Automated item picking and consolidation system and method

Abstract

Some embodiments provide an item collection and aggregation system comprising: a multi-level, multi-aisle storage structure; multiple workstations; multiple mobile robots that transfer containers through the storage structure and to and from the workstations; and a dynamic vertical buffer system comprising: a first access station positioned at a first level of a plurality of different levels of the vertical buffer system; a plurality of shelving systems movable between different levels, wherein each shelving system is configured to receive aggregated items for different orders; a shelving movement system including at least one lifting motor configured to move at least one of the plurality of shelving systems between different levels and the first access station; and a vertical buffer control circuit communicatively coupled to the shelving movement system and configured to control the shelving movement system to move the plurality of shelving systems to and from the access station.

Description

[0001] Cross-references to related applications This application claims the benefit of U.S. Provisional Application No. 63 / 544,763, filed on October 18, 2023, which is incorporated herein by reference in its entirety. Technical Field

[0002] The invention largely relates to automated item picking. Background Technology

[0003] Inventory picking and distribution are critical to the fulfillment system. Such picking and / or distribution can be time-consuming. Improvements to inventory picking and distribution are needed. Attached Figure Description

[0004] This document discloses embodiments of systems, apparatus, and methods related to automated item picking. The description includes figures, in which: Figure 1A A simplified perspective view of an exemplary item collection and consolidation system according to some embodiments is shown.

[0005] Figure 1B A simplified top view of a portion of an exemplary storage structure according to some embodiments is shown.

[0006] Figure 2A Illustrations based on some embodiments Figure 1A An enlarged view of a portion of an exemplary item collection and aggregation system.

[0007] Figure 2B Illustrations based on some embodiments Figure 2A An enlarged view of a portion of an exemplary item collection and aggregation system.

[0008] Figure 3A An enlarged view of an exemplary workstation according to some embodiments and a partially transparent view of an exemplary vertical buffer system are shown.

[0009] Figure 3B Partial transparent magnified views of an exemplary vertical buffer system and an exemplary workstation according to some embodiments are shown, the workstation including an automated robotic picking system.

[0010] Figure 4 A simplified partial transparent perspective view of an exemplary vertical buffer system according to some embodiments is shown.

[0011] Figure 5 A simplified perspective view is shown of a portion of an exemplary item collection and gathering system having multiple vertical buffer systems with a rotary movement system, according to some embodiments.

[0012] Figure 6 This illustrates two workstations positioned close to the storage structure according to some embodiments. Figure 5 A partially transparent simplified perspective view of an exemplary vertical buffer system.

[0013] Figure 7 A partially transparent, simplified perspective view of an exemplary vertical buffer system within an exemplary aggregation system according to some embodiments is shown.

[0014] Figure 8 A simplified block diagram is shown of an exemplary access station positioned close to an exemplary workstation according to some embodiments, the exemplary access station cooperating with an exemplary storage structure.

[0015] Figure 9A A simplified partial transparent view of an exemplary vertical buffer system according to some embodiments is shown, wherein the shelving system has different storage locations or sections.

[0016] Figure 9B A simplified block diagram of an exemplary access station according to some embodiments is shown, wherein Figure 9A The exemplary shelving system in the image is aligned with the access station.

[0017] Figure 10 A simplified block diagram of an exemplary shelving system according to some embodiments is shown.

[0018] Figure 11A A simplified perspective view of an exemplary vertical buffer system according to some embodiments is shown.

[0019] Figure 11B A simplified perspective view of an exemplary vertical buffer system according to some embodiments is shown, wherein some or all of the lateral dimensions are exposed, enabling access to one or more racking systems in addition to one or more racking systems accessible via access stations.

[0020] Figure 12 A simplified perspective view is shown of an exemplary vertical cushioning system with an exemplary mesh outer retaining cover according to some embodiments.

[0021] Figure 13A A simplified perspective view is shown of an exemplary vertical buffer system including an exemplary roller shutter door external retainer, according to some embodiments.

[0022] Figure 13B-13C A simplified perspective view is shown of an exemplary vertical buffer system with an exemplary roller shutter door external retaining cover according to some embodiments.

[0023] Figure 13D A simplified perspective view is shown of an exemplary vertical buffer system with an exemplary roller shutter door external retaining cover according to some embodiments.

[0024] Figure 14 A simplified block diagram of a portion of an exemplary vertical buffer system according to some embodiments is shown, wherein the exemplary racking system is visible through an exemplary mesh along the exterior of the buffer system.

[0025] Figure 15A A simplified block diagram of an exemplary shelving system according to some embodiments is shown, the system including an exemplary latchable panel retainer in the closed position.

[0026] Figure 15B Illustrations based on some embodiments Figure 15A A simplified block diagram of an exemplary shelving system, wherein an exemplary latchable panel is in the open position.

[0027] Figure 16 A simplified block diagram of an exemplary shelving system with an exemplary netting, according to some embodiments, is shown.

[0028] Figure 17 A simplified block diagram of an exemplary shelving system having one or more exemplary shelf doors is shown according to some embodiments.

[0029] Figure 18 A partial view of an exemplary vertical buffer system that is partially transparent according to some embodiments is shown.

[0030] Figure 19 This is a view showing a portion of an exemplary item collection and aggregation system with an exemplary vertical buffer system, according to some embodiments.

[0031] Figure 20 A simplified flowchart illustrates an exemplary process for assembling order items according to some embodiments.

[0032] Figure 21 A simplified flowchart illustrates an exemplary process for picking up and collecting items from a vertical buffer system according to some embodiments.

[0033] Figure 22 A simplified flowchart of an exemplary emergency access procedure according to some embodiments is shown.

[0034] Figure 23 Exemplary systems are shown, according to some embodiments, for implementing methods, techniques, apparatuses, devices, systems, servers, and resources for the aggregation and fulfillment of orders.

[0035] The elements in the figures are shown for simplicity and clarity and are not necessarily drawn to scale. For example, to better understand the various embodiments of the invention, the size and / or relative position of some elements in the figures may be exaggerated relative to other elements. Furthermore, to facilitate a clearer understanding of these various embodiments of the invention, common and well-understood elements that are useful or necessary in commercially viable embodiments are generally not depicted. Certain actions and / or steps may be described or depicted in a specific order of occurrence, and those skilled in the art will understand that such specificity regarding the order is not actually necessary. Except where different specific meanings are set forth herein, the terms and expressions used herein have the ordinary technical meaning as attributed to such terms and expressions by those skilled in the art as described above. Detailed Implementation

[0036] The following description should not be considered limiting, but only for the purpose of describing the general principles of exemplary embodiments. References throughout this specification to "one embodiment," "embodiment," "some embodiments," "implementation," "some implementations," "some applications," or similar language refer to a specific feature, structure, or characteristic described in relation to that embodiment, which is included in at least one embodiment of the invention. Therefore, the phrases "in one embodiment," "in an embodiment," "in some embodiments," "in some implementations," and similar language appearing throughout this specification may (but not necessarily) all refer to the same embodiment.

[0037] Some embodiments provide for partially improving order fulfillment systems by providing a dynamic vertical buffer system for storing aggregated order items. Stored aggregated orders can be readily incorporated into the vertical buffer system to await retrieval and / or subsequent temporary storage for delivery. The vertical buffer system significantly increases the storage capacity of the fulfillment system within a reduced floor space. In some embodiments, the vertical buffer system may be incorporated into and / or cooperate with an automated product picking system that utilizes mobile robots, humans, conveyors, other transport methods, or a combination of two or more of these methods to move items through a storage structure to one or more workstations where order items can be picked.

[0038] In some embodiments, the item collection and aggregation system may include a multi-level, multi-aisle storage structure comprising an array of container storage locations, each configured to store containers with inventory. One, and typically, multiple workstations may cooperate with the storage structure. Some embodiments utilize multiple mobile robots that transfer containers through the storage structure and between multiple workstations. One or more dynamic vertical buffer systems (separate from the storage structure) may be positioned adjacent to at least one of the multiple workstations. In some embodiments, the vertical buffer system may include a first access station, multiple shelving systems, a shelving movement system, and vertical buffer control circuitry and / or systems. The access station may be positioned at one or more levels of multiple different levels of the vertical buffer system, and typically relative to an adjacent workstation. The multiple shelving systems may move between any of the multiple different levels within the vertical buffer system and one or more of the access stations of the vertical buffer system. Each shelving system may be configured to receive aggregated items from multiple different orders fulfilled through one or more workstations. In some embodiments, the shelving movement system includes at least one lifting motor configured to move at least one of the multiple shelving systems between different levels and one or more access stations. The vertical buffer control circuit can be communicatively connected to the racking movement system and configured to control the racking movement system to move multiple racking systems to and from the storage station.

[0039] Some embodiments provide a method for aggregating order items, wherein each of a plurality of mobile robots is controlled to implement autonomous, automated transfer of containers through a multi-level, multi-aisle storage structure. The storage structure may include an array of container storage locations, each configured to store one of containers with inventory. The robots may transfer containers to multiple workstations. Items corresponding to different orders may be picked from containers transported by the mobile robots for aggregation. A shelf-moving system, separate from the storage structure and positioned near a first workstation, may be controlled to provide vertical movement of a shelf system within a plurality of shelf systems in the vertical buffer system to align with a retrieval station positioned at a first level of a plurality of different levels in the vertical buffer system. The method may guide the aggregated order items onto the shelf system of the vertical buffer system while the shelf system is positioned aligned with the first retrieval station; and while the shelf system holds the aggregated items of the first order, control the shelf-moving system to move the shelf system vertically away from the first retrieval station to free up the first retrieval station to receive another shelf system among the plurality of shelf systems.

[0040] Figure 1A A simplified perspective view of an exemplary item collection and aggregation system 100 according to some embodiments is shown, which can partially provide order fulfillment for numerous orders that are received over time. Figure 1B A simplified top view of a portion of an exemplary storage structure 102 according to some embodiments is shown. Figure 2AIllustrations based on some embodiments Figure 1A An enlarged view of a portion of an exemplary item collection and aggregation system 100. Figure 2B Illustrations based on some embodiments Figure 2A An enlarged view of a portion of the exemplary item collection and aggregation system 100, with a partially transparent view of the vertical buffer system 106. Figure 3A An enlarged view of an exemplary workstation 104 and a partially transparent view of an exemplary vertical buffer system 106, according to some embodiments, are shown, which can be used in the aggregation system 100. Figure 3B Partially transparent magnified views of an exemplary vertical buffer system 106 and an exemplary workstation 104 according to some embodiments are shown. The workstation includes an automated robotic picking system 304 that can be used in the collection system 100. Referring to Figures 1-3B, in some embodiments, the collection system 100 includes at least a portion of a multi-level, multi-aisle storage structure 102, one or more (and typically multiple) workstations 104 cooperating with the storage structure, one or more dynamic vertical buffer systems 106, and multiple mobile robots 122 that enable the transfer of crates, boxes, cartons, and other such containers through the storage structure and to and from the workstations.

[0041] The aggregation system 100 provides an automated system that stores a large number of items in different totes and / or other containers, each stored in a corresponding container storage location 120 within a three-dimensional storage location matrix within a multi-level storage structure. The multi-level rack or storage structure 102 can hold picked items and is generally configured to maximize space utilization by optimizing the use of available three-dimensional volume, which may extend from floor to ceiling. Some embodiments utilize mobile vehicles or robots 122, which are autonomous vehicles that, depending on the embodiment, perform various transfer and transport functions, including handling the movement of totes and / or other product containers (picked items) between container storage locations 120 within the storage structure 102 and one or more workstations 104. Depending on the embodiment, workstations 104 may employ human and / or robotic picking systems 304 to transfer single items, multiple single items, boxes, and / or other quantities of items to aggregate items for collecting one or more orders and / or to incorporate single items, multiple single items, boxes, and / or other quantities into totes to replenish the storage structure 102. Some embodiments include one or more central control circuits 110 and / or systems, including one or more computers, software, and communication components, which can at least partially provide management of the operation of the system. The aggregation system 100 may also include one or more input / output interfaces, wherein products are introduced into the system to replenish picked goods, and completed orders are issued from the system for final delivery to the customer, but the details of the interface often vary from application to application.

[0042] Storage structure 102 provides a three-dimensional matrix or grid of container storage locations 120 configured to receive and store containers 120 transported by mobile robot 122. In some embodiments, storage structure 102 may include a plurality of vertically spaced levels 108, wherein a plurality of vertical tower-like passages establish vertical paths between the levels. A plurality of aisles 124 extend through storage structure 102, each aisle including a track extending along the length of each of the aisles, along which the mobile robot travels. Tote box storage locations 120 are situated at the multiple levels and positioned along both sides of each of the plurality of aisles 124. At least some of the storage locations 120 are configured with predetermined widths, heights, and depths corresponding to the size of the tote boxes and are configured to store tote boxes delivered by and picked up by the mobile robot 122. The movement of the storage structure 102, the turnover box storage location 120, the track, and the mobile robot 122 via the storage structure and the collection system is similar to that described in U.S. Patent Nos. 9,139,363, 10,435,241, 11,142,398, and 11,203,486, which are incorporated herein by reference in their entirety, and in U.S. Patent Application Publications Nos. 2019 / 0270591, 2021 / 0229271, and 2022 / 0033183, which are incorporated herein by reference in their entirety, respectively. Some embodiments include a central control system 110 implemented by one or more processors, microprocessors, computers, software, network devices and / or other such control circuitry, which can be communicatively connected via one or more distributed communication and / or computer networks (e.g., local area network (LAN), wide area network (WAN), Internet, cellular network, local wireless network (e.g., Bluetooth, Wi-Fi, ZigBee, etc.), other such networks or combinations of two or more of such networks).

[0043] Some embodiments enhance product collection and aggregation of order items by partially incorporating one or more multi-level dynamic vertical buffer systems 106 and / or temporary storage systems (which can receive items from collected aggregate orders and, in some applications, temporarily store aggregate orders for retrieval and / or delivery). One or more of these dynamic vertical buffer systems 106 may be located near one or more workstations 104 to allow easy access by employees, robotic picking systems 304, mobile robots 122, other unmanned mobile vehicles, conveyors, and / or other systems. In some embodiments, workstations 104 and dynamic vertical buffer systems 106 may enable bags and / or sub-tote boxes to be picked directly into dynamic vertical buffer systems 106. Dynamic vertical buffer systems 106 can improve picking speed at workstations 104 because two mobile robots 122 bring containers that may include ambient, refrigerated, and / or frozen items corresponding to a specific order arriving at the workstation for aggregation. In addition, compared to the floor space occupied by the dynamic vertical buffer system 106, the dynamic vertical buffer system 106 greatly increases the storage capacity, which can partially improve the store's order processing capacity.

[0044] Referring again to Figures 1-3B, the item collection and aggregation system 100 may utilize a multi-level, multi-aisle storage structure 102 to store containers (e.g., crates, boxes, sub-crates, etc.) in an array of container storage locations 120, each configured to store containers with inventory. Multiple workstations 104 collaborate with the storage structure 102 at least through the scheduling of mobile robots 122. In some embodiments, the workstations 104 are integrally integrated within the architecture of the storage structure 102. Multiple mobile robots 122 transfer containers through the storage structure 102 to schedule containers to and / or from one or more of the multiple workstations 104. One or more workstations 104 may be configured to receive items, dispense those items, and place items into containers scheduled to container storage locations 120 for subsequent use in fulfilling orders. One or more workstations 104 may be used to aggregate order items by picking items from containers scheduled to the workstations by mobile robots 122. Furthermore, some and / or all workstations may be configured to perform both the receiving and distributing of items. For example, a workstation can be designated as a receiving workstation for a period of time and then used as a distribution workstation for a subsequent period of time.

[0045] One or more mobile robots 122 are configured to directly transfer containers between inventory storage location 120 and workstation 104. The mobile robots may be similar to, and operate in the same or similar manner as, those described in U.S. Patent Nos. 9,139,363, 10,435,241, 11,142,398, and 11,203,486, respectively, and in U.S. Patent Application Publications Nos. 2019 / 0270591, 2021 / 0229271, and 2022 / 0033183, respectively, which are incorporated herein by reference in their entirety.

[0046] Figure 4 A simplified partial transparent perspective view of an exemplary vertical buffer system 106 according to some embodiments is shown. Referring to Figures 1-4, in some embodiments, the vertical buffer system 106 is separate from the storage structure 102. In other embodiments, the vertical buffer system may cooperate with and / or be formed as part of the storage structure. The vertical buffer system 106 may be positioned close to one or more workstations 104. For example, in some embodiments, the vertical buffer system 106 is within twenty feet of the workstation 104, and typically within ten feet.

[0047] Each vertical buffer system 106 includes one or more access stations 204, windows, ports, or other such interfaces. Each of the one or more access stations 204 is located at one of multiple different levels of the vertical buffer system 106, typically positioned relative to at least one workstation 104. The access station 204 provides an interface to the vertical buffer system 106 to insert one or more collected items into and / or retrieve one or more items from the vertical buffer system. In some embodiments, the vertical buffer system 106 includes multiple shelving systems 210 movable between multiple different levels within the vertical buffer system and the one or more access stations 204. Each of the shelving systems 210 is configured to receive aggregated items from multiple different orders fulfilled via a first workstation, temporarily store those items, and subsequently approach to allow item retrieval.

[0048] In some embodiments, the vertical buffer system 106 includes one or more rack movement systems configured to move one or more of the rack systems 210 between different levels and one or more access stations 204. In some embodiments, the rack movement system includes at least one lifting motor configured, upon activation, to move at least one of the plurality of rack systems 210 between different levels and one or more access stations. The vertical buffer system 106 also includes one or more vertical buffer control circuits 206 and / or systems communicatively coupled to at least one rack movement system and configured to control the rack movement system to move the plurality of rack systems 210 to and from the access stations. The vertical buffer control circuit 206 may be implemented by one or more vertical buffer control circuits including one or more processors, microprocessors, computer memory, computers, other such circuit systems, or combinations of two or more of such circuit systems. In some embodiments, the vertical buffer control circuit 206 is wired and / or wirelessly coupled to one or more workstation control systems of one or more workstations 104, central control circuit 110, other components of the aggregation system 100, or combinations of two or more of such system components. Furthermore, in some embodiments, the vertical buffer control circuit 206 may communicate wired and / or wirelessly with one or more external computers, servers, mobile devices, and / or other such remote systems. For example, in some embodiments, the vertical buffer control circuit 206 may receive communications from a remote item ordering server, which may provide instructions and / or notifications to the vertical buffer control circuit 206 (e.g., notifying that an order is ready for pickup).

[0049] Furthermore, in some embodiments, the vertical buffer system 106, access station 204, and / or shelving system 210 may include one or more user interface systems 410 (e.g., keyboard, display, touchscreen, touchpad, button, light, barcode reader, scanner, scale, camera, etc.) that enable a user to interact with the vertical buffer system 106, input information, execute commands, and / or receive information (e.g., status information, shelving system identifier information, order identifier information, bag and / or packaging identification information, etc.). For example, in some embodiments, the access station control circuitry is communicatively coupled to one or more cameras, sensors, lighting systems and / or laser pointer systems, audio systems, other such user interface systems, or combinations of such systems. For example, the user interface system may include one or more machine vision subsystems (“MVS”) that are included in and / or installed within and / or near the access station 204. The camera assembly (including the required illumination) may be aimed at one or more empty spaces, bags, boxes, doors, baskets, sub-turnover boxes, etc., and / or at the user or the user's hand. In some embodiments, a camera may be connected to a vision computer, which is programmable to track user and / or user hand movements and analyze placement and / or items moved onto and / or removed from the shelving system 210. Cameras, barcode readers, and / or other identification systems may identify the shelving system (e.g., using shelving system barcodes or other identifiers) and maintain and track inventory information for each item on the shelving system. Similarly, cameras and / or other sensors may detect user movement and / or track the movement of items relative to the access station 204 and / or the shelving system 210. Lights and / or lasers may be aimed and / or focused to illuminate locations, bags, boxes, indicating items to be removed from and / or placed on the shelving system. Displays and / or audio systems may provide instructions to the user, providing detailed explanations, which may include images, pictograms, animations, videos, and / or other relevant content to provide relevant instructions and / or information. User interface systems may be similar to those described in U.S. Patent Nos. 9,139,363, 10,435,241 and 11,142,398, and U.S. Patent Application Publications Nos. 2019 / 0270591 and 2021 / 0229271, each of which is incorporated herein by reference in its entirety.

[0050] In some embodiments, the shelving movement system includes one or more lifting systems 212 that are separate from and independent of the plurality of shelving systems 210. The lifting system 212 may be configured to move vertically within the vertical buffer system 106 independently of the plurality of shelving systems 210. In some embodiments, the lifting system 212 engages one or more gears, pinions, wheels, and / or other such components that engage one or more tracks, chains, racks, gear drives, or other such climbing mechanisms. Additionally or alternatively, the system may also include one or more cables and motors that are activated to raise and lower the lifting system. One or more motors may be attached to and / or attached to the lifting system 212 (e.g., attached to the base and / or top of the vertical buffer system 106). In some embodiments, the lifting system 212 may operate similarly to an elevator. The lifting system 212 also includes one or more picking systems that releasably engage the shelving systems 210 to remove the shelving systems from the shelving storage slots 402 of the vertical buffer system 106 and return the shelving systems 210 to the shelving storage slots.

[0051] The vertical buffer system 106 may include multiple different shelf storage slots 402, which may include shelf storage slots that are part of and / or cooperate with the access station 204. Figure 4 An exemplary open shelving storage slot 402a is shown. Open shelving storage slot 402a can receive a first shelving system 210a, such as a shelving system currently positioned at access station 204. Lifting system 212 can pick up the first shelving system 210a from access station 204, move the first shelving system 210a vertically to align with an empty or open shelving storage slot 402a, move the first shelving system 210a into the open shelving storage slot 402a, and disengage from the first shelving system 210a, which allows lifting system 212 to then pick up another shelving system 210 and move that shelving system within vertical buffer system 106 (e.g., to access station 204).

[0052] Therefore, the lifting system 212 is configured to align with one of the shelving systems 210, typically responding to instructions to transport, pick up, and vertically transport the shelving system to a destination level within the vertical buffer system. The destination level may be located at a level in one of the access stations, an open shelving storage slot 402, or another level within the vertical buffer system 106. In some embodiments, the lifting system 212 is positioned within a central region 404 of the vertical buffer system. A first group of multiple shelving systems 210 is positioned on a first side of the central region 404, and a second group of multiple shelving systems 210 is positioned on a second side of the central region 404 opposite to and separated from the first side by the central region. Each of the multiple shelving systems in both the first and second groups can be accessed via the lifting system 212. Thus, in some embodiments, the lifting system is configured to engage and pick up the shelving system, and return the shelving system to either side of the central region 404. Furthermore, in some embodiments, the shelving system 210 can be accessed via access stations 204 located on opposite sides of the vertical buffer system 106. In some embodiments, the shelving system can be accessed from a first side via a first access station located on a first side of the vertical buffer system 106, and similarly, the same first shelving system can be accessed from a second side opposite to the first shelving side via a second access station located on opposite sides of the vertical buffer system 106. Thus, the shelving system can be used in combination with multiple different access stations 204 on different sides of the vertical buffer system 106 without rotating or turning the shelving system.

[0053] Figure 5 A simplified perspective view of a portion of an exemplary item collection and gathering system 100 having multiple vertical buffer systems 106 (partially transparently shown) according to some embodiments, the vertical buffer systems having a rotary movement system. Figure 6 The diagram shows two workstations 104 positioned close to storage structure 102 according to some embodiments. Figure 5 A partially transparent simplified perspective view of an exemplary vertical buffer system 106. (Refer to...) Figure 5-6In some embodiments, the vertical buffer system 106 may include a shelf movement system comprising a vertical rotary system 602, which includes a rotary guide 604, each of the plurality of shelf systems 210 of the vertical buffer system 106 cooperating with the rotary guide 604. The rotary guide 604 may include one or more cables, belts, chains, tracks, and / or other such systems that enable the shelf systems 210 to move. In some embodiments, the rotary guide 604 establishes a generally oval travel path along which the plurality of shelf systems 210 may travel simultaneously. In some embodiments, one or more motors may cooperate with the rotary guide 604 and cause movement of the rotary guide 604, causing the plurality of shelf systems 210 that may be fixed to the rotary guide to move simultaneously. In other embodiments, the shelf systems include one or more motors and pinions to autonomously propel themselves along the rotary guide 604 in response to commands. The vertical buffer control circuit 206 can be configured to control the simultaneous movement of multiple racking systems to align different racking systems 210 with one or more access stations 204 of the vertical buffer system 106. The rotary guide 604 causes each of the racking systems 210 to move simultaneously around a travel path. This movement can be controlled so that at least one racking system 210 is simultaneously aligned with one or more access stations 204 located on one or more sides of the vertical buffer system 106 and / or on one or more levels of the vertical buffer system 106.

[0054] As described above and further described below, in some embodiments, the vertical buffer system 106 may include a plurality of access stations 204. In some embodiments, the vertical buffer system 106 may include one or more first access stations 204 located on a first outer side 406 of the vertical buffer system 106, and one or more second access stations 204 located on different second outer sides 407 of the vertical buffer system 106. For example, a second access station may be located in a second outer side 407 opposite to the first outer side 406 and separated from the first outer side by a shelf storage slot 402, a shelf system 210, and a central region 404. The first and second access stations 204 can be accessed from outside the vertical buffer system, and access to at least one of the shelf systems 210 from the outside is achieved when at least one of the shelf systems 210 is moved to align with the corresponding access station 204. In the exemplary vertical buffer system 106 shown in Figures 1-4, the vertical buffer system has a generally cuboid shape. However, the vertical buffer system 106 may be implemented in other shapes.

[0055] Figure 7A partially transparent, simplified perspective view shows an exemplary vertical buffer system 106 within an exemplary aggregation system 100 according to some embodiments. As described above, the vertical buffer system 106 may include multiple different levels. In some embodiments, the vertical buffer system 106 includes multiple access stations 204 at vertically spaced levels. Although Figure 7 The example shown illustrates two access stations 204 vertically spaced apart at different levels, but it is conceivable that any number of access stations 204 could be incorporated into the vertical buffer system. The racking movement system is configured to transport the racking system 210 to and from each of the multiple different access stations at different levels.

[0056] Figure 8 A simplified block diagram is shown of an exemplary access station 204 positioned close to an exemplary workstation 104 cooperating with an exemplary storage structure 102, according to some embodiments. An exemplary shelving system 210 is positioned at and accessible from the access station 204. The access station may include one or more user interface systems, such as, but not limited to, a display 410a, a touchscreen, a keyboard, buttons 410b, lights, audio, and / or other such systems. In some embodiments, the shelving system 210 may include multiple different storage locations 802a-802c or sections. These different storage sections can be used to store different types of items, such as items with different temperature requirements (e.g., different temperature-controlled storage locations), different chemical compositions, items that should be separated, and / or other such differences. For example, in some embodiments, the shelving system 210 may include: an ambient temperature storage location 802a that receives items that can be maintained at ambient temperature; a cooling temperature storage location 802b, separate from the ambient temperature storage location and configured to receive items that will be maintained below a first temperature threshold (and in some cases, above a second temperature threshold); and a third cold temperature storage location 802c that may be configured to receive items that will be maintained below a third temperature threshold (e.g., below freezing), and the third temperature threshold may be the same as or different from the second temperature threshold. Other temperature zones may also be included (e.g., zones that maintain heated items above a threshold temperature). One or more temperature control systems may cooperate with different storage locations 802, such as refrigeration and / or heating systems, which use sensor data to maintain the temperature within the respective storage location 802 at a predetermined temperature and / or within a respective temperature threshold range within the respective storage location 802.

[0057] In some embodiments, portions of an order may be picked and / or aggregated at one or more other locations within and / or outside the premises, and the partially aggregated order may be dispatched to the appropriate workstation 104 for further aggregation and placement in the vertical buffer system 106. In some applications, this may include picking and / or aggregation of one or more items to be maintained at different temperatures, and then dispatching these one or more items to a workstation for placement in the vertical buffer system 106. Product turnover boxes may be dispatched via one or more mobile robots 122 to a designated workstation 104 near the vertical buffer system 106. In some embodiments, at the workstation, one or more items may be picked from one or more turnover boxes and aggregated by bagging, packaging, or other means, and stored in the vertical buffer system 106.

[0058] Product scheduling may also include the scheduling of one or more previously gathered items. In some embodiments, for example, when it is anticipated that a customer will not retrieve the item for a certain threshold duration (e.g., more than 30 minutes, more than one hour, more than two hours, etc.), items to be kept at non-ambient temperatures may be picked from turnover boxes in areas of storage system 102 corresponding to the respective non-ambient temperatures (e.g., may be present in “cooling” areas within storage structure 102 where the product is kept above freezing but below a threshold temperature; “freezing” areas within storage structure where the item is kept frozen; etc.), and the corresponding workstation 104 may be located in these very-temperature areas. These very-temperature items may be gathered and kept in those very-temperature areas (e.g., bagged and kept in “cooling” and / or “freezing” areas of storage system 102). When requested (e.g., based on customer confirmation that they are ready to retrieve the item within a specified time period), these previously gathered items may be picked and scheduled through storage system 102 by mobile robots, conveyors, workers, and / or other such transport to the intended workstation 104 to be gathered with the remaining items in the order within the workstation. For example, in some embodiments, in the case of refrigerated and frozen goods, these items may be picked at refrigerated workstations within a refrigerated environment not adjacent to the vertical buffer system 106. In this case, bagged refrigerated and / or frozen items can be returned to the refrigerated workstation and / or other storage locations for later transport from the refrigerated environment to an ambient temperature workstation 104 adjacent to the vertical buffer system 106 via mobile robot 122 or other transport. When an order is picked at the ambient temperature workstation 104, a turnover box containing ambient temperature single items arrives, is bagged, and stored in the vertical buffer system 106. Additionally, turnover boxes containing previously bagged refrigerated and / or frozen items may arrive at the same ambient temperature workstation 104 for aggregation with bagged ambient temperature items in the vertical buffer system 106. In other words, the mobile robot 122 is used to transfer pre-assembled items (e.g., refrigerated and / or frozen order bags) and individual ambient temperature products to the ambient temperature workstation 104 for storage in the corresponding cooled temperature storage location 802b, frozen temperature storage location 802c and ambient temperature storage location 802a of the shelving system 210 within the vertical buffer system 106.

[0059] As described above, in some embodiments, one or more of the shelving systems 210 may be configured to be accessible from both sides or more sides. Therefore, in some embodiments, the ambient temperature storage location 802a and one or more temperature control locations 802b-802c may be accessible from both the first shelving side and the second shelving side.

[0060] Still refer to Figure 8In some implementations, one or more sections (e.g., cooling and / or cold locations 802b-802c) may each include a refrigeration enclosure, insulation walls, and / or a door (e.g., door 804 shown as leading to cooling temperature location 802b), which can be opened to insert and / or remove items and can be closed to help maintain a desired temperature. Each section of shelving system 210 may receive one or more items, which may have been inserted into bags 806, boxes, crates, sub-turnover boxes, and / or other such packages. Each bag 806 or other package may include one or more items. Typically, when there is sufficient space, items for a single order are consolidated into one or more bags 806 and placed on a single shelving system 210. This simplifies and speeds up order consolidation and picking, as only a single shelving system must be moved to align with the requesting storage station 204. However, orders with a large number of items may be consolidated onto two or more shelving systems. Similarly, when there is not enough space on any one shelving system to receive the entire order, the order can be distributed to multiple shelving systems, and / or instructions can be directed to the user and / or robot system to move items and / or bags of items from the first shelving system to the second shelving system in order to free up space on the first shelving system to accommodate the entire order.

[0061] In some embodiments, the central control circuit 110 and / or the remote order fulfillment system communicating may be configured to receive order picking requests to pick up specific orders. Picking requests may be received from customers (e.g., upon arrival at or imminent at a retail location to pick up an order, to prepare for delivery, and / or for other such reasons). Based on identification information obtained when the aggregated items of a specific order are picked and placed on the first shelving system 210 (e.g., identification information of items when removing items from a tote at a workstation, identification information of bags or boxes used to hold the aggregated order items at a workstation, identification information of items and / or bags or other containers obtained through one or more identification systems of the access station 204 and / or shelving system 210 (e.g., barcode readers, text recognition, image capture and processing, etc.), and identifiers of the first shelving system (e.g., shelving system barcodes, shelving system RFID tags, alphanumeric characters on the first shelving system, other such identifier information, or combinations of two or more of such information)), the central control circuit may identify at least a portion of the items of a specific order positioned on the first shelving system in response to the picking request. The central control circuit 110 can send a picking instruction to the vertical buffer control circuit 206 to move the first racking system to a designated access station 204 of one or more access stations of the vertical buffer system 106. The vertical buffer control circuit 206 can be configured to control the racking movement system in response to the picking instruction so that the first racking system is aligned with the designated access station 204.

[0062] Figure 9AA simplified partial transparent view of an exemplary vertical buffer system 106 according to some embodiments is shown, wherein the shelving system 210 has different storage locations 802a-802c or sections. Figure 9B A simplified block diagram of an exemplary access station 204 according to some embodiments is shown, wherein Figure 9A An exemplary shelving system 210 is aligned with an access station. The shelving system 210 is moved to align with the access station 204 to allow items to move back and forth within the shelving system. The shelving system 210 may include multiple different storage locations 802a-802c or sections (e.g., ambient temperature location 802a, cooling temperature location 802b, and freezing temperature location 802c). Cooling temperature location 802b and / or freezing temperature location 802c may include a refrigerated enclosure and / or an insulated container with a cover 805 and / or a door (in some embodiments, which can be rotated upwards to open).

[0063] Figure 10 A simplified block diagram of an exemplary shelving system 210 according to some embodiments is shown. In some embodiments, the shelving system 210 may be removed from the vertical buffer system 106, such as by a shelving removal system, a robotic system, and / or other such systems. As described above, in some embodiments, the shelving system 210 may include multiple different storage locations 802 (e.g., ambient temperature location 802a, cooling temperature location 802b, and freezing temperature location 802c). The shelving system 210 may also include one or more shelving control circuits 1002, one or more temperature control systems 1004 (e.g., refrigeration systems, heating systems, etc.), one or more sensors 1006 (e.g., temperature sensors, accelerometers, gyroscopes, etc.), and / or other systems.

[0064] In some embodiments, the vertical buffer system enables access to multiple different racking systems 210 in the event of a racking movement system failure and / or inoperability. This ensures that aggregated orders can be accessed to fulfill orders even in the event of a failure. Accessing aggregated orders within a reasonable timeframe can be crucial for customer satisfaction and / or fulfillment of contractual obligations.

[0065] Figure 11A A simplified perspective view of an exemplary vertical buffer system 106 according to some embodiments is shown. Figure 11B A simplified perspective view of an exemplary vertical buffer system 106 according to some embodiments is shown, wherein some or all of the lateral dimensions are exposed, allowing access to one or more racking systems 210 in addition to those accessible via access station 204. (Refer to...) Figure 11A-11BIn some embodiments, some or all of one or more external retaining covers 1102 along one or more external lateral sides of the vertical buffer system 106 may be opened and / or otherwise removed to provide access from outside the vertical buffer system to at least a subset of a plurality of shelving systems 210 other than access to one or more shelving systems via access station 204 (e.g., shelving systems on a first side 1102a of the vertical buffer system, while providing similar access to those shelving systems on the other side 1102b of the vertical buffer system). In some embodiments, the external covers 1102 may be removed at one or more different levels of a plurality of different hierarchies of the vertical buffer system 106 to expose one or more shelving systems 210 from outside the vertical buffer system independently of access station 204. External retaining covers may include one or more panels, wire mesh, screens, doors, roller shutters, other such external retaining covers, or combinations of two or more of such covers. For example, one or more panels may form an external retaining cover outside the vertical buffer system, and the panels may be removed or opened to allow access to different shelving systems within the vertical buffer system from outside the vertical buffer system. The exposed shelving system 210 can be accessed by one or more methods, such as, but not limited to, ladders, scissor lifts 1110, other such methods or combinations thereof.

[0066] Figure 12 A simplified perspective view of an exemplary vertical buffer system 106 having an exemplary mesh outer retaining cover 1202 according to some embodiments is shown. The mesh cover 1202 may allow some or all of the mesh cover to be moved and / or removed to access the shelving system inside the vertical buffer system 106. Similarly, in some embodiments, the mesh cover 1202 is composed of a plurality of sub-mesh covers to allow the movement and / or removal of one or more of the sub-mesh covers to expose some or all of one or more of the shelving systems 210.

[0067] Figure 13A A simplified perspective view is shown of an exemplary vertical buffer system 106 including an exemplary roller shutter door external retainer 1302, according to some embodiments. Figure 13B A simplified perspective view of an exemplary vertical buffer system 106 with an exemplary roller shutter door external retainer 1302 according to some embodiments is shown, wherein the roller shutter door external retainer 1302 is partially opened to expose some of the shelving system 210. Figure 13C Illustrations based on some embodiments Figure 13B A simplified perspective view of an exemplary vertical buffer system 106, wherein the outer retaining cover 1302 is fully open (e.g., Figure 13C (The external retaining cover 1302 of the roller shutter door is fully open). (See reference...) Figures 13A-13CIn some embodiments, the roller shutter outer retainer 1302 can be raised, wherein as the roller shutter outer retainer 1302 moves upward, the roller shutter's cooperating panel moves upward and exposes the shelving system 210. In some embodiments, the roller shutter outer retainer 1302 rolls into a storage area inside or outside the vertical buffer system 106. In some embodiments, the roller shutter outer retainer 1302 operates similarly to a conventional garage door and may include one or more manual and / or automatic opening systems that can vertically move the roller shutter outer retainer 1302. Although the exemplary roller shutter outer retainer 1302 in Figure 13B The image shows the roller shutter exterior retainer 1302 moving upward to expose the shelving system 210, but it is conceivable that the roller shutter exterior retainer 1302 may move downward, or there may be two or more roller shutter exterior retainers 1302 moving in different directions (e.g., one or more roller shutter exterior retainers 1302 moving downward and one or more roller shutter exterior retainers 1302 moving upward).

[0068] Figure 13D A simplified perspective view of an exemplary vertical buffer system 106 having an exemplary roller shutter door external retainer 1302 according to some embodiments is shown. The roller shutter door external retainer 1302 is vertically movable upward and / or downward to expose or close the interior of the vertical buffer system 106 and the shelving system 210. In some embodiments, the roller shutter door external retainer 1302 may be stored in a door storage area 1304. In some embodiments, the external retainer may be provided on one or more or all sides of the vertical buffer system 106.

[0069] Figure 14 A simplified block diagram of a portion of an exemplary vertical buffer system 106 according to some embodiments is shown, wherein an exemplary shelf system 210 is visible via an exemplary net 1402 along the exterior of the buffer system. Some or all of the net 1402 is movable (e.g., detached from one or more hook systems, Velcro® and / or other such securing systems) to allow access to one or more of the shelf system.

[0070] In some embodiments, the vertical cushioning system 106 has no external retaining cover, skin, or similar covering on at least some of one or more lateral sides. However, the shelving system 210 includes a protective system that retains items, bags, packages, and / or other such containers within the shelving system 210. Figure 15A A simplified block diagram of an exemplary shelving system 210 according to some embodiments is shown, the system including an exemplary latchable panel 1502 retainer in the closed position. Figure 15B Illustrations based on some embodiments Figure 15A A simplified block diagram of an exemplary shelving system 210, wherein an exemplary latchable panel 1502 is in the open position. (Refer to...) Figures 15A-15BThe latchable panel 1502 can be moved or removed. For example, the latchable panel 1502 can be hinged relative to the shelving system and, when unlocked, can swing downward to expose items, bags, packages, etc. Figure 16 A simplified block diagram of an exemplary shelving system 210 with an exemplary net 1602 is shown according to some embodiments. The net 1602 removably cooperates with the shelving system 210 (e.g., hooks, Velcro®, snaps, etc.). The net is removable to allow access to items stored on the shelving system. Figure 17 A simplified block diagram of an exemplary shelving system 210 according to some embodiments is shown, having one or more exemplary shelf doors 1702, screens, etc. The doors 1702 provide retaining covers and can be opened to access the interior of the shelving system 210.

[0071] The dimensions of the shelving system 210 and the vertical buffer system 106 depend on a variety of different factors, including but not limited to: expected order rate, expected pickup and / or delivery rate, the size of the items and / or bags 806 (and / or other containers) to be received in the shelving system, the number of vertical buffer systems in the location, the ease of loading the shelving system by employees and / or the ease of picking order items by employees and / or customers, other such factors, and typically a combination of two or more of such factors.

[0072] Figure 18 A partial view of an exemplary vertical buffer system 106 that is partially transparent according to some embodiments is shown. Figure 19 A view is shown of a portion of an exemplary item collection and gathering system 100 having an exemplary vertical buffer system 106, according to some embodiments. (Refer to...) Figure 18-19 In some embodiments, one or more dimensions in the shelving system 210 are configured to receive wheeled trolleys 1802, each trolley capable of holding one or more items from a pool of multiple different orders. The wheeled trolleys may include typical shopping carts 1802 commonly used in many different retail locations. The shelving movement system 1810 may be controlled to position the first shelving system 210 such that the receiving surface 1804 of the first shelving system is aligned with the surface 1806 of the workstation, and the wheeled trolley is supported on this surface and moved to the first shelving system. This allows the trolley 1802 to be rolled directly into one of the shelving systems 210. In some embodiments, the shelving system may include multiple different compartments, such as one or more trolley compartments 1812, which may include doors, or doors may be fixed at a specific level of the access station 204, and one or more temperature-controlled compartments 1811, which have temperature-controlled positions to receive products that will be maintained within a threshold temperature range.

[0073] Figure 20A simplified flowchart of an exemplary process 2000 for aggregating order items according to some embodiments is shown. In step 2002, each transfer container in a plurality of mobile robots 122 is guided through a multi-level, multi-aisle storage structure 102. In step 2004, the mobile robots are guided to transport one or more containers to a first workstation 104 among a plurality of workstations. In step 2006, items picked from the containers transported by the mobile robots and corresponding to a first order are aggregated at the first workstation. In some embodiments, this may include picking one or more items from one or more turnover boxes and inserting those items into one or more bags 806, trolleys 1802, etc.

[0074] In step 2008, the shelf movement system 1810, positioned close to the first workstation, is controlled to move a first shelf system 210 within the vertical buffer system vertically to align with a first access station 204 located at a first level of a plurality of different levels within the vertical buffer system. In some embodiments, control of the movement system may include: moving a lifting system 212, independently of the plurality of shelf systems 210, between a first group of multiple shelf systems positioned on a first side of the central region 404 and a second group of multiple shelf systems positioned on a second side of the central region opposite the first side, within the central region 404 of the vertical buffer system 106, wherein each of the plurality of shelf systems is accessible via the lifting system; aligning the lifting system with the first shelf system 210; picking the first shelf system via the lifting system; and vertically transporting the first shelf system via the lifting system to a destination level within the vertical buffer system (e.g., to the first access station). In other embodiments, the movement may include controlling multiple racking systems 210 to move simultaneously relative to a vertical slewing device 602 including a slewing guide 604 along a generally oval travel path established by the slewing guide extending vertically through a vertical buffer system, with the multiple racking systems 210 cooperating with the slewing guide. Furthermore, in some embodiments, control of the movement may include controlling a lifting system 212 to align a receiving surface 1804 of a first racking system 210 with a surface 1806 cooperating with a workstation 104 on which a wheeled trolley 1802 is supported and moves toward the first racking system 210.

[0075] Still refer to Figure 20In step 2010, when the first shelving system is positioned aligned with the first access station 204, the aggregated items of the first order can be guided to be placed onto the first shelving system of the vertical buffer system. In some embodiments, the aggregated items of the first order can be guided to be placed onto the first shelving system by guiding at least one wheeled trolley 1802 containing one or more items of the aggregated items to roll onto the receiving surface 1804 of the first shelving system 210. In some embodiments, guiding the items to be placed onto the first shelving system may include guiding a first item of the aggregated items to be placed at one of the ambient temperature storage locations 802a of the first shelving system, and guiding a second item of the aggregated items to be placed in a temperature-controlled storage location 802b that is separate from the ambient temperature storage location and accessible from both the first and second shelving sides, and maintaining the temperature within the temperature-controlled storage location at a predetermined temperature. In step 2012, the shelving movement system is controlled to vertically move the first shelving system 210 away from the first access station 204 while the first shelving system 210 holds the aggregated items of the first order, to free up the first access station 204 to receive another shelving system among the multiple shelving systems.

[0076] Some embodiments include step 2014, in which a moving system is controlled to subsequently move the first shelving system 210 and align the first shelving system with a second access station 204 of the vertical buffer system 106, the second access station being positioned on a second outer side of the vertical buffer system, opposite to the first outer side where the first access station is located, such that the assembled items on the first shelving system can be accessed through the second access station on the second shelf side, opposite to the first shelf side of the first shelving system accessible through the first access station.

[0077] Figure 21A simplified flowchart of an exemplary process 2100 for picking up aggregated items from a vertical buffer system 106 according to some embodiments is shown. In step 2102, an order picking request is received to pick up a first order that has been previously aggregated and placed in one or more shelf systems 210 of one or more vertical buffer systems 106. In step 2104, in response to the picking request, items of the first order that have been aggregated and positioned on the first shelf system 210 are identified. In some embodiments, one or more vertical buffer control circuits, a central control circuit, and / or other systems may identify one or more vertical buffer systems containing items, and shelf systems within one or more vertical buffer systems containing items of the requested order. In step 2106, in response to the picking request, a shelf movement system is controlled to move the first shelf system to align with one of the access stations 204 of the first vertical buffer system 106. In some embodiments, vertical movement of the shelving system 210 within the vertical buffer system may include a control movement system aligning the shelving system 210 with an access station 204 located at a second level of a plurality of different levels of the vertical buffer system, wherein the second level is vertically spaced from the first level, at which one or more items are loaded into the shelving system.

[0078] Figure 22 A simplified flowchart of an exemplary emergency access procedure 2200 according to some embodiments is shown. In step 2202, a malfunction is detected within the vertical buffer system 106, preventing one or more shelving systems 210 from moving vertically to align with a predetermined access station. This malfunction may be detected based on one or more sensors detecting a lack of movement, employee reactions, a reduced threshold for movement speed, other such malfunctions, or a combination of two or more such malfunctions. In step 2204, the vertical buffer control circuit 206 and / or the central control circuit 110 may guide the movement and / or removal of one or more retaining covers 1102 of the vertical buffer system, positioned at one or more different levels to prevent items from falling outside the vertical buffer system and exposing one or more of the shelving systems 210 from outside the vertical storage system 106, independent of the first access station 204. This guided removal may include automatic unlocking and / or unlocking of one or more locking systems and / or latching systems of the retaining covers 1102. Some embodiments include step 2206, wherein the vertical buffer control circuit 206 and / or the central control circuit 110 may guide the use of one or more secondary modes of approaching the racking system 210 from outside the vertical buffer system. In some embodiments, the vertical buffer control circuit 206 and / or the central control circuit 110 may command an automated robotic scissor lift system to move to a location near the vertical buffer system.

[0079] In some embodiments, the aggregation system 100 may include and / or implement a retail inventory picking system comprising one or more vertical buffer systems 106 cooperating with a multi-level automated storage structure 102. The vertical buffer system 106 can be used to temporarily store, hold, and / or pick aggregated customer orders picked from the multi-level automated storage structure. The multi-level automated storage structure provides multiple levels with a plurality of container storage locations 120, which store turnover boxes and / or other containers, each capable of storing one or more products, parts, and / or other items. A mobile robot 122 can be used to transport containers between storage locations 120 and workstations 104, where items can be picked from the containers to fulfill orders. The ordered items are then collected and temporarily stored in one of the vertical buffer systems 106, which enable order aggregation within a reduced footprint.

[0080] In some embodiments, the vertical buffer system 106 is a vertical, multi-level storage system comprising multiple distinct shelving systems 210 movable within the vertical buffer system to be positioned at one or more access stations 204, through which customer orders are loaded onto the corresponding shelving system 210. The shelving system can then be moved back to an empty storage slot within the vertical buffer system to await customer pickup, preparation for delivery, and / or for other such picking reasons. In some embodiments, when a customer comes to pick up an order, one or more shelving systems 210 containing the compiled order can be moved to one or more access stations 204 of the vertical buffer system 106, picked by a worker, and delivered to the customer pickup location. Access stations 204 may be located at the same level accessible to workers, or at multiple different levels each accessible to workers.

[0081] In some embodiments, the movable shelving system 210 of the vertical buffer system may be implemented as a vertical lifting module (VLM) system, a circulating vertical rotating module (VCM) system, or other such moving systems. Using a VLM system, an internal lifting system 212 picks up the shelving system 210 from one of a plurality of different vertically spaced shelving storage slots 402 and transports the shelving system to an access station 204 to receive assembled orders and / or to pick up fulfilled orders. The lifting system 212 can then move the shelving system back to one of the empty shelving storage slots 402. This allows the lifting system 212 to repeatedly transport and return different shelving systems between one or more access stations of the vertical buffer system 106 without moving other shelving systems within the vertical buffer system.

[0082] In some embodiments, the VCM system includes a plurality of racking systems 210 secured by one or more guides 604, conveyors, chains, belts, and / or other such mechanisms that enable the plurality of racking systems to move collectively and simultaneously around a generally oval path. The VCM system controls the movement of the racking systems 210 to position one or more intended racking systems to align with a corresponding access station 204 of the vertical buffer system 106 to receive fulfilled orders and / or allow the picking of fulfilled orders. Using the VCM system, the racking systems move collectively together when one of them is aligned with an intended access station 204.

[0083] In some embodiments, the shelving system 210 is double-sided to allow access from each side of the shelving system, which allows access stations 204 to be positioned on two opposite sides of the vertical buffer system 106. One or more of all shelving systems 210 may have multiple storage locations 802 with different temperatures to accommodate products that need to be kept at different temperatures. For example, each shelving system may have a normal temperature storage location 802a or area, a cooling location 802b or area, and a freezing location 802c or area. In some embodiments, the cooling / freezing area may include a sealable door 804 to help maintain the desired temperature. Other storage locations may provide additional separation (e.g., for heated items, items containing chemicals that should be kept separate from food items, etc.).

[0084] Furthermore, in some embodiments, the vertical buffer system 106 may be configured to allow access to each of the shelving systems 210 in the event of a shelving movement system failure. For example, even in the event of a movement system failure, one or more panels on the exterior of the vertical buffer system may be opened or removed to allow access from the outside of the vertical buffer system 106 to different shelving systems 210 within the vertical buffer system for picking fulfilled customer orders.

[0085] Furthermore, the circuits, circuit systems, systems, devices, processes, methods, technologies, functions, services, servers, resources, etc., described herein can be used, implemented, and / or operated on many different types of devices and / or systems. Figure 23An exemplary system 2300 is illustrated, which can be used to implement any and / or other systems or devices mentioned above or below, of the components, circuits, circuit systems, systems, functions, devices, processes, or apparatuses of the assembly system 100. For example, system 2300 can be used to implement some or all of the central control circuit 110, workstation 104 and / or workstation control circuitry, vertical buffer system 106, vertical buffer control circuit 206, shelf control circuit 1002, mobile robot 122 and / or robot control circuitry, and / or other such components, circuit systems, functions, and / or devices. However, the use of system 2300 or any part thereof is certainly not essential.

[0086] By way of example, system 2300 may include one or more control circuitry or processor modules 2312, one or more memories 2314, and one or more communication links, paths, buses, or the like 2318. Some embodiments may include one or more user interfaces 2316, and / or one or more internal and / or external power sources or supplies 2340. Control circuitry 2312 may be implemented by one or more processors, microprocessors, central processing units, logic circuits, local digital storage, firmware, software, and / or other control hardware and / or software, and may be used to perform or assist in performing the steps of the processes, methods, functions, and techniques described herein, as well as to control various communications, decisions, programs, content, lists, services, interfaces, logging, reporting, etc. Furthermore, in some embodiments, control circuitry 2312 may be part of a control circuitry system and / or control system 2310, which may be implemented by one or more processors capable of accessing one or more memories 2314, which may store instructions, code, etc., implemented by the control circuitry and / or processor to perform the intended functions. In some applications, control circuitry and / or memory may be distributed across a communication network (e.g., LAN, WAN, Internet) to provide distributed and / or redundant processing and functionality. Again, system 2300 may be used to implement one or more of the components, circuits, systems, processes, etc. described above or below, or portions thereof.

[0087] User interface 2316 allows users to interact with system 2300 and receive information through the system. In some cases, user interface 2316 includes display 2322 and / or one or more user inputs 2324, such as buttons, touchscreens, trackballs, keyboards, mice, etc., which may be part of system 2300 or wired or wirelessly connected to system 2300. Typically, system 2300 also includes one or more communication interfaces, ports, transceivers 2320, etc., which allow system 2300 to communicate via communication buses, distributed computers and / or communication networks (e.g., local area networks (LANs), the Internet, wide area networks (WANs), etc.), communication links 2318, other networks, or communication channels with other devices, and / or via other such communications or combinations of two or more of such communication methods. Furthermore, transceiver 2320 may be configured for wired, wireless, optical, fiber optic, satellite, or other such communication configurations, or combinations of two or more of such communications. Some embodiments include one or more input / output (I / O) ports 2334 that allow one or more devices to connect to system 2300. The I / O ports can be virtually any associated port or combination of ports, such as, but not limited to, USB, Ethernet, or other such ports. The I / O interface 2334 can be configured to allow wired and / or wireless communication connections to external components. For example, the I / O interface can provide wired and / or wireless communication (e.g., Wi-Fi, Bluetooth, cellular networks, RF, and / or other such wireless communications), and in some cases, may include any known wired and / or wireless interface devices, circuitry, and / or connection devices, such as, but not limited to, one or more transmitters, receivers, transceivers, or combinations of two or more of these devices.

[0088] In some embodiments, the system may include one or more sensors 2326 to provide information to the system and / or to provide sensor information transmitted to another component, such as a central control system, delivery vehicle, etc. Sensors may include virtually any relevant sensor, such as, but not limited to, distance measurement sensors (e.g., optical units, sound / ultrasonic units, etc.), optical-based scanning sensors for sensing and reading optical patterns (e.g., barcodes), radio frequency identification (RFID) tag reader sensors capable of reading RFID tags near the sensor, accelerometers, GPS, and / or other such sensors. The examples above are intended to be illustrative and are not intended to provide an exhaustive list of all possible sensors. Instead, it will be understood that these teachings will be suitable for sensing any of a variety of situations in a given application environment.

[0089] System 2300 includes examples of control systems and / or processor-based systems having control circuitry 2312. Again, control circuitry 2312 can be implemented by one or more processors, controllers, central processing units, logic circuits, software, etc. Furthermore, in some embodiments, control circuitry 2312 may provide multiprocessor functionality.

[0090] The memory 2314, accessible by the control circuitry 2312, typically includes one or more processor-readable and / or computer-readable media accessible by the control circuitry 2312, and may include volatile and / or non-volatile media such as RAM, ROM, EEPROM, flash memory, and / or other memory technologies. Furthermore, the memory 2314 is shown as being internal to the control system 2310; however, the memory 2314 may be internal memory, external memory, or a combination of internal and external memory. Similarly, some or all of the memory 2314 may be internal memory, external memory, or a combination of internal and external memory of the control circuitry 2312. External memory may be substantially any associated memory, such as, but not limited to, solid-state storage devices or drives, hard disk drives, one or more Universal Serial Bus (USB) flash drives or drives, Flash Secure Digital (SD) cards, other memory cards, and other such memories or combinations of two or more of these memories, and some or all of the memory may be distributed across multiple locations on a computer network. The memory 2314 can store code, software, executable files, scripts, data, content, lists, programming, programs, logs or historical data, user information, customer information, product information, etc. Although Figure 23 The diagram shows various components connected together via a bus, but it should be understood that the various components can actually be directly connected to the control circuit and / or one or more other components.

[0091] Some embodiments provide an item collection and aggregation system comprising: a multi-level, multi-aisle storage structure including an array of container storage locations, each configured to store containers with inventory; a plurality of workstations cooperating with the storage structure; a plurality of mobile robots that transfer containers through the storage structure and to and from the plurality of workstations; a dynamic vertical buffer system positioned near a first workstation among the plurality of workstations, the first buffer system including: a first retrieval station located at a first level of the plurality of different levels of the vertical buffer system and positioned relative to the first workstation; a plurality of shelving systems movable between any of the plurality of different levels within the vertical buffer system and the first retrieval station, wherein each of the plurality of shelving systems is configured to receive aggregated items from a plurality of different orders fulfilled through the first workstation; a shelving movement system including at least one lifting motor configured to move at least one of the plurality of shelving systems between different levels and the first retrieval station; and a vertical buffer control circuit communicatively coupled to the shelving movement system and configured to control the shelving movement system to move the plurality of shelving systems to and from the retrieval station.

[0092] Some embodiments provide a method for aggregating items from an order, comprising: guiding each of a plurality of mobile robots to transfer containers through a multi-level, multi-aisle storage structure including an array of container storage locations each configured to store one of containers with inventory, and transferring the containers to a first workstation among a plurality of workstations; guiding the aggregation of items picked from containers transported by the mobile robots corresponding to a first order; controlling a shelf movement system of a vertical buffer system separated from the storage structure and positioned near the first workstation, and vertically moving a first shelf system of a plurality of shelf systems within the vertical buffer system to align with a first access station positioned at a first level among a plurality of different levels of the vertical buffer system; guiding the aggregated items of the first order onto the first shelf system of the vertical buffer system while the first shelf system is positioned aligned with the first access station; and controlling the shelf movement system while the first shelf system holds the aggregated items of the first order, and vertically moving the first shelf system away from the first access station to free up the first access station to receive another shelf system of the plurality of shelf systems.

[0093] This application is incorporated in its entirety by reference to each of the following U.S. patent publications: U.S. Publication No. 2014 / 0288696, published September 25, 2014, U.S. Patent Application Serial No. 14 / 213,187, filed March 14, 2014, entitled "Automated system for transporting payloads"; and U.S. Patent Publication No. 2017 / 0313514, published November 2, 2017, U.S. Patent Application Serial No. 15 / 591,956, filed May 10, 2017, entitled "Order Fulfillment System". U.S. Patent Publication No. 2019 / 0270591, published in September 2019, with U.S. Patent Application Serial No. 16 / 419,910, filed on May 22, 2019, and entitled "Order Fulfillment System"; and U.S. Patent Publication No. 2018 / 0134492, published on May 17, 2018, with U.S. Patent Application Serial No. 15 / 816,832, filed on November 17, 2017, and entitled "Automated-service retail system and method". The patent application serial number is 15 / 867,373, filed on January 10, 2018, and is entitled "Interchangeable automated mobile robots with aplurality of operating modes configuring a plurality of different robot task capabilities"; the patent application serial number is 15 / 826,045, filed on May 31, 2018, and is entitled "Automated retail supply chain and inventory management system".U.S. Patent Publication No. 2018 / 0305123, published on October 25, 2018, with U.S. Patent Application Serial No. 15 / 956,346, filed on April 18, 2018, and entitled "Picking workstation with mobile robots & machine vision verification of each transfer performed by human operators"; and U.S. Patent Publication No. 2018 / 0247257, published on August 30, 2018, with U.S. Patent Application Serial No. 15 / 903,993, filed on February 23, 2018, and entitled "Inventory management system and method". The patent application is titled “Fully automated self-service store”; U.S. Patent Publication No. 2018 / 0341908, published on November 29, 2018, with U.S. Patent Application Serial No. 15 / 987,736, filed on May 23, 2018; and U.S. Patent Publication No. 2019 / 0047787, published on February 14, 2019, with U.S. Patent Application Serial No. 16 / 058,065, filed on August 8, 2018. U.S. Patent Publication No. 2020 / 071076, published on March 5, 2020, with U.S. Patent Application Serial No. 16 / 554,512, filed on August 28, 2019, and entitled "Tote handling for chilled or frozen goods"; and U.S. Patent Publication No. 2020 / 0156871, published on May 21, 2020, with U.S. Patent Application Serial No. 16 / 676,732, filed on November 7, 2019, and entitled "System having robotic workstation".U.S. Patent Publication No. 2020 / 0223630, published on July 16, 2020, with U.S. Patent Application Serial No. 16 / 742,119, filed on January 14, 2020, and entitled "System having workstation with toteretention and release mechanism"; U.S. Patent Publication No. 2021 / 0300664, published on September 30, 2021, with U.S. Patent Application Serial No. 16 / 831,468, filed on March 26, 2020, and entitled "Tote handling for chilled or frozen goods"; and a patent application filed on April 21, 2020, entitled "Transport Rack". U.S. Provisional Patent Application Serial No. 63 / 013,504, entitled “High Density Micro Fulfillment Center “HD-MFC” with Nightly G2P Storage Batch Pick Replenishment from Store Floor and Method of Operating Same”, filed August 19, 2020; and U.S. Provisional Patent Application Serial No. 63 / 067,759, entitled “High Density Micro Fulfillment Center “HD-MFC” with Nightly G2P Storage Batch Pick Replenishment from Store Floor and Method of Operating Same”.

[0094] Those skilled in the art will recognize that various other modifications, alterations, and combinations can be made to the above embodiments without departing from the scope of the invention, and such modifications, alterations, and combinations should be considered within the scope of the inventive concept.

Claims

1. An item collection and aggregation system, comprising: A multi-level, multi-lane storage structure, comprising an array of container storage locations, each configured to store containers with inventory. Multiple workstations, which cooperate with the storage structure; Multiple mobile robots that transfer the container through the storage structure and to and from the multiple workstations; as well as A dynamic vertical buffer system, wherein the vertical buffer system is positioned close to a first workstation among the plurality of workstations, and the first buffer system includes: The first access station is located at the first level of the multiple different levels of the vertical buffer system and is positioned relative to the first workstation. Multiple shelving systems, which are movable between any of the multiple different levels within the vertical buffer system and the first access station, wherein each of the multiple shelving systems is configured to receive aggregated items from multiple different orders fulfilled through the first workstation; A racking movement system, the racking movement system including at least one lifting motor configured to move at least one of the plurality of racking systems between the different levels and the first access station; and A vertical buffer control circuit is communicatively connected to the rack movement system and configured to control the rack movement system to move the plurality of rack systems to and from the storage station.

2. The system according to claim 1, wherein, The vertical buffer system includes an external retaining cover positioned on the lateral side of the vertical buffer system, wherein the external retaining cover is movable at one or more different levels of the plurality of different layers to expose one or more of the plurality of racking systems from the outside of the vertical buffer system independently of the first access station.

3. The system according to claim 2, further comprising: The second access station is located on the second outer side of the vertical buffer system and is accessible from the outside of the vertical buffer system; The first access station is located on the first outer side of the vertical buffer system opposite to the second outer side, and is accessible from the outside of the vertical buffer system. The first shelving system is accessible from the first shelving side via the first access station; and The first shelving system is accessible from the second shelving side, which is opposite to the first shelving side, via the second access station.

4. The system according to claim 3, further comprising: A central control circuit is configured to receive an order picking request to pick a first order, and in response to the picking request, identify the items of the first order, which are located on the first shelf system; and Send a picking instruction to the vertical buffer control circuit to move the first shelf system to the second storage station; and The vertical buffer control circuit is configured to control the shelf movement system in response to the picking instruction, so as to move the first shelf system to the second storage station.

5. The system according to claim 3, wherein, The first shelving system includes an ambient temperature storage location and a first temperature control system, the first temperature control system including one or more first temperature-controlled storage locations separate from the ambient temperature storage location, wherein the first temperature control system is configured to maintain the temperature within the one or more first temperature storage locations at a predetermined temperature, and wherein the ambient temperature storage location and the one or more first temperature locations are accessible from both the first shelving side and the second shelving side.

6. The system according to claim 2, wherein, The vertical buffer system further includes a second access station located at a second level in a plurality of different levels, wherein the second level is vertically spaced from the first level; and The racking movement system is configured to transport the racking system individually to and from each of the first and second access stations.

7. The system according to claim 1, wherein, The shelf moving system includes: A lifting system independent of the plurality of shelving systems, wherein the lifting system moves vertically within the vertical buffer system independently of the plurality of shelving systems to align with a first shelving system in the plurality of shelving systems, picks up the first shelving system in response to an instruction to transport the first shelving system, and vertically transports the first shelving system to a destination level within the vertical buffer system.

8. The system according to claim 7, wherein, The lifting system is located in the central area of ​​the vertical buffer system, and a first group of multiple racking systems is located on a first side of the central area, and a second group of multiple racking systems is located on a second side of the central area opposite to the first side, wherein each of the multiple racking systems is accessible by the lifting system.

9. The system according to claim 1, wherein, The first shelving system is sized to receive wheeled trolleys, each trolley accommodating one or more items from multiple different orders, wherein the moving system is controlled to position the first shelving system so that the receiving surface of the first shelving system is aligned with the surface of the first workstation, and the wheeled trolley is supported on the surface and moved to the first shelving system.

10. The system according to claim 1, wherein, The shelf moving system includes: A vertical slewing device includes a slewing guide, with multiple racking systems cooperating with the slewing guide, wherein the slewing guide extends vertically through the vertical buffer system to establish a generally oval-shaped travel path along which the multiple racking systems travel simultaneously; and The vertical buffer control circuit is configured to control the simultaneous movement of the multiple racking systems so that the first racking system is aligned with the first access station.

11. A method for aggregating order items, comprising: Each of a plurality of mobile robots is guided to transfer a container through a multi-level, multi-aisle storage structure and to transfer the container to a first workstation among a plurality of workstations, the multi-level, multi-aisle storage structure comprising an array of container storage locations each configured to store one of the containers having stock. Guide the collection of items corresponding to the first order picked from the container transported by the mobile robot; Controls a shelf movement system that is separate from the storage structure and positioned close to the first workstation in a vertical buffer system, and vertically moves the first shelf system in a plurality of shelf systems within the vertical buffer system to align with the first access station located at the first level in a plurality of different levels of the vertical buffer system; When the first shelving system is positioned aligned with the first access station, guide the collected items of the first order to be placed on the first shelving system of the vertical buffer system; and While the first shelving system holds the aggregated items of the first order, the shelving movement system is controlled to move the first shelving system vertically away from the first access station, so as to free up the first access station to receive another shelving system among the plurality of shelving systems.

12. The method of claim 11, further comprising: The movement of the retaining cover of the vertical buffer system is guided, the retaining cover being positioned at one or more different levels among the plurality of different levels to prevent items from falling outside the vertical buffer system, and independently of the first access station, to expose one or more of the plurality of shelving systems from the outside of the vertical storage system.

13. The method of claim 12, further comprising: The moving system is controlled to subsequently move the first shelving system and align the first shelving system with a second access station of the vertical buffer system, the second access station being located on a second outer side of the vertical buffer system and accessible from outside the vertical buffer system, wherein the first access station is located on a first outer side of the vertical buffer system opposite to the second outer side and accessible from outside the vertical buffer system, and wherein the first shelving system is accessible from the first shelving side through the first access station, and the first shelving system is accessible from the second shelving side opposite to the first shelving side through the second access station.

14. The method of claim 13, further comprising: Receive an order picking request to pick up the first order; In response to the picking request, the items of the first order are identified, and the items of the first order are gathered and located on the first shelf system; as well as In response to the picking request, the shelf moving system is controlled, and the first shelf system is moved to the second storage station.

15. The method of claim 13, wherein, Guiding the collection of items for the first order to be placed on the first shelf system includes: The first item in the collected items is placed at one of the ambient temperature storage locations in the first shelving system; and The second item in the collection is guided to be placed in a temperature-controlled storage location that is separate from the ambient temperature storage location and accessible from both the first shelf side and the second shelf side, and the temperature in the temperature-controlled storage location is maintained at a predetermined temperature.

16. The method of claim 12, further comprising: The vertical movement of a second shelving system within the vertical buffer system is controlled to align with a second access station located at a second level among the multiple different levels, wherein the second level is vertically spaced from the first level.

17. The method of claim 12, wherein, Controlling the shelving movement system includes: moving the lifting system independently of the plurality of shelving systems within the vertical buffer system, and aligning the lifting system with the first shelving system; The first shelf system is picked up via the lifting system; and The first racking system is vertically transported to the destination level within the vertical buffer system via the lifting system.

18. The method of claim 17, wherein, Moving the lifting system includes moving the lifting system within the central area of ​​the vertical buffer system between a first group of multiple racking systems positioned on a first side of the central area and a second group of multiple racking systems positioned on a second side of the central area opposite to the first side, wherein each of the multiple racking systems is accessible by the lifting system.

19. The method of claim 17, wherein, Moving the first racking system vertically within the vertical buffer system to align it with the first access station includes controlling the lifting system to align the receiving surface of the first racking system with the surface of the first workstation, on which a wheeled trolley is supported and moves toward the first racking system. and The process of guiding the aggregated items of the first order onto the first shelving system includes guiding at least one wheeled trolley containing one or more items of the aggregated items to roll onto the receiving surface of the first shelving system.

20. The method according to claim 11, wherein, Vertically moving the first shelving system includes: The plurality of racking systems are controlled to move relative to a vertical rotating device including a rotary guide, along a generally oval travel path established by the rotary guide extending vertically through the vertical buffer system, the plurality of racking systems cooperating with the rotary guide.

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