions: A first position, wherein the spacing between the first lug and the second lug is adapted to allow the receiver to be positioned between the first lug and the second lug and removed from between the first lug and the second lug; as well as In the second position, the distance between the first lug and the second lug is such that the first lug and the second lug engage the side surface of the receiver to fix the receiver between the first lug and the second lug.

252. The AMR of claim 251, wherein the upper surface of the first belt and the upper surface of the second belt are configured to support the receiver thereon, and wherein the receiver is supported on the upper surface of the first belt and the upper surface of the second belt when the transport container is secured between the first lug and the second lug.

253. An autonomous mobile robot (AMR) for transporting receiving items, the AMR comprising: Mobile cart; A control system for controlling the operation of the autonomous mobile robot; A receiving container securing mechanism, operable to releasably secure a transport container to a mobile trolley during movement within a warehouse, when the receiving container carries at least one product from a product order and when the receiving container contains no products. The control system is operable to control and adjust the operation of the receiver fixing mechanism between the following states: In the first state, when the receiving container carries at least one product from the product order and when the receiving container contains no products, the receiving container is secured to the mobile cart and is able to move within the warehouse. as well as In the second state, the receiver can be removed from the mobile cart.

254. The AMR of claim 253, wherein in the second state, the receiver can be received onto the mobile trolley.

255. A product unloading system, comprising: Product racks for storing products, the product racks comprising: Multiple storage layers for storing the product thereon, the multiple storage layers being spaced apart from each other and arranged vertically within the product rack; and Multiple raised platforms are configured for autonomous mobile robots (AMRs) to travel on, with each of the multiple raised platforms approaching a corresponding storage layer of the multiple storage layers for positioning. A lifting system comprising a lifting platform for raising the AMR between the ground plane and the plurality of elevated platforms; and A product retrieval robot is used to retrieve products from one of the plurality of storage layers and unload the products onto a receiver held by the AMR at a corresponding storage layer among the plurality of storage layers.

256. The system of claim 255, wherein the product retrieval robot includes an end-of-arm tool (EOAT) for engaging the product during retrieval.

257. The system of claim 255 or 256, wherein the product removal robot includes sensors for detecting the product to be removed.

258. The system of claim 257, wherein the sensor is a camera.

259. The system of any one of claims 256 to 258, further comprising a pallet positioned on one of the plurality of storage layers, the pallet comprising a plurality of containers, each of wherein each of the containers contains an item having a known size of the product retrieval robot, and wherein engaging the product during retrieval comprises engaging the item.

260. The system of claim 259, wherein the plurality of containers are reusable containers.

261. An execution system comprising: A processor that is operable to: Generate carton forming instructions; Generate product retrieval instructions; and Generate instructions for the Autonomous Mobile Robot (AMR). The carton forming system is configured as follows: Receive the carton forming instruction from the processor; According to the carton forming instruction, a carton blank is selected from the hopper; and The cardboard box blank is formed into an upright cardboard box; The product retrieval robot is configured as follows: Receive the product retrieval instruction from the processor; and According to the product retrieval instruction, the product is retrieved from the product shelf in the product storage location; AMR, which is configured as follows: Receive the AMR instruction from the processor; According to the AMR command, proceed to the carton forming system and receive the upright carton from the carton forming system; According to the AMR instruction, while maintaining the upright cardboard box, proceed to the product shelf; At the product rack, the product from the product removal robot is received into the upright cardboard box; as well as According to the AMR instruction, while maintaining the upright carton containing the product inside, the vehicle moves to a position for further processing of the upright carton.

262. The system of claim 261, wherein the carton forming instruction is generated by the processor based on a customer order received by the processor, the product removal instruction is generated by the processor based on a customer order received by the processor, and the AMR instruction is generated by the processor based on a customer order received by the processor.

263. The system of claim 261 or claim 262, wherein the product rack comprises: Multiple storage layers for storing products thereon, the multiple storage layers being spaced apart from each other and arranged vertically within the product rack; as well as Multiple raised platforms are configured for the AMR to travel on, with each of the multiple raised platforms positioned close to a corresponding storage layer among the multiple storage layers.

264. The system of claim 263, further comprising a lifting system configured to receive from the processor a lifting command for raising the AMR between the ground plane and one of the plurality of raised platforms, wherein the AMR is further configured to: At the product rack, the product is transported by the lifting system to one of the plurality of raised platforms; According to the AMR command, proceed along one of the plurality of elevated platforms; and The robot removes the product from the product and receives it into the upright cardboard box.

265. The system of claim 263 or 264, further comprising a pallet positioned on one of the plurality of storage layers, the pallet comprising a plurality of reusable containers, each of the plurality of reusable containers holding a plurality of products, and wherein: In response to the AMR receiving the last of the plurality of products from any of the reusable containers, the empty AMR is configured as follows: Receive an empty AMR instruction generated by the processor from the processor; According to the empty AMR command, proceed to the product rack; At the product shelf, a robot retrieves the reusable container from the product. as well as According to the empty AMR instruction, while holding the container, proceed to a position for further processing of the reusable container.

266. The system of claim 265, wherein further processing of the reusable container includes unloading the reusable container onto another pallet.

267. An execution system comprising: A processor that is operable to: Generate delivery instructions for the receiving item; as well as Generate instructions for the Autonomous Mobile Robot (AMR). A carton delivery system is configured as follows: Receive the receiver delivery instruction from the processor; and According to the receiving delivery instruction, select a receiving item for delivery from the selection of receiving items; AMR, which is configured as follows: Receive the AMR instruction from the processor; According to the AMR instructions, proceed to the receiver delivery system and receive the selected receiver from the receiver delivery system; According to the AMR instructions, while keeping the selected receiver in place, proceed to the station in the product introduction area; The product is received at the selected receiving station; as well as According to the AMR instruction, while keeping the selected receiver containing the product inside, proceed to a position for further processing of the selected receiver.

268. The fulfillment system of claim 267, wherein the receiving delivery system includes a carton forming system, the carton forming system being configured to: Receive a receiving delivery instruction, including a carton forming instruction, from the processor; According to the carton forming instruction, a carton blank is selected from multiple hoppers, thereby establishing the selected carton blank; and The selected cardboard blank is formed into an upright cardboard box.

269. The fulfillment system of claim 267 or claim 268, wherein the station in the product introduction area includes a robot product loading station, and wherein the AMR is configured to receive the product from the product removal robot into the selected receiver.

270. The fulfillment system of claim 267 or claim 268, wherein the station in the product introduction area includes a manual product loading station, and wherein the AMR is configured to receive a product from a manual product removal assistant into the selected receiver.

271. An execution system comprising: A processor that is operable to: Generate transport container selection instructions; as well as Generate instructions for the Autonomous Mobile Robot (AMR). The transport container delivery system is configured as follows: Receive the transport container selection instruction from the processor; and According to the transport container selection instruction, select the desired transport container from a plurality of transport containers; AMR, which is configured as follows: Receive the AMR instruction from the processor; According to the AMR instructions, proceed to the transport container delivery system and receive the selected transport container from the transport container delivery system; According to the AMR directive, while maintaining the selected transport container, the vehicle proceeds to a station in the product introduction area, wherein the product introduction area includes a product tower, the product tower includes multiple compartments for storing products, and at least one of the multiple compartments contains one or more products, the one or more products corresponding to at least one inventory unit. At the site, the first product is received into the selected transport container; According to the AMR instruction, while holding the selected transport container, proceed to a given product storage rack in the storage area, wherein the storage area contains multiple product storage racks for storing products in pallets; At the given product storage rack, the second product is received into the selected transport container; as well as According to the AMR directive, while maintaining the selected transport container containing the first product and the second product inside, the vehicle proceeds to a location for further processing of the selected transport container.

272. The fulfillment system of claim 271, wherein the transport container selection instruction is generated by the processor based on a customer order received by the processor, and the AMR instruction is generated by the processor based on a customer order received by the processor.

273. The fulfillment system of claim 271 or claim 272, further comprising a sealing device operable to seal the open flap of the selected transport container.

274. The fulfillment system of claim 273, wherein as the AMR moves through the sealing device, the sealing device seals the open flap of the selected transport container.

275. The execution system of claim 274, wherein the AMR further comprises a drive mechanism operable to drive movement of the AMR, and wherein the AMR is driven by the drive mechanism through the sealing device.

276. The fulfillment system of claim 275, further comprising a first guide belt and a second guide belt that are laterally spaced apart and extend longitudinally, the first guide belt and the second guide belt being operable to guide the selected transport container through the sealing device during longitudinal movement of the AMR on which the selected transport container is located.

277. The fulfillment system of claim 271, wherein the processor is further operable to generate instructions for tower repositioning AMR to reposition the product tower to the site in the product introduction area.

278. The fulfillment system of claim 271, wherein the processor is further operable to generate instructions for a product picking robot associated with the given product storage rack, to: Pick up the second product; and The second product is placed in the selected shipping container.

279. The fulfillment system of claim 271, wherein the AMR is further configured to travel to a position in a second product introduction area while holding the selected transport container, according to the AMR instruction, wherein the second product introduction area includes a container storage structure that holds a plurality of containers for storing products, and wherein at least one of the plurality of containers contains one or more products, the one or more products corresponding to a single inventory unit.

280. The fulfillment system of claim 279, wherein the AMR is a transport container AMR, and the system further includes a cargo storage AMR, wherein the processor is further operable to generate a cargo storage AMR instruction that instructs the cargo storage AMR to transport the cargo storage structure to the second product introduction area to meet the transport container AMR.

281. The execution system of claim 271, wherein the storage area comprises a plurality of partitions.

282. The fulfillment system of claim 281, wherein the plurality of zones includes the zone in which the product is maintained at a temperature below freezing.

283. The fulfillment system of claim 281, wherein the plurality of partitions includes the partition in which the product is maintained at ambient temperature.

284. The fulfillment system of claim 281, wherein the plurality of zones includes a zone in which the product temperature is maintained above freezing and below ambient temperature.

285. The fulfillment system of claim 271, wherein the product tower storage represents approximately 50 inventory units of products.

286. The fulfillment system of claim 285, further comprising a tower storage area configured for storing a plurality of product towers.

287. The fulfillment system of claim 286, wherein the tower storage area stores products representing more than 500,000 inventory units.

288. The fulfillment system of claim 271, wherein each pallet in the storage area stores a product representing a single inventory unit.

289. The fulfillment system of claim 288, wherein the storage area stores products representing fewer than 10,000 inventory units.

290. The fulfillment system of claim 289, wherein the products stored in the storage area include grocery items.

291. An execution system comprising: A processor that is operable to: Generate carton forming instructions; Generate product retrieval instructions; and Generate instructions for the Autonomous Mobile Robot (AMR). The carton forming system is configured as follows: Receive the carton forming instruction from the processor; According to the carton forming instruction, a carton blank is selected from a plurality of available carton blanks; and The cardboard box blank is formed into an upright cardboard box; The product retrieval robot is configured as follows: Receive the product retrieval instruction from the processor; and Retrieve the product from the product storage location according to the product retrieval instruction; A reusable container containing multiple products for fulfilling multiple orders, wherein when the multiple products are removed from the reusable container to fulfill the multiple orders, the reusable container becomes an empty reusable container. AMR, which is configured as follows: Receive the AMR instruction from the processor; According to the AMR command, proceed to the carton forming system and receive the upright carton from the carton forming system; According to the AMR instructions, while maintaining the upright position of the cardboard box, proceed to the product loading station; The product is received into the upright carton at the product loading station; According to the AMR instruction, while maintaining the upright carton containing the product inside, the vehicle moves to a position for further processing of the upright carton, wherein further processing of the upright carton includes removing the upright carton from the AMR. Subsequently, according to the AMR instructions, it proceeds and receives the empty reusable container; as well as According to the AMR instruction, while keeping the empty reusable container, proceed to a position for further processing of the empty reusable container.

292. The system of claim 291, wherein the plurality of available carton blanks are stored in a plurality of hoppers.

293. The system of claim 291, wherein the carton forming instruction is generated by the processor based on a customer order received by the processor, the product removal instruction is generated by the processor based on a customer order received by the processor, and the AMR instruction is generated by the processor in part based on a customer order received by the processor.

294. The system of claim 291, wherein the product loading station includes a robot product loading station, and wherein the AMR is configured to receive the product from the product robot into the upright carton.

295. The system of claim 291, wherein the product loading station includes a manual product loading station, and wherein the AMR is configured to receive the product from the manual product loading assistant into the upright carton.

296. An execution system comprising: A processor that is operable to: Generate delivery instructions for transport containers; Generate product retrieval instructions; and Generate instructions for autonomous mobile robots (AMRs); The transport container delivery system is configured as follows: Receive the delivery instruction for the transport container from the processor; and According to the transport container delivery instruction, a transport container is selected from multiple available transport containers; The product retrieval robot is configured as follows: Receive the product retrieval instruction from the processor; and Retrieve the product from the product storage location according to the product retrieval instruction; A reusable container containing multiple products for fulfilling multiple orders, wherein when the multiple products are removed from the reusable container to fulfill the multiple orders, the reusable container becomes an empty reusable container. AMR, which is configured as follows: Receive the AMR instruction from the processor; According to the AMR instructions, proceed to the transport container delivery system and receive the transport container; According to the AMR instructions, proceed to the product loading site while maintaining the transport container; The product is received into the transport container at the product loading site; According to the AMR instruction, while keeping the transport container containing the product inside, the transport container is moved to a position for further processing of the transport container, wherein further processing of the transport container includes removing the transport container from the AMR; Subsequently, according to the AMR instructions, the system proceeds and receives the empty reusable container on the AMR; and According to the AMR instruction, while keeping the empty reusable container, proceed to a position for further processing of the empty reusable container.

297. The system of claim 296, wherein the product loading station includes a robot product loading station, and wherein the AMR is configured to remove the product from the product robot and receive it into the transport container.

298. The system of claim 296, wherein the product loading station includes a manual product loading station, and wherein the AMR is configured to receive the product from the manual product removal assistant into the transport container.

299. The system of claim 296, wherein the transport container delivery instruction is generated by the processor based on a customer order received by the processor, the product retrieval instruction is generated by the processor based on a customer order received by the processor, and the AMR instruction is generated by the processor in part based on a customer order received by the processor.

300. A method for receiving a product into a fulfillment center, the method comprising: Transmit instructions to a first autonomous mobile robot (AMR), the instructions causing the first AMR to: Navigate to the cargo storage structure in the first transport trailer, the cargo storage structure holding cargo boxes containing multiple products therein; and The cargo container storage structure is transported to the product introduction area, where a single product among the plurality of products can be removed from the cargo container at the product introduction area; A command is transmitted to the second AMR, the command causing the second AMR to: Navigate to the cargo box storage structure in the product introduction area, where the cargo box no longer stores the product; Transport the cargo storage structure to the second transport trailer; and Navigate away from the second transport trailer, which does not have the aforementioned cargo container storage structure.

301. The method of claim 300, wherein the origin of the first transport trailer includes a supplier of the product.

302. The method of claim 301, wherein the destination of the second transport trailer includes the supplier of the product.

303. The method of claim 301, wherein the destination of the second transport trailer includes suppliers of different products.

304. The method of claim 300, further comprising configuring the first transport trailer to allow navigation by the first AMR within the first transport trailer.

305. The method of claim 304, wherein configuring the first transport trailer includes using a configuration consistent with the configuration of the fulfillment center to facilitate navigation of the first AMR within the fulfillment center.

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