Order fulfillment system and method using nested totes

Abstract

Some embodiments provide an order fulfillment system comprising: sub-totes; and order totes, each order tote sized to receive and store a plurality of sub-totes; a sub-tote comprising a body comprising: a first lateral side and a second lateral side, a first end side and a second end side extending between the first lateral side and the second lateral side, and a base comprising: a door pivotably secured with the first lateral side and pivotable relative to the first lateral side between a closed position and an open position, wherein in the closed position the door closes at least a portion of an interior cavity and in the open position the door exposes the interior cavity through the base; and a first latch mechanically cooperating with the door, the first latch moving between a latched position and an unlatched position, and in the latched position holding the door in the closed position and when actuated transitions to the unlatched position to release the door to enable the door to move to the open position.

Description

[0001] Cross-references to related applications This application claims the benefit of U.S. Provisional Application No. 63 / 627473, filed January 31, 2024, which is incorporated herein by reference in its entirety. Technical Field

[0002] This invention generally relates to automated inventory storage and picking. Background Technology

[0003] Inventory management can be critical to the operations of many industries. Some industries use systems to transfer inventory. There is a need to improve inventory control and allocation. Attached Figure Description

[0004] This document discloses embodiments of systems, apparatus, and methods related to automated inventory storage and picking. This description includes figures, in which: Figure 1 A perspective view of an exemplary bin system according to some embodiments is shown. The bin system includes an exemplary bin and one or more (and typically more) exemplary sub-bins configured to allow multiple sub-bins to be positioned within the bin.

[0005] Figure 2 A perspective view of an exemplary bin system according to some embodiments is shown, the bin system including an exemplary bin from which a plurality of exemplary sub-bins are removed.

[0006] Figure 3 An elevated perspective view of an exemplary hopper according to some embodiments is shown.

[0007] Figure 4 A lower perspective view of an exemplary hopper according to some embodiments is shown.

[0008] Figure 5-12 Different views of an exemplary sub-bin according to some embodiments are shown at different angles.

[0009] Figure 13 A simplified perspective view of an exemplary bin system according to some embodiments is shown. The bin system has an exemplary bin that accommodates a plurality of exemplary sub-bins, and the exemplary sub-bins are vertically positioned such that the bottom of the sub-bin's compartment is aligned with the container.

[0010] Figure 14 An exemplary latching mechanism with the latch in the latched position according to some embodiments is shown.

[0011] Figure 15 An exemplary latching mechanism is shown according to some embodiments, in which the latch is in an unlatched position when the actuator is in the actuated position in response to the activation of the trigger.

[0012] Figure 16 A close-up view of an exemplary latch in the latched position according to some embodiments is shown.

[0013] Figure 17 A cross-sectional view of an exemplary bin including one or more door closing guides according to some embodiments is shown.

[0014] Figure 18 A cross-sectional view of an exemplary bin system according to some embodiments is shown, and a series of sub-bins of the bin system are shown at different stages of insertion into the exemplary bins of the bin system by engaging corresponding guides.

[0015] Figure 19 An exemplary order fulfillment system according to some embodiments is shown, which can automate at least partially the picking of items, order picking, and order unloading in response to customer orders placed over a period of time.

[0016] Figure 20 An exemplary bin transfer robot according to some embodiments is shown, along with an exemplary sub-bin positioned relative to an exemplary container. The bin transfer robot supports an exemplary bin containing nested exemplary sub-bins.

[0017] Figure 21 A simplified flowchart of an exemplary order fulfillment process according to some embodiments is shown.

[0018] Figure 22 A simplified flowchart of an exemplary order fulfillment process, according to some embodiments, is shown.

[0019] Figure 23 A simplified flowchart of an exemplary order fulfillment process according to some embodiments is shown, which unloads orders into shopping carts, trolleys, mobile shelves and / or other transport devices.

[0020] Figure 24 Exemplary systems are shown, according to some embodiments, for implementing methods, techniques, apparatuses, devices, systems, servers, resources, and providing product order fulfillment, unpacking and transfer, consolidation, and inventory management.

[0021] The elements in the figures are shown for simplicity and clarity and are not necessarily drawn to scale. For example, to aid in understanding the various embodiments, the size and / or relative positioning of some elements may be exaggerated relative to other elements. Additionally, for the sake of a less obstructive view of these various embodiments, common but well-known 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 particular sequence of occurrence, and those skilled in the art will understand that such specificity regarding the sequence is not actually necessary. Unless otherwise specified 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 described above. Detailed Implementation

[0022] The following description should not be considered limiting, but is merely 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.

[0023] According to some embodiments, a bin system is provided that includes bins in which sub-bins are nested. A bin system that can be used in an order fulfillment system is also provided herein. In some embodiments, the order fulfillment system may be an Automated Storage and Picking System (ASRS) and may be used in a retail supply chain to fulfill orders for individual product units (referred to herein as “pieces” or “items”).

[0024] The field of single-item picking within the retail supply chain can be considered, at least in some cases, to include two application areas: (1) store replenishment applications, where orders are placed by retail stores and the picked items are delivered to those stores and placed on shelves for customers to pick up and purchase in the stores; and (2) direct-to-consumer applications, where orders are placed by end users or customers and the picked items are unloaded directly to those end users. For example, in direct-to-consumer applications, picked items associated with a customer order may be consolidated and then unloaded to the customer at an unloading point in the store (e.g., a pickup location) or at the customer's vehicle.

[0025] Direct-to-consumer applications can have many inefficient steps. For example, in a typical direct-to-consumer workflow, several plastic bags are placed in an empty order bin, and the item associated with the order is picked at a picking station and placed into a plastic bag. The order bin containing the filled bags is then handed to the customer by a store clerk in the store or at the customer's vehicle, and the customer leaves with the filled bag. In this process, securing and unsecured plastic bags to the order bin is both time-consuming and labor-intensive. Furthermore, plastic bags are not environmentally friendly and cannot be reused in the order fulfillment system. Moreover, reusable bags provided by customers cannot be introduced into automated order fulfillment systems to replace plastic bags due to potential pollution.

[0026] The systems and methods described herein are particularly useful in, for example, direct-to-consumer single-item picking applications and address some of the problems mentioned above. They may also be particularly useful in store replenishment applications and other applications in some cases. Embodiments of the bin system and order fulfillment system provide more efficient and time-saving order unloading to customers. In some embodiments, the bin system and order fulfillment system are environmentally friendly because they facilitate workflows in automated order fulfillment that can be combined with customer-supplied reusable bags. Specifically, sub-bins are reusable within the order fulfillment system, can be efficiently nested and removed from the main bin, and are configured to easily unload ordered items directly into bags or other containers, such as customer-supplied reusable bags. In embodiments, items in an order can be unloaded from the sub-bin into containers or bags in a shopping cart or carrier, or directly into the shopping cart.

[0027] Figure 1 A perspective view of an exemplary bin system 100 according to some embodiments is shown. The bin system includes an exemplary bin 110 and one or more (and typically multiple) exemplary sub-bins 140 configured to allow multiple sub-bins 140 to be positioned within bin 110. Figure 2 A perspective view of an exemplary bin system 100 according to some embodiments is shown. The bin system includes an exemplary bin 110 from which a plurality of exemplary sub-bins 140 are removed. According to some embodiments, the bin system 100 may be part of an order fulfillment system, such as… Figure 19An exemplary order fulfillment system 300 is shown and fully described below. For example, the order fulfillment system 300 may employ a bin system 100 having multiple bins 110 and multiple sub-bins 140 to be nested within the bins 110. In a non-limiting manner, bins 110 and sub-bins 140 are “order bins,” i.e., used to combine picked items associated with a customer order during order fulfillment. However, the bin system, bins, and sub-bins described herein are not limited to order fulfillment in their use and can be used for other suitable applications in other fields.

[0028] As used herein, a “bin” (and “sub-bin”) is generally understood to be a container having an open top (or an openable top) and at least one internal cavity. In embodiments, the bin described herein is a pentahedral container in the shape of a cuboid, having a base or bottom, four continuous sidewalls, an internal cavity defined by the sidewalls and the bottom, and an open top. However, it will be appreciated that bins of other shapes may also be used without departing from the inventive aspect of the invention.

[0029] In some embodiments, the bins 110 of the bin system 100 may each be sized to receive three sub-bins 140 side by side. However, in some embodiments, the bins 110 may be sized to receive one, two, four, six, or eight sub-bins. Other numbers of sub-bins 140 for each bin 110 are also conceivable.

[0030] In some approaches, bin system 100 may include bins 110 of different sizes, the bins being sized for different purposes, such as receiving different sizes and / or different numbers of sub-bins 140, cooperating with different equipment, fitting into different storage locations, etc. In some bin systems 100, all bins 110 are the same size, and all sub-bins 140 are also the same size, which maximizes interchangeability or simplifies some or all of the automation in system 100. In some applications, bins 110 and sub-bins 140 may also be used independently of each other. Furthermore, in some embodiments, bins of different sizes and / or sub-bins of different sizes may be used within bin system 100.

[0031] The number and size of the sub-boxes 140 nested within the hopper 110 can be selected or configured such that the sub-boxes 140 completely or almost completely fill the hopper 110. For example, in the illustrated embodiment, there are three sub-boxes 140, each occupying approximately one-third of the internal space of the hopper 110. For example, one of the sub-boxes may occupy one-third of the space of the hopper at a first end portion, a second sub-box may occupy one-third of the space of the hopper at a middle portion, and a third sub-box may occupy one-third of the space of the hopper at a second end portion. The sub-boxes 140 may be nested within the hopper 110 such that the side of one of two sub-boxes is flush or almost flush with the side of the hopper 110, and the adjacent side of the middle sub-box 140 is flush or almost flush with the side of the adjacent sub-box 140. In some embodiments, the bottom of the sub-box 140 may sit on the bottom of the box 110, and the top of the opening of the sub-box 140 may be substantially flush with the top of the opening of the box 110. In some embodiments, the sub-box 140 may protrude from the top of the opening of the box 110 and expose a portion of the side wall (or handle) of the sub-box 140 above the box 110. In other embodiments, when nested, the top of the opening of the sub-box 140 may be lower than the top of the opening of the box 110.

[0032] Figure 3 An elevated perspective view of an exemplary hopper 110 according to some embodiments is shown. Figure 4 A lower perspective view of an exemplary hopper 110 according to some embodiments is shown. (Reference) Figure 3 and Figure 4 In some embodiments, the container 110 may be a generally rectangular container having a generally rectangular compartment 116 or interior, and an open top leading to the compartment 116. For example, the container 110 may have a rectangular base or bottom 115, and four sidewalls 111, 112, 113, 114 extending upward therefrom. The sidewalls may include a first end side 113, a second end side 114, a first lateral side 111, and a second lateral side 112, and together with the bottom 115 define the rectangular compartment 116. The sides 111, 112, 113, and 114 may be generally perpendicular to the bottom 115, or in some ways may be slightly angled or radially outward tapered from bottom to top, such that the compartment 116 has a gradually increasing cross-sectional area from bottom to top. In some ways, the latter configuration allows the containers 110 to be nested, or nested with other identical containers 110 (e.g., in storage). However, the bin 110 can be implemented in other related shapes, such as, but not limited to, cubes, octagons and / or other such shapes.

[0033] In some embodiments, bin 110 may include a flange 118 adjacent to the top or upper edge of bin 110. For example, flange 118 may extend from and around the top periphery of bin 110. The flanges, sides, and / or ends of bin 110 may include one or more engagement structures to facilitate the transfer, clamping, stacking, or other handling of bin 110. These engagement structures may include, but are not limited to, posts, pins, recesses, openings, extensions, handles, slots, other such engagement structures, or combinations of two or more engagement structures. For example, the illustrated embodiment includes four slots 120 defined in the flanges near each corner of bin 110 to facilitate handling of bin 110 (e.g., by a robot or human). In some embodiments, the engagement structures may be similar to those described in U.S. Patent Application Publication No. 20220063910, which is incorporated herein by reference in its entirety. In some approaches, bin 110 includes one or more handles at the top, ends, and / or sides.

[0034] In some embodiments, the internal compartments 116 of bin 110 may be divided into multiple compartments or sections for receiving and positioning sub-bins. For example, multiple registration features may be present to align and / or position each individual sub-bin within a corresponding compartment 116 of bin 110. The compartments may be provided by, but not limited to, partition walls, ridges, ribs, slots, notches, guides, inserts, recesses (not shown), other such structures, or combinations of two or more such structures, which may facilitate proper positioning of sub-bins within bin 110 and / or constrain movement of nested sub-bins 140, regardless of whether one or more other sub-bins 140 are installed in bin 110. Additionally or alternatively, one or more sensors may be used to properly position sub-bins 140 within bin 110, such as in automated systems to help guide workers in inserting sub-bins, and / or in other similar situations.

[0035] Figure 5-12 Different views of an exemplary sub-bin 140 according to some embodiments are shown at different angles. Reference Figure 5-12Sub-bin 140 may be a generally rectangular container having a generally rectangular compartment 146 or interior, and an open top leading to the compartment 146. For example, sub-bin 140 may have a rectangular base or bottom 145, and four lateral sides 141, 142, 143, 144 extending therefrom. The sidewalls include a first end side 143, a second end side 144, a first lateral side 141, and a second lateral side 142, and together with the bottom 145 define the rectangular compartment 146. The first lateral side 141 and the second lateral side 142 extend along the length of sub-bin 140, and the first end side 143 and the second end side 144 extend along the width of sub-bin 140. As shown, the sides 141, 142, 143, 144 may be slightly angled or radially tapered relative to the bottom 115, such that the compartment 146 has a gradually increasing cross-sectional area from bottom to top. In some approaches, the latter construction allows sub-bins 140 to be nested with other identical sub-bins 140 (e.g., in storage), or facilitates the insertion of sub-bins 140 into bins 110 having corresponding angled sides. However, sub-bins 140 can be implemented in other related shapes, such as, but not limited to, cubes, octagons, and / or other such shapes.

[0036] refer to Figure 1 , Figure 3 and Figure 5 The lateral sides 141, 142 of the sub-bins 140 may have a length approximately equal to the width of the compartment 116 of the bin 110, such that each sub-bin 140 extends longitudinally along the width of the bin 110 (i.e., from the first lateral side 111 of the bin 110 to the second lateral side 112 of the bin 110). In some embodiments, the sub-bins 140 may be sized to contact the side of the bin 110 when inserted therein. In other ways, some space may exist between the sub-bins 140 and the bin 110.

[0037] The end sides 143, 144 of the sub-bins 140 may have widths selected such that a certain number of sub-bins 140 fit together along the length of the bin 110 (i.e., between the first end side 113 and the second end side 114 of the bin 110). For example, as shown, the width of the end sides 143, 144 of the sub-bins 140 is approximately one-third the length of the compartment 116 of the bin 110, such that three sub-bins 140 can be arranged side by side along the length of the bin 110.

[0038] The sub-bin may include one or more handles 151 for handling the sub-bin 140. In one approach, the handles 151 may be located near the top portion of one or more of the lateral sides 141, 142, 143, 144. For example, opposing handles may be provided on the lateral sides 141, 142 and / or the end sides 143, 144. In other approaches, four handles 151, 152, 153, 154 may be provided on the four sides 141, 142, 143, 144 (e.g., as shown in the image). Figure 5 (As shown in the figure). The handles can be configured to be carried by a person, robot, and / or other transportation system. As shown, in a non-limiting manner, handles 151, 152, 153, 154 are defined by an elongated opening at the top portion of each of the respective four sides 141, 142, 143, 144. However, the handles can also be positioned in other relevant locations. Furthermore, the handles are shown as openings extending from the sides. However, in other embodiments, the handles may be formed as part of the hopper and not as openings (e.g., one or more ridges, bosses, or other portions extending from one or more of the sides).

[0039] Advantageously, the bottom 145 of the sub-bin 140 may be defined by at least one movable door that can be moved to a closed position or to an open position. The movable door may be configured to pivot between the closed and open positions, for example, via one or more hinges located on one of the sides of the sub-bin 140. In the closed position of the bottom 145, the door closes the compartment 146 at the bottom 145, and any items inserted into the sub-bin 140 are contained within the compartment 146. In the open position of the bottom 145, the interior of the compartment 146 is exposed through the bottom 145. In this position, items inserted into the sub-bin 140 can be released or unloaded from the bottom 145 of the sub-bin 140.

[0040] Figure 13 A simplified perspective view of an exemplary bin system 100 according to some embodiments is shown, wherein an exemplary bin 110 accommodates a plurality of exemplary sub-bins 140, and the exemplary sub-bins are vertically positioned such that the bottom of the sub-bin's compartment 146 is aligned with a container 199 (e.g., a bag, box, carton, drum, or other such container). Reference Figure 5-13In a non-limiting approach, the bottom 145 of the sub-bin 140 may include one or more movable doors configured to move, pivot, rotate, and / or otherwise move to expose the interior of the sub-bin. For example, in some embodiments, the sub-bin 140 may include two opposing movable doors 155, 165. A first movable door 155 may be pivotally secured near the bottom of a first lateral side 141 via one or more hinges 155a, while a second movable door 165 may be pivotally secured near the bottom of a second lateral side 142 via one or more hinges 165a. Each of the one or more doors may extend at least some of the length of the bottom or base of the compartment 146 of the sub-bin 140 and extend across at least some of the width of the bottom of the compartment. In some embodiments, the first movable door 155 and the second movable door 165 may each extend approximately or the entire length of the compartment 146 of the sub-bin 140, and approximately half the width of the compartment 146, such that the movable doors 155, 165 each surround approximately half of the bottom of the compartment 146, and together surround some, most, or all of the bottom of the compartment 146. Alternatively, the movable doors 155, 165 may be hinged to the end sides 143, 144 of the sub-bin 140, wherein each movable door 155, 165 extends the entire width of the compartment 146 and half the length of the compartment 146. In some embodiments, the movable doors 155, 165 are configured to open outwards away from the interior of the compartment.

[0041] Figure 6 The closed positions of the first movable door 155 and the second movable door 165 of the exemplary sub-bin 140 are shown, while Figure 12 An exemplary sub-bin 140 is shown with a first movable door 155 and a second movable door 165 open, according to some embodiments. Each of the first movable door 155 and the second movable door 165 includes a first outer edge 159a, 169a, a second outer edge 159b, 169b opposite the first outer edges 159a, 169a, and an inner edge 159c, 169c extending therebetween. In one approach, in the closed position, the movable doors 155, 165 engage each other along their inner edges 159c, 169c with an overlap joint 158. Specifically, the first movable door 155 has a first inner overlap joint portion 156, and the second movable door 165 has a corresponding second outer overlap joint portion 166. In the closed position, the first inner overlap joint portion 156 rests against and is held in place by the outer overlap joint portion 166.

[0042] Figure 13An exemplary use of a bin system 100 according to some embodiments is illustrated. One of the sub-bins 140 nested within a bin 110 can be removed from the bin 110. The sub-bin 140 can be aligned with a bag 199, box, or other container (e.g., positioned above, partially inside, or fully inserted therein). When the sub-bin 140 is aligned with the bag 199 or other container, a first movable door 155 and a second movable door 165 can be actuated to change from a closed position to an open position. When the first movable door 155 and the second movable door 165 are opened, the items or products contained in the sub-bin 140 (such as items picked to fulfill customer orders) are released into the bag 199. The same process can be performed for the remaining sub-bins 140 in bin 110 that have the same bag 199 or container, or one or more other bags or containers.

[0043] In the context of fulfilling a customer order, the process of aligning one or more sub-bins with one or more bags and / or containers can continue until the customer order is completed. For example, a customer order may use multiple sub-bins 140, each receiving one or more items, and may be nested within one or more bins 110, and the process may output multiple bags 199 and / or containers containing one or more items for the customer to take home. In this context, in some embodiments, the volume of each sub-bin 140 may be configured to substantially correspond to a specific volume, such as the volume of the expected bag or container the customer can take home, such that the volume of the picked items in each sub-bin 140 fits within a single bag or container. For example, the sub-bin 140 may be sized to fit predetermined standard-sized paper bags, plastic bags, and / or standard-sized reusable bags. The bag or container is intended to have a top opening, the size and geometry of which allow the bottom sections 155, 165 of the sub-bin 140 to be at least substantially aligned with, and typically perfectly aligned with, the opening of the bag 199 or container, such that when the sections 155, 165 are opened, items are released into the bag or container without falling out. In some embodiments, the opening of the takeaway bag or container should be slightly larger than the bottom 145 to ensure that the customer's bag or container catches all items. In one embodiment, the bottom 145 of the sub-bin 140 is slid into the opening of the bag 199 or container before the bottom 145 is opened to ensure that all items are caught. In some embodiments, the sub-bin 140 has a volume slightly smaller than that of a bag or container of a predetermined or anticipated standard size to ensure that items in the sub-bin 140 fit within the bag or container. Other bags or containers of sufficient size may also be used to allow one or more items to be distributed from multiple different sub-bins into a single large bag and / or container. Similarly, in some cases, two or more sub-boxes corresponding to an order may not be full, and thus multiple items from different sub-boxes may be allocated into a single standard-sized bag and / or large bag or container.

[0044] In some embodiments, one or more movable doors defining the bottom 145 may include one or more latching mechanisms that mechanically cooperate with, and / or cooperate with, the one or more latching mechanisms. The latching mechanisms are movable between a closed or latched position and an open or unlatched position. In the latched position, the one or more latching mechanisms may hold the one or more movable doors in the closed position; and when actuated, the one or more latching mechanisms may shift to the unlatched position to release the one or more movable doors, causing the one or more movable doors to move to the open position. The latching mechanism may include a latch and an actuator fixed to the sub-bin 140 that initiates movement of the latch between the latched and unlatched positions. The actuator may include a trigger, which will be further described below. Although mechanical latches are described herein, it is also contemplated that latches for one or more movable doors may have electronic or powered components and be electronically operable.

[0045] refer to Figure 12 In some embodiments, the sub-bin 140 may include one or more latching mechanisms 175, 190, which can be used to open the first movable door 155 and the second movable door 165 and / or hold one or more of the first movable door 155 and the second movable door 165 in a closed position. For example, the first latching mechanism 175 may include a first latch (not shown) that cooperates with a first outer side of the first movable door 155 and the second movable door 165 near a first end side 143 of the sub-bin 140. The second latching mechanism 190 may include a second latch (not shown) that cooperates with a opposite second side of the first movable door 155 and the second movable door 165 at an opposite second end side 144 of the sub-bin 140. In some embodiments, holding the movable doors 155, 165 in the closed position or fully opening the movable doors 155, 165 requires two latching mechanisms 175, 190. Alternatively, multiple latching mechanisms may be included in the sub-bin as a safety feature. For example, multiple latching mechanisms prevent the opening of one or more doors if a user or system accidentally releases one of the multiple latching mechanisms. However, other embodiments use a single latching mechanism. Furthermore, some embodiments activate two or more latching mechanisms in response to the activation of a single trigger.

[0046] The sub-bin 140 may include one or more actuators. For example, in Figure 12In the illustrated embodiments, one or more of the latching mechanisms 175, 190 may include a corresponding actuator that actuates the latch to move the latch between a latched position and an unlocked position. In some embodiments, the actuator may be fixed to or within an opposing sidewall of the sub-bin 140 and may be biased to the unlocked position to hold the latch in the latched position. In some approaches, each actuator includes a corresponding trigger 176, 191 that, when activated, moves the corresponding actuator to the activated position to cause the latch to move to the unlocked position. An external force (e.g., applied by a person or robot) on triggers 176, 191 may move the actuator to the activated position.

[0047] In some approaches, triggers 176 and 191 may be positioned near and accessible to the handle of the sub-bin. For example, in Figure 12 In the illustrated embodiment, exemplary triggers 176, 191 are positioned in and / or near elongated openings 153, 154 that define handles in the first end side 143 and the second end side 144. In this configuration, the actuators are at least partially disposed near and / or inside the walls of the first end side 143 and the second end side 154, respectively. In some embodiments, the triggers 176, 191 of the actuators may extend internally, externally, and / or upwardly through the walls of the first end side 143 and the second end side 144 to align with the elongated openings 153, 154, and at least partially extend into the region of the openings. For example, the triggers 176, 191 may be sized to sit substantially within the openings 153, 154 and are movable along a portion of the length of the openings 153, 154. In the unactuated position, the triggers 176, 191 may be positioned close to one side of the respective opening 153, 154, but slightly spaced apart from that side of the opening. In some embodiments, when a force is applied to triggers 176, 191, the actuators can be actuated to move triggers 176, 191 along elongated openings 153, 154 closer to the nearest side. For example, in some embodiments, triggers 176, 191 may move from an extended position exposed in the elongated opening to a retracted position at or near the end of the elongated opening and / or contact or abut against the side of openings 153, 154 as they move to actuate the actuators.

[0048] Figure 14-16 An exemplary, non-limiting latching mechanism for an exemplary sub-bin 240 according to some embodiments is shown. The illustrated sub-bin 240 may include some or all of the features described above with respect to sub-bin 140. Features identical to those in sub-bin 140 are indicated by the same numbers, although the numbers in sub-bin 240 will begin with "2". Additionally, it is noted that since the first and second latching mechanisms on opposite sides of the movable doors 255, 265 are identical, only the first latching mechanism 275 will be described in detail below.

[0049] In some embodiments, the latching mechanism 275 may include a first latch 279 cooperating with movable doors 255, 265 to latch and unlock the doors, a first actuator 277 for the first latch 279, and a first trigger 276. In some embodiments, as will be described in further detail below, the first latch 279 has a hook-like construction, a ridge, an "L"-shaped protrusion, and / or other such structures, and is movable from a latched position to an unlocked position and vice versa.

[0050] In some embodiments, the first actuator 277 may have an elongated strip or rod 278 extending along and / or within a corresponding elongated passage 285, guides, etc. (which extend along and / or within the first end sidewall 243). In some embodiments, the passage 285 extends substantially vertically or at an angle from one side of the elongated opening 253 of the handle to a substantially central opening 285a at the bottom of the first end sidewall 243 within the first end sidewall 243. The passage 285 may have a varying width and is typically slightly wider than the first actuator 277, such that in different positions of the actuator 277 (described below), the actuator 277 can contact a first angled side surface 287 or an opposing second angled side surface 288 of the passage 285. In some embodiments, the actuator 277 is pivotally connected to the passage 285 via a pivot pin 282, bolt, rivet, hinge, etc., which may define a first upper portion 280 of the rod 278 to a second lower portion 281 of the rod 278. In some embodiments, the portion of the passage 285 at or immediately adjacent to the pivot pin 282 may be narrower than the distal portions of the passage 285 above and below the pivot pin 282.

[0051] In some embodiments, a first latch 279 may extend from the bottom end of a first actuator 277 and through an opening 285a. The top end of the first actuator 277 may cooperate with and / or form a trigger 276, which in some embodiments may extend into an elongated opening 253 of the handle, protruding above the sub-bin and / or otherwise positioned for access by a user and / or robot.

[0052] In some embodiments, a biasing element 289 may be included in a latching mechanism 275 to bias an actuator 277 such that the first latch 279 is in a latched position. In the illustrated embodiment, a cavity 286 extends from a passage 285 near the latch 279 (e.g., near the top portion of the passage 285, the bottom portion of the passage, or other relevant location to cause the latch 279 to be biased in the intended direction). Biasing may be caused by one or more springs, helical springs, magnets, deformation of a portion of the actuator 277, other such biasing mechanisms, or combinations of two or more biasing mechanisms. For example, in the illustrated embodiment, the biasing element may include one or more U-shaped springs that may be at least partially disposed in the cavity 286 and may engage the actuator 277 (e.g., at the upper first portion 280 of the actuator 277) to bias the actuator 277 in the intended direction and hold the latch 279 in the latched position. Specifically, the spring in its neutral position may extend partially into the passage 285 to engage the actuator 277. The opening of cavity 286 between cavity 286 and passage 285 can be sized to expose actuator 277 and engage some or all of the entire length of the proximal side of the U-shaped spring. The biasing element 289 is not limited to a U-shaped spring or a spring. Other elastomeric biasing elements or non-elastomeric biasing elements (e.g., magnets) can also be used to achieve the intended bias of actuator 277.

[0053] Figure 14 An exemplary latching mechanism 275 is shown with the latch 279 in a latched position according to some embodiments. In this position, a U-shaped spring extends partially into the passage 285 and biases the actuator 277 such that a first upper portion 280 of the actuator 277 pushes away from the second angled side surface 288 of the passage 285 and towards the first angled side surface 287. In this position, a trigger 276 also pushes away from the side of the elongated opening 253 of the handle, such that the trigger is spaced apart from it. The pressure of the first upper portion 280 of the actuator 277 against the first angled side surface 287 forces the latch 279 into the latched position, for example, by forcing the second lower portion 281 of the actuator 277 against the second angled side surface 288 of the passage 285. In this position, the latch 279 is positioned to engage and hook onto a receiving portion (e.g., an extension pin 267) on at least one of the movable doors (e.g., the second movable door 265). Figure 16 ( ), below the shoulder, ridge and / or other such structures, and in some cases engages and hooks around them to lock one or more latches of movable doors 255, 265 in the closed position.

[0054] Figure 15An exemplary latching mechanism 275, according to some embodiments, is shown where the latch 279 is in an unlocked position when the actuator 277 is in the actuated position in response to the activation of the trigger 276. When the trigger 276 is pushed against the side of the elongated opening 253 of the handle, the first upper portion 280 of the actuator 277 simultaneously pushes away from the first angled side surface 287 of the passage 285 and against the second angled side surface 288. This movement causes the first upper portion 280 of the actuator 277 to act on the biasing element 289 (e.g., further compressing the U-shaped spring into the cavity 286), such that the first upper portion 280 can engage the second angled side surface 288 of the passage 285. In some embodiments, because the distance that trigger 276 moves toward the side of the elongated opening 253 is greater than the space between the first upper portion 280 of actuator 277 and the second angled side surface 288 of passage 285, moving trigger 276 to its full range (e.g., until it abuts the sidewall of the elongated opening 253) causes the first upper portion 280 of actuator 277 to apply pressure to the second angled side surface 288. The angle of the second angled side surface 288 forces the second lower portion 281 of actuator 277 away from the second angled side surface 288 and pivot toward the first angled side surface 287. Therefore, the hook of latch 279 pivots away from the protruding pin 267 on the second movable door 265 ( Figure 16 This causes one or more of the movable doors 255 and 265 to unlock and be released to the open position.

[0055] Figure 16 A close-up view of an exemplary latch 279 in the latched position according to some embodiments is shown. As described above, the hook latch 279 extends from the passage 285 through a centrally located opening 285a at the bottom of the first end sidewall 243, such that the latch 279 extends through the opening 285a, and in some embodiments, is located below the bottom of the first end sidewall 243 at the interface between the first movable door 255 and the second movable door 265.

[0056] The latch 279 may extend from the gradually narrowing or tapered end portion 281a of the second portion 281 of the actuator rod 278. The tapered portion 281a of the rod 278 may abut against the protrusion 288a of the angled second side surface 288 of the passage 285 in the unbiased latched position; and may pivot away from the protrusion 288a in the actuated unlatched position.

[0057] In some embodiments, movable doors 255, 265 engage with each other in the closed position via one or more overlaps 258, ridges, bosses, extension tabs, etc., which may extend to cover one or more portions of the door length, or extend along the length of the movable doors 255, 265 to the other side. In some embodiments, the first movable door 255 may have a first inner overlap portion 256, and the second movable door 265 may have a corresponding second outer overlap portion 266. In the closed position, the first inner overlap portion 256 sits on the outer overlap portion 266 and is held in place by the outer overlap portion. In an embodiment, a space or groove 268 may be formed between the movable doors 255, 265, near the overlap portions 256, 266, and below the opening 285a of the passage 285. The latch 279 extends downward into a slot 268 large enough to allow the latch 279 to pivot between the latched and unlocked positions as described above.

[0058] In some embodiments, the second movable door 265 may include a pin 267 extending laterally and outwardly from a side edge of the second movable door 265 and inside a slot 268. In the latched position, a latch 279 hooks under and around the pin 267 to hold the second movable door 265 in the closed position. In this position, the first movable door 255 is also held closed along with the second movable door 265 due to the overlap joint 258. When the actuator 277 is actuated, the latch 279 pivots away from the pin 267 to the unlocked position to disengage from the pin 267 and release the doors 265, 255 to the open position. In some embodiments, the second pin 257 extends from the first movable door 255. As further described below, the first pin 267 and the second pin 257 may serve to facilitate closing the movable doors 255, 265. In some embodiments, one or two pins 267, 257 extend outward from the side edges of the movable doors 255, 265 and beyond the first end sidewall 143, so that they protrude from the side of the sub-box 140.

[0059] As described above, it is envisioned that in some embodiments, movable doors 255, 265 are released to the open position when two or more latches of two or more latching mechanisms are unlocked in a coordinated manner (e.g., simultaneously, sequentially, etc.). For example, in some embodiments, movable doors 255, 265 are released to the open position when two or more latches of two or more latching mechanisms similar to or identical to the first mechanism are unlocked in a coordinated manner (e.g., simultaneously, sequentially, etc.) from pins extending from opposite sides of a second movable door 265 located at opposite ends of the sub-bin 240.

[0060] In one embodiment, once movable doors 255, 265 are opened and no longer exert force on trigger 276, actuator 277 returns to the unactuated position, causing latch 279 to return to the “latched” position, but this time doors 255, 265 are not actually latched. In some approaches, movable doors 255, 265 need to be moved upwards back to the closed position (e.g., manually, by a robot, or by returning them to the main bin, as further described below) to close doors 255, 265 and engage latch 279. In some embodiments, moving movable doors 255, 265 back to the closed position causes movable doors 255, 265 to engage one or more latches (e.g., a first latch and a second latch) to re-latch the doors in the closed position.

[0061] For example, in some embodiments, the force of moving the movable doors 255, 265 to the closed position can cause the pin 267 to push against the lower angled surface of the latch 279, causing the latch 279 to pivot slightly to one side until the pin 267 passes over the latch 279 (and in some cases overcomes bias), and the latch 279 swings back under the pin 267. In some embodiments, similar actions can occur on opposite sides of the movable doors 255, 265, and in some cases, simultaneously, causing the movable doors 255, 265 to be fully closed and re-latched at both ends of the doors.

[0062] Figure 17 A cross-sectional view of an exemplary bin 210 including one or more door closing guides 295 according to some embodiments is shown. Figure 18 A cross-sectional view of an exemplary bin system 200 according to some embodiments is shown, and a series of sub-bins 240a-240c of the bin system 200 are shown at different stages of engaging corresponding guides 295 inserted into an exemplary bin 210 of the bin system 200. Reference Figure 17 and Figure 18 In some embodiments, where pins 267, 257 (and opposing pins of a second latching mechanism located on opposite sides of movable doors 255, 265) extend outward from the edges of movable doors 255, 265 such that they protrude beyond the end sides 243, 144 of sub-bins 140, pins 267, 257 may be configured to cooperate with the main bin 210 to close and re-latch doors 255, 265. For example, in some embodiments, the inner surfaces of opposite sides of bin 210 include one or more guides 295 that guide pins 257, 267, and thus guide the movable doors 255, 265 of sub-bins 140 to a closed and latched position when the doors 255, 265 are opened and the sub-bin 140 is placed back into bin 210.

[0063] Figure 17A simplified view of a first lateral side 211 of an exemplary hopper 210 is shown, the hopper 210 having a plurality of guides 295 on its inner surface. Figure 17 As shown, in some embodiments where multiple (e.g., three) sub-boxes 240 may be nested side-by-side within a box 210, for example, three sets of opposing guides 295 may be present on the inner surfaces of the first lateral side 211 and the second lateral side (not shown) of the box 210. Those skilled in the art will recognize that, depending on one or more factors, including but not limited to the size of the box 210 and the size of the sub-boxes 240a-240c that may cooperate with the box 210, more or fewer guides 295 may be included. The guides 295 may be recesses, protruding ridges, ribs, or other variations in surface, configured to align and engage with protruding pins and / or other portions of doors on one or both sides of the sub-box 240 when the sub-box 240 is positioned or falls into the box 210. The guides 295 may be configured to gradually pull the pins together as the sub-box 240 falls into the box 210, causing the movable doors 255, 265 to pull to the closed position and automatically latch.

[0064] In the exemplary embodiment shown, each guide 295 includes a first guide portion 296 positioned to engage a second pin 267 on a second movable door 265; and a second guide portion 297 which may be symmetrically disposed relative to the first guide portion 296 and positioned to engage a first pin 257 on a first movable door 255. For example, the guide portions 296, 297 may be a ridge, recess, or curvature in the inner surface of the lateral sidewall 211. The guide portions 296, 297 may extend generally vertically along the inner surface of the bin 210 such that when the sub-bin 240 falls into the bin 210, the pins 267, 257 of the sub-bin 240 are guided downward along the guide 295.

[0065] In some approaches, the first guide portion 296 and the second guide portion 297 may be widely spaced from each other toward the top of the guide 295 to define the wide portion 295a of the guide 295. The first guide portion 296 and the second guide portion 297 may be gradually curved and / or angled toward each other and define the narrow portion 295b of the guide 295 adjacent to the bottom of the bin 210. The gradually curved and / or tapered geometry of the guide portions 296, 297 toward each other causes the pins 267, 257 of the sub-bins 240 to gradually pull toward each other and the latch 279 during downward movement into the bin 210.

[0066] Figure 18 A simplified cross-sectional view is shown of an exemplary bin 210 and exemplary sub-bins 240a-240c cooperating within the bin 210, according to some embodiments. Figure 18A simplified progressive view is further shown of the first end side 243 of the exemplary sub-bins 240a, 240b, and 240c when the sub-bins are positioned within the exemplary bin 210. (At least refer to...) Figure 17-18 One or more pins 257, 267 and / or other portions of one or more doors 255, 265 contact guides 295, which guides and moves the movable doors 255, 265 of each sub-box 240 from an open position to a closed position. The first sub-box 240a is shown initially inserted into the box 210, where one or more pins 257, 267 initially engage guides 295. With the movable doors 255, 265 in the fully open position, pins 267, 257 are spaced apart from and aligned with the top areas of the corresponding guide portions 296, 297 of guides 295, and engage. As the first sub-box 240a is pushed into and / or further into the box 210, the inwardly curved guide portions of the guides pull the pins 257, 267 of sub-box 240a toward each other, which begins to fold the movable doors 255, 265 into the closed position.

[0067] The second sub-box 240b is shown with movable doors 255, 265 almost in the closed position, where pins 257, 267 are about to enter the narrow portion 295b of guide 295 along guide 295, which will cause the overlapping joint portions 256, 266 on movable doors 255, 265 to ( Figure 15 They move to engage with each other, wherein the outer lap joint portion 266 is located below and supports the inner lap joint portion 256.

[0068] The third sub-bin 240c is shown with movable doors 255, 265 fully closed because sub-bin 240c is fully seated near or against the bottom of bin 210. In some cases, contact between at least partially inwardly folded doors 255, 265 and the bottom of bin 210 or other parts of bin 210 (e.g., protrusions) forces movable doors 255, 265 reliably into the closed position and latches them by one or more latching mechanisms. As described above, the process of fully moving movable doors 255, 265 into the closed position also latches movable doors 255, 265. Similarly, movable doors 255, 265 can be closed before insertion into bin 210, wherein the doors and / or pins do not engage guide 295.

[0069] Advantageously, for example in the context of order fulfillment, the aforementioned guide 295 simplifies the process of transferring the sub-box 240 between different orders and boxes, because simply inserting the sub-box 240 back into the box 210 automatically closes and re-latches the movable doors 255, 265, and can skip and / or eliminate the need for additional steps and / or machinery for closing the doors 255, 265.

[0070] In other ways, other forms of guides can be used to guide the closing of movable doors 255, 265. For example, the guides can be placed on inserts or containers within bin 210. Additionally, in some embodiments, movable doors 255, 265 can be manually closed by a person or robot and inserted into bins with or without guides. Furthermore, in some embodiments, when sub-bin 240 is positioned in bin 210, the guide 295 can conform to and / or be based on the shape of the lower body of the sub-bin; and after picking up the sub-bin, the guide can return to its original configuration to receive subsequent sub-bins.

[0071] The aforementioned bins and / or sub-bins may also include tags or IDs to identify and distinguish a particular bin or sub-bin from other bins or sub-bins. For example, bins and / or sub-bins may include radio frequency identification (RFID) tags, barcodes, QR codes, alphanumeric characters, other such tags or IDs, or combinations of two or more such tags and / or IDs on their exterior and / or interior, which can be scanned by scanning devices (e.g., on robots, conveyor systems, workstations, and / or other such systems). In some ways, tags can be used to associate bins or sub-bins with specific customer orders, associate sub-bins with bins, associate items with the sub-bin in which they are placed, and / or other such associations. Tags may also be associated with other information, such as the bin's location within the system, the bin type (e.g., product bin, order bin, repackaging bin, etc.), the bin and / or sub-bin status (e.g., full, empty, number of items, number of sub-bins in the bin, etc.), other such associations, or combinations of two or more associations.

[0072] In some embodiments, the bins and / or sub-bins disclosed herein may be configured to store articles at different specified temperatures (e.g., refrigeration temperature, freezing temperature, ambient temperature, one or more heating temperatures, etc.). Generally, the refrigeration temperature range may be, for example, from 0℉ to 34℉, and the freezing temperature may be below or equal to 0℉. For example, the bins and / or sub-bins may include one or more of the insulation features described in PCT Publication No. 2022 / 133353, published on June 23, 2022, which is incorporated herein by reference in its entirety. For example, the bins and / or sub-bins may include lids, such as hinged lids, to better maintain the bins or sub-bins at the desired refrigeration or freezing temperature. Additionally, the refrigeration or freezing sub-bin may have one or more insulation panels disposed along the inner and / or outer surfaces of the compartment, the insulation panels being made of various materials, including but not limited to polystyrene foam and polyurethane foam. The compartment may also include a heat-insertion element, which may include a phase change material, such as pure water, water mixed with propylene glycol, ethylene glycol, glycerin and / or salt, sodium polyacrylate, and dry ice. The sub-bin may also include a sensor to monitor the temperature of the compartment.

[0073] Other insulation features available in the bins and / or sub-bins can be found in U.S. Patent Publication No. 2020 / 071076, published March 5, 2020, and U.S. Patent Publication No. 2021 / 0300664, published September 30, 2021, both of which are incorporated herein by reference in their entirety.

[0074] As described above, the aforementioned bins, sub-bins, and bin systems can be used as part of an order fulfillment system, such as an order fulfillment system including an Automated Storage and Picking System (ASRS) and / or a Goods-to-Picker (G2P) system. Generally, such order fulfillment systems may employ a centralized control system, product bins and order bins, bin storage structures for storing bins and inventory items, bin transfer systems (which may include autonomous mobile robots or carriers for transferring and transporting bins), picking workstations (where human or robotic pickers remove individual items from product bins and place them into order bins), output / unloading systems for unloading orders into customers' takeaway bags or containers for home delivery, and input systems where bins enter or are recycled back into the system.

[0075] This application incorporates by reference the entirety of the following U.S. and WO patent publications relating to automated order fulfillment systems, many of which have any additional systems, processes, and features described therein: U.S. Publication No. 2014 / 0288696, published September 25, 2014, having U.S. Application Serial No. 14 / 213187, filed March 14, 2014, entitled "Automated system for transporting payloads"; and U.S. Patent Publication No. 2017 / 0313514, published November 2, 2017, having U.S. Application Serial No. 15 / 591956, filed May 10, 2017, entitled "Order Fulfillment System". U.S. Patent Publication No. 2019 / 0270591, published in September 2019, with U.S. Application Serial No. 16 / 419910, 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. Application Serial No. 15 / 816832, filed on November 17, 2017, and entitled "Automated-service retail system and method". The patent application is titled “Interchangeable automated mobile robots with a plurality of operating modes configuring a plurality of different robot task capabilities”; and U.S. Patent Publication No. 2018 / 0194556, published on July 12, 2018, with U.S. application serial number 15 / 867373, filed on January 10, 2018. The patent application is titled “Automated retail supply chain and inventory management system”.U.S. Patent Publication No. 2018 / 0305123, published on October 25, 2018, with U.S. Application Serial No. 15 / 956346, was filed on April 18, 2018, and is entitled "Picking workstation with mobile robots & machine vision verification of each transfers performed by human operators"; and U.S. Patent Publication No. 2018 / 0247257, published on August 30, 2018, with U.S. Application Serial No. 15 / 903993, was filed on February 23, 2018, and is 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. Application Serial No. 15 / 987736, filed on May 23, 2018; and U.S. Patent Publication No. 2019 / 0047787, published on February 14, 2019, with U.S. Application Serial No. 16 / 058065, filed on August 8, 2018. U.S. Patent Publication No. 2020 / 071076, published on March 5, 2020, with U.S. Application Serial No. 16 / 554512, 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. Application Serial No. 16 / 676732, filed on November 7, 2019, and entitled "System having robotic workstation".U.S. Patent Publication No. 2020 / 0223630, published on July 16, 2020, has U.S. Application Serial No. 16 / 742119, filed on January 14, 2020, and is entitled "System having workstation with tote retention and release mechanism"; U.S. Patent Publication No. 2021 / 0300664, published on September 30, 2021, has U.S. Application Serial No. 16 / 831468, filed on March 26, 2020, and is entitled "Tote handling for chilled or frozen goods". U.S. Patent Publication No. 2021 / 0323769, published on October 21, 2021, has U.S. Application Serial No. 17 / 236082, filed on April 21, 2021, and is entitled "Transport Rack Cartridge"; U.S. Publication No. 2023 / 0230031, published on July 20, 2023, has U.S. Application Serial No. 17 / 927851, filed on November 25, 2022, and is entitled "High Density Micro Fulfillment Center 'HD-MFC' with NightlyG2PStorage Batch Pick Replenishment from Store Floor and Method of" OperatingSame); and WO Publication No. 2022 / 133353, published on June 23, 2022, which has PCT application number PCT / US2021 / 064424, filed on December 20, 2021, and entitled "Methods and apparatus for facilitating transport of items between a store and a customer via a customer accesslocation".

[0076] refer to Figure 19An exemplary order fulfillment system 300 according to some embodiments is illustrated, which can at least partially automate the picking of items, order picking, and order unloading in response to customer orders placed over a period of time. System 300 may include a centralized control system 380, which includes software, computers, servers, circuit systems, memory, databases, other network devices, or combinations of two or more such components, which manages resources within system 300 (including some or all of various robots and robot circuit systems, when present), coordinates the order fulfillment processing and related processes of some or all pending orders, and provides status and control interfaces to operators, system users, control systems, and / or external systems. Furthermore, in some embodiments, the control system 380 may provide instructions to and / or control the computer system (such as a smartphone, tablet, desktop computer, wearable device, etc.) to guide one or more workers to move sub-boxes and / or boxes containing sub-boxes through retail facilities (such as picking one or more items from one or more orders from a store sales area, store fulfillment area, one or more areas of a fulfillment facility and / or other such locations, and delivering them to customers, such as delivery vehicles to customers).

[0077] The order fulfillment system 300 may also include a material control system 382, ​​which may include one or more control circuits, processors, servers, etc., to execute one or more software applications for the operation of various components in the control system 300. For example, the material control system 382 can manage the operation of the output / unloading system 320 by controlling the transportation of order bins to the output / unloading system 320, and the timing and sequence of the temporary storage of order bins at the unloading location or customer pickup location 322 for pickup by one or more customers. In another example, the material control system 382 may designate a specific workstation 315 (e.g., picking workstation, unpacking and transfer workstation, general workstation, etc.) to fulfill customer orders, and then instruct one or more robots 312a to transport product bins and order bins to workstation 315, provide instructions to operators or robot pickers (including the type and quantity of items to be transferred from product bins to one or more order bins), instruct robots to transport product bins back to bin storage structure 302, and transport order bins to output / unloading system 320 or order storage structure 318. In some embodiments, the bins are held within the order fulfillment system. For example, the system may hold a first set of one or more product bins 140 containing sub-bins; simultaneously, one or more sub-bins may be picked from the one or more product bins, and those one or more picked sub-bins may be placed into one or more order bins to fulfill the order, which may include fulfillment outside the system. In other embodiments, product bins with one or more sub-bins may be sent to a picker at a workstation, where the picker sequentially retrieves one or more sub-bins and distributes one or more items from the one or more retrieved sub-bins into one or more bags or containers. The retrieved sub-bins may be returned to the system (e.g., returned to the same bin or a different bin), while one or more bags from the order may be delivered to the corresponding customer.

[0078] The order fulfillment system 300 can be integrated into an e-commerce system, where customers of retail facilities (such as fulfillment facilities, warehouses, stores, etc.) can use software applications or websites on computer devices (such as computers (desktop computers, laptops, self-service kiosks) or personal mobile devices (e.g., tablets, mobile phones, smartphones)) to browse and select items to place orders. When a customer places an order to purchase items, the order is automatically fulfilled by the order fulfillment system 300, which may be located in a store, a separate fulfillment facility, or distributed across several different stores and / or fulfillment facilities. Specifically, the picking workstation 315 of the order fulfillment system 300 can successfully pick items from product bins 305 to consolidate orders. In this way, the order fulfillment system 300 can significantly save customers' time by delegating the task of picking order items to staff or automated systems. Once a customer's order is ready, the customer can either pick it up at the store or have it delivered to their door.

[0079] Various individual items or goods processed in the order fulfillment system 300 may be stored and transported in one or more bins, such as any of the bins disclosed above. Some of the bins may be used as product bins 305 for storing one or more inventory items. In some embodiments, a given product bin stores at least one corresponding product having a unique stock unit (SKU). Some product bins may be configured to accommodate multiple products with different SKUs via one or more sub-bins or partitions. Product bins 305 may be similar to the bins described above (e.g., bins 110, 210) or may have other configurations. Other bins may be used as order bins 310 for accommodating one or more items picked to fulfill a specific customer order. It is contemplated that at least some of the order bins 310 are configured similarly to the bins described above (e.g., bins 110, 210) and have one or more of the features described above. For example, in some embodiments, order bins 310 may include the aforementioned internal guides to facilitate closing sub-bins 340.

[0080] System 300 further includes an order sub-box 340 that can be nested within the order box 310. The order sub-box 340 may be configured similarly to the sub-boxes described above (e.g., sub-boxes 140, 240) and may have some or all of the features described above. For example, the sub-box 340 includes a movable door and latching mechanism similar to those described above, and may also include the identification or temperature holding features described above.

[0081] In an exemplary approach, the various bins 305, 310 in system 300 are designed to have a common shape and size, and the various sub-bins 340 are designed to have a common shape and size. This largely facilitates any automation function of system 300 by providing standardized components for storing and transporting items. On one hand, the common shape and size of the respective bins facilitates the implementation of bin transfer system 312, which employs multiple mobile robots (discussed in further detail below) to transport bins between at least one bin storage structure 302 and workstation 315 of system 300. Additionally, the common shape and size of the sub-bins 340 can correspond to the conventional shape and size of outer bags or containers (e.g., customer-supplied reusable bags) to ensure the proper functioning of the unloading mechanism of sub-bins 340. While bins conforming to a common shape and size may be preferred in some cases, it should be recognized that the various concepts and features of system 300 are not, in principle, limited to a single bin design. System 300 can also use bins and sub-bins of different sizes and / or shapes, wherein various automation components of system 300 are designed to be compatible with different bins. For example, in some approaches, system 300 may include small, medium, and large bins to carry corresponding small, medium, and large items. In addition, sub-bins 340 of different sizes may be available in the system to correspond to different sizes of takeaway containers or bags (e.g., reusable bags of different sizes provided by the customer).

[0082] System 300 includes a bin storage structure 302 that provides structural support for storing bins and also for mobile robots operating therein. The bin storage structure 302 includes one or more multi-level storage rack structures and is generally configured to maximize the use of available cubic volume from floor to ceiling for storage rack modules, which are separated by aisles that provide access for the robot to different locations within the bin storage structure 302. The multi-level storage rack structure stores product bins 305 filled with inventory items. The bin storage structure 302 may also store empty bins and empty sub-bins that can be used as order bins 310 and order sub-bins 340 to fulfill customer orders. In some embodiments, the bin storage structure 302 may include multiple temperature zones, for example, to accommodate refrigerated and frozen foods as well as other items stored at room temperature.

[0083] System 300 also includes a bin transfer system 312, which may include various robots, carriers, conveyors, rails, tracks, or other transport structures. The bin transfer system 312 can be used in and between different parts of system 300 in various ways and implementations, such as in bin storage structure 302 or at picking station 315, for order unloading and for inputting bins back into the system. In embodiments, the bin transfer system 312 provides a unified system for transporting bins. In some embodiments, the bin transfer system 312 is fully or nearly fully automated. In some approaches, certain parts of the bin transfer system 312 may involve some manual operation. For example, in some approaches where orders are unloaded at a customer carrier or in certain parts of a store to a customer, personnel may transfer order bins 310 and order sub-bins 340 to or from the customer.

[0084] In an exemplary embodiment, the bin transfer system 312 includes an autonomous bin transfer mobile robot. In some ways, a transport structure (e.g., a guide rail or track structure) is included to guide the movement of the bin mobile robot. The transport structure may include multiple paths between or within the various parts of the system, allowing multiple bins to be transported by the mobile robot. One function is that the mobile robot is able to traverse the storage rack structure of the bin storage structure 302 and conveniently access and transport product bins 305 to one or more picking workstations 315, where items are picked to fulfill customer orders. Each mobile robot may be able to navigate and traverse the multi-level storage rack structure in all three dimensions (i.e., at any of multiple vertical levels, and along the horizontal width and length of the structure) to access any bin in a given storage rack structure. In some embodiments, the mobile robot travels horizontally on a planar transport platform that interconnects the rack structure and workstations 315, and vertically on vertical tracks or ramps that interconnect storage aisles and workstations 315 at multiple elevations.

[0085] Additionally, as further described below, the bin transfer system 312 may include one or more bin transfer or bin handling mechanisms to move bins into and out of their storage locations within the bin storage structure 302, and / or into and out of other parts of the system. For example, if the bin transfer system 312 includes multiple robots that transport bins, each robot may include a bin transfer mechanism to move bins into and out of the robot. For example, a bin transfer robot 312a may be used to pick product bins containing ordered items from storage shelves in the bin storer 302 using a bin transfer mechanism. The same bin transfer robot 312a may transport the picked product bins to picking station 315. The bin transfer mechanism of bin transfer robot 312a may be used to transfer the picked product bins from bin transfer robot 312a to picking station 315. In embodiments, the bin transfer mechanism may include an extendable arm or other gripper and may rotate and move along at least three axes to position or align bins during transfer.

[0086] The bin transfer robot 312a can also be used to transport order bins 310 and sub-bins 340 from bin storage structure 302 or from another location to picking station 315. For example, the bin transfer robot 312a can switch roles between handling product bins 305 or order bins 310 based on each transaction. In some approaches, the bin transfer robot 312a transfers order bins 310 with nested sub-bins 340 to picking station 315. In some embodiments, the bin transfer robot 312a can also be configured to nest the sub-bins 340 within the order bin 310 before delivering them to picking station 315. For example, the bin transfer robot 312a may have a bin transfer mechanism that includes picking the sub-bins 340 and nesting them within the order bin 310. In some approaches, the bin transfer robot 312a, which transfers bin 310 to workstation 315, does not nest bin 310 and sub-bin 340. In this approach, a nesting robot 330 can be used to nest the sub-bin 340 into the order bin 310.

[0087] At least some of the tasks performed by bin transport robots are typically round-trip transactions, consisting of two segments: the first segment involves removing bins from bin storage 302 and transporting them to a destination (e.g., a workstation), and the second segment involves returning the bins from the same or a different destination to bin storage 302. However, it should be noted that bins may be transported between multiple different destinations within the facility before returning to their storage location (e.g., between two different workstations, to an unpacking and transfer system, to a customer pickup location, etc.). Different bin transport robots 312 may perform different parts of the task. Typically, the bin transfer robot 312 travels carrying a bin payload.

[0088] System 300 further includes one or more picking stations 315 for picking one or more items to fulfill customer orders. In an embodiment, a product bin 305 corresponding to each of the ordered items and an order bin 310 containing nested sub-bins 340 therein are transported to the picking station 315. The station 315 may be manually operated, automated using one or more robotic pickers, or a combination thereof. In some embodiments, the station 315 includes a conveyor system that moves the order bins 310 and product bins 305 to a picking location, for example as described in U.S. Patent Publication No. 2018 / 0134492, published May 17, 2018, which is incorporated herein by reference in its entirety. The order bins 310 are presented to the picker in the same order as the product bins 305 arrive, such that each order bin 310 of a particular customer order can be filled before continuing to fill the next order bin 310. Ordered items are picked from product bin 305 and placed into sub-bins 340 nested within order bin 310 until all ordered items for the order are combined.

[0089] In some approaches, product bins 305, order bins 310, and sub-bins 340 nested within order bins 310 are presented to the picker in a predetermined order corresponding to the optimal insertion of one or more items when filling sub-bins 340. For example, as described above, one or more sub-bins 340 within order bins 310 may be configured (e.g., with insulation and / or inserts) to store items at refrigerated or frozen temperatures. Thus, for example, the picking sequence may be predetermined such that refrigerated or frozen items are picked into sub-bins configured to store refrigerated or frozen items, and temperature-insensitive items are picked into sub-bins designated for storage at room temperature. In one or more cases, this may be advantageous for several reasons. First, for example, sub-bins may help maintain the temperature of any temperature-sensitive items throughout the remainder of the order fulfillment process, including when order bins 310 and sub-bins 340 are temporarily stored in order storage structure 318 after order picking and before unloading (further described below). Secondly, for example, items picked from sub-bins 340 can ultimately be unloaded directly from the bottom of sub-bins 340 into bags for customers to take home, with each sub-bin 340 being generally sized so that its contents can fit into a single bag, as described below. Therefore, grouping items together by temperature into each sub-bin 340 will result in the takeaway bag also containing items grouped together by temperature. Thus, for example, refrigerated or frozen items picked from a sub-bin 340 configured to store refrigerated or frozen items will be unloaded together into the takeaway bag, which helps keep the items refrigerated when transported home. Note that even without using sub-bins 340 specifically configured to store refrigerated or frozen items, refrigerated or frozen items can still be generally grouped together in sequence when they are picked into sub-bins.

[0090] Additionally, since items picked from sub-bins 340 can be directly unloaded from the bottom of sub-bins 340 into takeaway bags, the sorting of product bins can be optimized to provide other desired filling results. For example, in one approach, when determining the order in which items are placed into sub-bins 340, the sorting can consider fragile items (e.g., eggs) or heavy items. For example, fragile items can be placed in separate sub-bins, or picked last in the sub-bins so that they are at the top in both the sub-bins and takeaway bags. Large or heavy items can be picked into the sub-bins first, so that they are at the bottom in both the sub-bins and takeaway bags. In other embodiments, one or more items, such as but not limited to fragile items, can be prevented from being inserted into the sub-bins. In some embodiments, fragile items can be prevented from being inserted into the sub-bins when a threshold percentage is predicted to cause damage to the fragile items if they fall from the sub-bin into the bag or container.

[0091] In some embodiments, the sorting of sub-boxes 340 begins before the order box 310 is presented to the picker to ensure that different types and quantities of sub-boxes (e.g., refrigerated or frozen sub-boxes) can be nested within the order box 310 in the correct order. For example, system 300 may determine the volume and / or number of refrigerated or frozen items included in the order and determine how many refrigerated or frozen sub-boxes and how many standard sub-boxes are needed to determine the picking order for the order. Sub-boxes 340 can then be nested or further nested within the order box 310 to correspond to the quantity of different types of sub-boxes 340 required for the order and the thus determined picking order.

[0092] Other features and mechanisms associated with picking individual items at a picking workstation that may be incorporated herein include: U.S. Patent Publication No. 2018 / 0305123, published October 25, 2018, with U.S. Application Serial No. 15 / 956346, filed April 18, 2018, entitled "Picking workstation with mobile robots & machine vision verification of each transfers performed by human operators"; and U.S. Patent Publication No. 2018 / 0247257, published August 30, 2018, with U.S. Application Serial No. 15 / 903993, filed February 23, 2018, entitled "Inventory management system and method". The following patents are incorporated herein by reference: U.S. Patent Publication No. 2020 / 0223630, published on July 16, 2020, with U.S. Application Serial No. 16 / 742119, filed on January 14, 2020, entitled “System having workstation with tote retention and release mechanism”; and WO Publication No. 2022 / 133353, published on June 23, 2022, with PCT Application No. PCT / US2021 / 064424, filed on December 20, 2021, entitled “Methods and apparatus for facilitating transport of items between a store and a customer via a customer access location”, each for all purposes, hereby incorporated herein by reference in its entirety.

[0093] In some embodiments, the order fulfillment system 300 may further include an output or unloading system 320, which includes one or more unloading locations 322 or stations to unload orders into takeaway bags or containers. In some embodiments, the unloading location 322 may be located at a customer pickup location and may provide customers with at least one pickup point to collect their ordered items. Picked order bins 310 may be transported to the unloading location 322 via a bin transfer system 312, for example, via an autonomous bin transfer mobile robot 312b and / or a conveyor. In some cases, the bin transfer robot 312b is configured to transport a single order bin 310 to the unloading location 322; in other examples, the bin transfer robot 312b may include a carrier that supports transporting multiple picked order bins 310 to the unloading location 322 at a time.

[0094] In some embodiments, unloading point 322 may be located at a customer pickup location, which may be located in the customer-facing portion of an order fulfillment facility or store. In some approaches, a customer pickup location may be present within the store where customers can collect their orders. At unloading point 322, orders may be unloaded from order bin 310 into takeaway bags or containers, including reusable bags provided by the customer. In one approach further described below, ordered items may be unloaded directly into a shopping cart (e.g., at the customer pickup location or in another area of ​​the facility or store) or into bags or containers within the shopping cart. This can be useful for customers as it provides a time-saving process for transporting their orders from the store to their carrier. Additionally, in some embodiments, customers may have the option to pay for their order at a point-of-sale checkout in the store after receiving the ordered items in their shopping cart.

[0095] Alternatively or concurrently, there may be an unloading location 322 or a customer pickup location with access to an outdoor vehicle pickup area. For example, some designs for a customer pickup location may include a customer driving their vehicle into the unloading location or customer pickup location and then receiving their order directly at their vehicle without entering the store. As further described below, in some embodiments, the unloading location 322 may simply be a parking space for the vehicle or a designated area outside the store (e.g., a “curbside pickup point”) where orders can be transported and unloaded directly at the customer’s vehicle.

[0096] In some cases, filled order bins 310 (i.e., where nested sub-bins 340 are filled with picked items) can be temporarily stored in the order storage structure 318. For example, bins 310 can be transported directly from picking station 315 to order storage structure 318. Order storage structure 318 can be used to store multiple order bins 310 for several customers expected to arrive and pick up their orders around the same time, or if orders have been picked before customer arrival. Order storage structure 318 can be used to reduce transport time for order bins 310 to unloading location 322. This can be particularly advantageous during "peak hours" when many customers come to pick up their ordered items. For example, order storage structure 318 may include multiple shelves, each supporting multiple order bins 310 for multiple customers. The shelves may be positioned near or at unloading location 322 so that once one customer picks up their order, the next customer can quickly follow suit. In another example, the order storage structure 318 may be one or more shelves that define a buffer space near or located at the unloading point 322, which is accessible to robots or personnel.

[0097] When the order storage structure 318 is located in an area separate from the unloading location 322, it is preferably nearby to reduce delivery time. The order storage structure 318 may include one or more multi-level storage rack structures similar to those used in the main bin storage structure 302. In some embodiments, an autonomous bin transfer robot may transport bins to and from the order storage structure 318 in a manner similar to that performed in the main bin storage structure 302. In some embodiments, picked order bins 310 may instead be stored in the main bin storage structure 302 awaiting pickup before being transported to the unloading location 322.

[0098] In some embodiments, the order storage structure 318 and any storage structure at the unloading location 322 may be configured to store filled order boxes 310, in which sub-boxes 340 are nested, at different temperatures. For example, the order storage structure 318 may have different temperature zones (e.g., a room temperature zone, a refrigerated zone, and / or a frozen zone). Based on their item contents, order boxes 310 and sub-boxes 340 may be transported to the appropriate area of ​​the order storage structure 318 until customer pickup. However, in other cases, the order storage structure 318 may not include different temperature zones because refrigerated or frozen items are picked into different types of sub-boxes 240, which, as described above, are configured to maintain refrigerated or frozen temperatures during order storage.

[0099] In some scenarios, system 300 may be configured to transport the filled order bin 310 from order storage structure 318 to unloading location 322 while the customer is en route to the store or before a designated pickup period, thus reducing the amount of time the customer waits for their order. In some scenarios, the filled order bin 310 is transported from order storage structure 318 to unloading location upon receiving an indication that the customer has arrived at the store or unloading location 322. If the customer does not pick up the order as expected, the order bin 310 may be moved back to order storage structure 318. In some scenarios, the order bin 310 may remain in order storage structure 318 for a maximum period of time without being picked up by the customer before the order is cancelled.

[0100] In some embodiments, the output / unloading system 320 may be a partially automated or substantially fully automated system. For example, as described above, the order bin 310 may be automatically moved to and from the unloading location 322 via a mobile robot and / or other transport elements (e.g., the conveyor system of the bin transfer system 312). In this way, the output / unloading system 320 can reduce the amount of labor required to operate the order fulfillment system 300. For example, in some embodiments, orders can be unloaded to customers without the assistance of any personnel.

[0101] In some embodiments, the customer pickup location or unloading location 322 includes an unloading mechanism for unloading orders from sub-bins 340 into takeaway bags or containers. The unloading mechanism may include bin locations 322a and container locations 322b, which are adjacent to each other to process the unloading of one order at a time. Bin location 322a temporarily stores filled order bins 310 ready for unloading. In some approaches, a bin transfer system 312 transports order bins 310 to bin location 322a. Bin location 322a has a support structure for supporting the order bins 310, such as a raised platform, table, workstation, or even a floor. In one approach, the order bins 310 remain on a bin transfer robot 312b (see [link to relevant documentation]). Figure 20 And the bin transfer robot 312b supports the order bin 310 at bin location 322a. For example, as Figure 20 As shown, according to some embodiments, the exemplary mobile bin transfer robot 312b may have a platform with a holding structure that supports and holds a single order bin 310. The holding structure is open at the top, allowing a sub-bin 340 to be lifted from the bin 310 and removed to allocate the order to a bag or container 399.

[0102] Bags 399 and / or other types of containers for customers and / or other individuals to pick up their orders (e.g., to take the orders home) may be positioned at container location 322b near bin location 322a. In some embodiments, a human worker or robot prepares several bags or containers, which may correspond to several sub-bins 340 including the order. The bags or containers may be set sequentially or all at once at container location 322b. When using the bags, the worker or robot may position the bags so that they are fully open on top. In some embodiments, a blow-bag system 326 may be used, which blows air into the bags during order unloading to keep the bags in the proper open position.

[0103] Once bin 310 is at bin location 322a and the corresponding bag or container is at the adjacent container location 322b, a human worker or robot can unload items from each sub-bin 340 into the corresponding bag or container. In an exemplary unloading mechanism, a human worker or robot removes the sub-bin 340 from bin 310, positions and holds the sub-bin 340 at a predetermined location and / or directly above the outer bag or container (e.g., based on sensor data, such as, but not limited to, image processing, distance measurement, etc.), and actuates one or more latching mechanisms of the sub-bin 340 to open one or more bottom doors, releasing the items contained in the sub-bin 340 into the aligned bag or container. In some cases, the sub-bin 340 may be partially inserted into and / or slid into the bag or container to ensure alignment and to ensure that the items are caught by the bag or container. At least for items stored in sub-bins, workers or robots continue to unload items from one or more order bins 310 into additional takeaway bags or containers until the customer order is completed. The takeaway bags or containers can then be provided to the customer to take home.

[0104] In some embodiments, the bags or containers may include standard plastic bags or brown paper bags. However, in particularly advantageous embodiments, reusable bags provided by the customer may be used. In these embodiments, for example, the customer provides the reusable bags to staff at the unloading point or customer pickup point 322 before the items are unloaded from sub-bin 340. Alternatively or additionally, the customer may carry the bags or containers, and the customer may position the bags and / or containers in alignment with the sub-bin (e.g., feedback may be provided to the customer and / or staff based on sensor data when detecting alignment between the sub-bin and the bag or container). In some cases, the customer may have the option to purchase bags, containers, and / or reusable bags and then use them to fulfill the order. By some means, if the customer does not provide enough reusable bags for all ordered items, the remaining ordered items may be unloaded into standard plastic or paper bags and / or other relevant containers provided by the system and / or purchased by the customer. Other types of containers (e.g., cardboard containers, refrigerated boxes, etc.) are also conceivable.

[0105] As explained above, the sub-bin 340 may be sized to have a volume substantially corresponding to the expected and / or predefined volume range of one or more types of conventional customer reusable bags or containers, but typically slightly smaller, to ensure that items in the sub-bin 340 are reliably contained within the bags or containers. In some embodiments, the system 300 may also provide variable-sized sub-bins 340, sized to accommodate variable-sized customer reusable bags. In some embodiments, in order to participate in the order fulfillment system 300 described herein, a customer may be instructed to bring or provide a specified type and quantity of reusable bags.

[0106] In some embodiments, the output / unloading system 320 may include a disinfection or decontamination station 325 to decontaminate sub-bins 340 and / or bins 310. For example, in embodiments employing customer-supplied reusable bags or containers, sub-bins 340 may be contaminated. Customer-supplied reusable bags or containers may be contaminated with unknown contaminants, and during item unloading, the bottom and / or sides of sub-bins 340 may become contaminated with such contaminants through contact with the reusable bags or containers. Additionally, in some cases, workers or customers may physically touch one or more of sub-bins 340 or bins 310 during order unloading, which may contaminate sub-bins 340 or bins 310 with pathogens.

[0107] In some approaches, the outer surface of the sub-bin 340 may be decontaminated before being placed back into the order bin 310, with the assistance of human workers, robots, and / or other machinery. For example, a disinfection station 325 may include food safety disinfectant fluids, soaps, disinfectants, etc., which are sprayed or otherwise disposed onto at least the outer surface of the sub-bin 340. In some embodiments, the disinfection station 325 includes a conveying system that moves the bin through a washing and / or disinfection cycle (e.g., similar to a dishwasher), and / or may include a drying subsystem to dry the sub-bin 340 before it is placed back into the order bin 310. In some approaches, the sub-bin 340 may be disinfected when placed into the bin 310. In some embodiments, one or more ultraviolet (UV) light sources are used to irradiate the various surfaces of the sub-bin 340. In some configurations, the sub-bin 340 may be transported via a mobile robot or conveyor system through a decontamination module containing a UV light source. The sub-bin is exposed to UV light for a sufficient period of time to disinfect the surface. Generally, the overall size or length of the decontamination module can vary depending on the speed of the robot or conveyor and the intensity of the UV light emitted by the UV source. In some implementations, the speed at which the robot travels through the decontamination module can be varied to ensure that the sub-bin 340 is exposed to UV light for a sufficient period of time.

[0108] In some ways, the order bin 310 may also be decontaminated, for example, in a manner similar to that described above with respect to the order sub-bin 340. For example, this may occur within the output / discharge system 320, such as at the disinfection station 325, or in a separate disinfection system 332 within the input system 328.

[0109] In some approaches, when sub-bin 340 is emptied, a human worker or robot returns it to its original position in bin 310 and / or inserts it into a different bin. In some embodiments, such as where sub-bin 340 has a latching mechanism similar to the latching mechanism described above with respect to sub-bin 240, and bin 310 includes a guide for guiding the closing of the door of sub-bin 340, this action simultaneously closes and re-latches the door of sub-bin 340. This approach eliminates the need for separate steps or mechanisms to close and re-latch the door of sub-bin 340.

[0110] In other approaches, sub-bin 340 is not immediately returned to bin 310, but is nested again within bin 310 after being circulated through input system 328. In some approaches, a human worker or robot may close the door of sub-bin 340 after the order is unloaded, and sub-bin 340 and / or bin 310 are transported to input system 328 via bin transfer system 312, where they are nested again at a later stage. Through this approach, decontamination of sub-bin 340 (and / or bin 310) can be performed later in the process (e.g., in input system 328). In other embodiments, sub-bins may be stacked for subsequent use. Furthermore, in some embodiments, sub-bins may include one or more door closing guides 295, similar to those described above, to cause one or more doors to close when stacked into another sub-bin.

[0111] The output / unloading system 320 can also be configured to unload orders directly from the sub-bin 340 into a shopping cart or into bags or containers within the cart. That is, the container location 322b is located inside the shopping cart, allowing the cart to be transported to the unloading location 322. Unloading orders into the shopping cart allows customers to process and pay for their orders at traditional point-of-sale checkouts in the store. Furthermore, unloading orders into bags within the shopping cart provides customers with an easy way to transport their orders from the store to their carrier.

[0112] The output / unloading system 320 can be configured such that the final unloading location 322 is located at the customer carrier. The order bins 310 and sub-bins 340 for a specific customer order can be transported directly from the picking station or order storage structure 318 to the carrier, or they can be transported first to an intermediate order storage area in the store, where human staff can be responsible for transporting the order to the customer carrier.

[0113] For example, staff can use trolleys or flatbed trucks to transport order bins 310 and sub-bins 340 to a carrier. The carrier can be located at a curbside pickup point or a designated space within a parking lot. Once at the carrier, human staff can unload the ordered items from the sub-bin 340 into a carry-on bag or container by opening the bottom door of the sub-bin 340 as described above. In some cases, the bag or container is provided by the customer at the carrier and can be placed in the trunk of a vehicle, on the ground, or in a trolley or flatbed truck to receive the items from the sub-bin 340. After unloading the order, human staff return the empty bins 310 and empty sub-bins 340 to the facility and transfer them to bin transfer system 312 and / or input system 328. As explained above, in some ways, at least the empty sub-bin 340 can be decontaminated before being nested back into the bin 310, for example, at a designated discharge point 322 within the store or within the disinfection system 332 in the input system 328.

[0114] As described above, in some embodiments, the output / unloading system 320 can be almost fully automated, requiring minimal assistance from human workers or shop assistants to the unloading mechanism. For example, in some approaches, an unloading robot system 324 is used at the unloading location 322. For example, in one approach, such as... Figure 20 As shown, bin transfer robot 312b or other bin transfer robots of bin transport system 312 may support a single bin 310 containing nested sub-bins 340 at bin location 322a. Unloading location 322 may include one or more unloading robots of unloading robot system 324 that remove sub-bins 340 from bin 310, position and align sub-bins 340 above a bag or container located at container location 322b, and actuate latching mechanisms on sub-bins 340 to open doors and release ordered items from sub-bins 340 into bags or containers.

[0115] In embodiments, the unloading robot may be a mobile robot and may include one or more sub-bin grippers (e.g., movable arms) controlled by system 300 to engage and remove sub-bins 340 one by one from order bin 310. For example, the unloading robot may be positioned near bin locations 322a and container locations 322b, and the sub-bin grippers may extend laterally (e.g., toward the top of the sub-bin) or from above toward the sub-bin. In some embodiments, multiple sub-bin grippers extend to grasp handles of sub-bins 340. In this approach, the height of sub-bins 340 may be slightly higher than bin 310 to allow easy access to the handles. In some embodiments, the sub-bin may include other gripping portions, such as flanges, surface variations, knobs or other protrusions, levers, grooves or other recesses, etc., configured to be engaged by the sub-bin grippers. In some embodiments, the unloading robot is a 6-axis articulated robot. Once the sub-box 340 is gripped, the unloading robot is controlled to remove the sub-box 340 upward from the box 310, translate the sub-box 340 so that it is aligned above the bag or container at the adjacent container location 322b, and in some embodiments, lower the sub-box 340 until it is partially received in the bag or container.

[0116] In some approaches, the unloading robot lifts the sub-box 340 into position at container location 322b, and a human worker, robot, or customer positions a bag or container beneath the sub-box 340. The human worker, unloading robot, or customer can actuate a latching mechanism to release items into the bag or container. In another approach, the unloading robot lifts the sub-box 340 into position at container location 322b, and a container or bag is configured to pass sequentially beneath the sub-box 340, for example, via a conveyor system, to align with it. In this approach, when the bag or container is aligned with it, the unloading robot actuates a latching mechanism to release items into the bag or container.

[0117] In some approaches, the bag or container may be positioned at container location 322b by a human worker or a robot. As described above, a blow-bag system 326 may be used to blow air (e.g., one or more streams of air) into the bag at bin location 322b to fully open the bag and receive the items released from sub-bin 340.

[0118] Sensors may be included as part of the automated unloading mechanism using an unloading robot. Sensor systems may include one or more motion sensing systems, identification readers (e.g., barcode readers, QR code readers, radio frequency identification (RFID) tag detectors), cameras, image processing systems, weight sensor systems, accelerometers, gyroscopes, other such sensor systems, or combinations of two or more such sensor systems. The examples above are intended to be illustrative and are not intended to provide an exhaustive list of all possible sensor systems. Instead, it will be understood that these teachings will be suitable for sensing any of a variety of situations in a given application environment. For example, sensors may be used to align the unloading robot's sub-bin gripper with sub-bin 340 and precisely align sub-bin 340 (or specifically, the bottom section of the sub-bin) above the bag or container before releasing the latch mechanism.

[0119] In one exemplary embodiment, a release sensor having one or more of the above sensing mechanisms is communicatively coupled to an unloading robot. The release sensor is configured to detect a threshold alignment between the bag or container and a sub-bin or its door. When the threshold is reached, the unloading robot triggers a latching mechanism to open the door. The unloading robot may include an arm extending from a sub-bin gripper, or a separate arm configured to apply force to a trigger of the latching mechanism (e.g., at the sub-bin handle) to open the door.

[0120] After dispensing items from sub-bin 340 into containers or bags, the unloading robot may return sub-bin 340 to its initial nesting position in bin 310, or, as detailed above, move sub-bin 340 to sterilization station 325 for automatic decontamination before returning it to bin 310 (by the unloading robot or a different robot). As mentioned above, in some embodiments, sub-bin 340 may not be nested back into bin 310 in output / unloading system 320 and may instead be transported separately to input system 328.

[0121] In some embodiments, as the unloading robot returns sub-bin 340 to its initial position in bin 310, the same action simultaneously closes and re-latches the bottom door of sub-bin 340. This may occur, for example, in embodiments where sub-bin 340 has a latching mechanism similar to that described above with respect to sub-bin 240, and bin 310 includes a guide for guiding the closing of the door of sub-bin 340. In this manner, no separate step or mechanism is required to close and re-latch the door of sub-bin 340. However, in other embodiments, the bottom door may be closed by a robot or by a human worker.

[0122] The unloading location or customer pickup location 322 may include a customer interface to facilitate interaction between the customer and the unloading location 322. The user interface may be a physical device (e.g., a terminal) located at the unloading location 322. For example, the user interface may generally include a display, scanner, microphone, camera, keyboard, and / or speaker. When a customer arrives at the unloading location 322, they may scan or enter an order number, product code, or credit card, which in turn initiates steps to fulfill the order (e.g., transporting the filled order container 310 from the order storage 318 to the unloading location 322, or initiating the aforementioned unloading mechanism). It should be appreciated that in some embodiments, the unloading location 322 may not include a user interface. Instead, the customer may access a software application installed on the customer's computer or mobile device (e.g., a mobile phone or smartphone).

[0123] In some pathways, customers cannot access or view the area where the unloading mechanism at the unloading location or customer pickup location 322 occurs. Preventing customers from accessing the automated area of ​​unloading location 322 ensures the safety and reliability of the automation for the customer. Customers may provide any customer-supplied bags for the unloading mechanism, for example, for human workers, for conveyor systems, or for containers transported to the unloading mechanism area.

[0124] In some embodiments using the unloading robot system 324 as described above, the unloading mechanism does not occur at the carrier (i.e., externally). However, in some embodiments, the unloading location 322 may be located within the facility, such that windows and / or doors provide convenient access to customer carriers arriving at the pickup station. Customers can provide bags through doors or windows, and after the unloading mechanism via the unloading robot system 324, the filled bags can be provided to the customer through windows and / or doors for placement in the carrier. In some embodiments, the filled bags can be delivered directly to the carrier by human staff. Similar approaches may also be used for unloading locations 322 that do not employ the unloading robot system 324.

[0125] As described above, after an order is unloaded, empty bins 310 and sub-bins 340 are imported back into system 300 via input system 328 for availability in future orders (or other purposes). Input system 328 can also be used to input new bins into system 300. In an embodiment, input system 328 includes empty bins 310 and sub-bins 340 transported from unloading location 322 to input station 329 and / or directly returned to bin storage 302 by bin transfer system 312 (e.g., bin transfer robot 312c and / or conveyor system). For example, at input station 329, empty bins 310 and sub-bins 340 may be picked up by different bin transfer robots, which transport the empty bins 310 and sub-bins 340 to bin storage structure 302.

[0126] As described above, the input system 328 may include a disinfection system 332 (e.g., disinfection station 325 as described above) that disinfects or decontaminates bins 310 and / or sub-bins 340 returned to the system. The input system 328 may also include a nesting robot 330 that can nest the sub-bins 340 back into the order bin 310 if this was not completed at a previous stage (e.g., at unloading point 322). In some approaches, the nesting robot 330 may nest the sub-bins 340 according to the next order to be fulfilled (e.g., as described above, selecting the appropriate sub-bin 340 type based on the temperature-sensitive items in the order and ordering the nesting of the sub-bins accordingly). In some embodiments, the input system 328 is located near the bin storage structure 302.

[0127] Figure 21A simplified flowchart of an exemplary order fulfillment process 400 according to some embodiments is shown. In some embodiments, the order fulfillment process 400 can be used in any of the systems described above (e.g., systems 100, 200, 300). At step 405, a sub-bin is inserted into an order bin such that the sub-bin is nested within the order bin. As described above, nesting can be accomplished by a nesting robot or other bin transfer robots configured to engage with the sub-bin. Nesting can also be performed manually or by one or more robot nesting systems. In some embodiments, nesting occurs when the order bin and sub-bin are entered into the system and bin storage structure. As described above, nesting can also occur when the sub-bin and bin are re-nested after the order has been unloaded from the sub-bin into a container or bag. Nesting or re-nesting can also occur when the next fulfilled order determines that the order requires a different type (e.g., refrigerated or frozen sub-bin) or number of sub-bins and the order in which the sub-bins are presented to the picker. That is, in response to a particular customer order, sub-bins are selected, sorted, and nested accordingly within the bin.

[0128] At step 410, product bins, order bins, and sub-bins storing one or more items are transported to the workstation. This can be achieved via the bin transfer system described above. In some approaches, the transport is carried out via at least one mobile robot (e.g., a bin transfer robot) controlled by robot control circuitry. Specifically, the bin transfer robot can remove product bins containing items fulfilling orders from the bin storage structure and transport the product bins to the workstation. The bin transfer robot can also transport nested order bins and sub-bins from the bin storage structure, from the input system, to the workstation or other locations within the facility. In some approaches, the process does not involve robots. For example, human workers can transport product bins and nested order bins and sub-bins to the workstation.

[0129] At step 415, at the workstation, at least one ordered item is picked from one or more items stored in the product bin. A first sub-bin nested within the first order bin is filled with at least one ordered item. If the order includes more ordered items that can fit into more than one sub-bin, optional step 420 includes picking at least one additional ordered item from one or more items stored in the product bin at the workstation and filling a second sub-bin with at least one additional ordered item, and, if necessary, filling additional sub-bins nested within the first order bin and any additional order bins nested within it. This continues until all ordered items intended to be placed in the sub-bins have been picked and placed in them. Some embodiments include optional step 422, where the order bin and one or more sub-bins can be transported to the order unloading location or customer pickup location. For example, the bin can be transported via a bin transfer system, which may include, for example, one or more bin transfer robots, conveyors, other such transfer systems, or a combination of two or more such transfer systems.

[0130] In some embodiments, the order fulfillment process 400 may include an optional step 423, in which bags and / or containers are received. In some cases, this may include receiving bags or containers (e.g., reusable) provided by a customer's customer. At the order unloading location, one or more bags and / or containers may be arranged in an open configuration to prepare for sequential receipt of ordered items from one or more sub-bins.

[0131] At step 425, a “filled” sub-box containing one or more items is removed from its corresponding order box. At step 430, the filled sub-box is positioned above a container or bag (e.g., a takeaway container or bag), and / or positioned at a predetermined location to allow alignment of the bag or container. The bag or container may have been previously positioned at the predetermined location and is positioned in response to the positioning of the sub-box and / or other such operations. One or more sensors provide feedback to establish alignment between the sub-box and the bag (e.g., a user interface, lighting, laser, audio, and / or other such feedback may be provided to help guide alignment). At step 435, at least one ordered item is released from the filled sub-box into the container by opening at least one bottom compartment of the filled sub-box. In some embodiments, step 435 includes actuating or moving a first latch mechanically coupled to at least one bottom compartment from a latched position to an unlocked position (e.g., via an actuator fixed to the body of the first sub-box and mechanically coupled to the first latch), which moves at least one bottom compartment from a closed position to an open position. In some embodiments, the actuator is biased in the unacted position to hold the first latch in the unlatched position and is movable to the actuated position in response to an external force applied to the trigger to cause the first latch to move to the unlatched position. Actuating the actuator to move the first latch to the unlatched position may include a trigger, button, lever, etc., that moves the actuator; in some cases, the actuator is movably fixed to the first handle of the sub-bin. In some embodiments, there may be two bottom doors that can be opened and closed. In some approaches, as described above, two or more latches, two or more actuators, and / or two or more triggers located at opposite ends of the sub-bin unlock one or more bottom doors to allow two or more doors to open. At step 440, if the order has not yet been completed, one or more of steps 425, 430, and 435 may be repeated until the sub-bin associated with the order has unloaded the ordered items into a continuous container or bag 199. In some embodiments, the order fulfillment process 400 may include an optional step 442, wherein one or more bottom sections of the sub-box can be closed and / or latched by inserting the sub-box back into the order box. In some embodiments, this re-latching may be achieved via an extension pin positioned on at least one bottom section engaging a guide positioned along a portion of the inner surface of the box, wherein the guide guides the extension pin to move one or more bottom sections from an open position to a closed position when the sub-box is nested into the box.

[0132] At step 445, when it is determined that the order is completed (at least for those items picked from the sub-bins), the process may proceed to step 450. In optional step 450, one or more sub-bins and / or bins may be cleaned, disinfected, and / or decontaminated. For example, the internal and / or external surfaces of the sub-bins may be cleaned and / or disinfected before nesting the sub-bins back into the bins. This step is advantageous, for example, when the containers or bags are provided by the customer, to mitigate the transfer of unknown contaminants from the containers or bags to the system via the sub-bins that may come into contact with the containers or bags during the unloading mechanism. In some embodiments, the master bin is disinfected additionally or alternatively. Disinfection step 450 may be fully automated or may include at least some human assistance and may include the disinfection methods described above. In optional step 455, one or more sub-bins may be returned / re-nested into the corresponding order bins, and the sub-bins and order bins may be imported back into the system and / or storage structure for storage, sent to a workstation to fulfill additional orders, and / or sent to another location within the system.

[0133] In different approaches, steps 425-435 may be performed by a human worker, one or more robots, or a combination of both. These approaches have been described above with respect to systems 100, 200, and 300.

[0134] In some embodiments, steps 425-435 are performed via one or more unloading robots. For example, the unloading robot's sub-bin gripper engages with and removes the sub-bin from the order bin, and positions the sub-bin above the container. When positioned and correctly aligned, the unloading robot may also actuate actuators on the sub-bin to move a latch to an unlocked position to open at least one bottom section and release the ordered item from the sub-bin into the container. In some embodiments, sensors are used to provide feedback to align and / or ensure that the sub-bin is correctly aligned with the container. For example, the method may include sensing a threshold alignment of the container and the sub-bin via a release sensor communicatively coupled to the unloading robot, and in response to the sensing, triggering the unloading robot to actuate actuators to move a first latch to an unlocked position to open at least one bottom section, and / or providing confirmation to a user. The method may also use a blow-bag system. When the container is a bag, the blow-bag system may be configured to blow air into the bag to more fully open the bag when the first sub-bin is positioned and aligned with the container, so as to align the opening of the bag with the sub-bin.

[0135] Figure 22A simplified flowchart of an exemplary order fulfillment process 500, which unloads an order at a customer carrier according to some embodiments, is shown. In some embodiments, the order fulfillment process 500 may be used in any of the systems described above (e.g., systems 100, 200, 300) and may have steps similar to those described above with respect to order fulfillment process 400.

[0136] At step 505, one or more items associated with the order are picked, and one or more sub-boxes nested within one or more order boxes are filled with the one or more items. At step 510, the one or more sub-boxes nested within one or more order boxes are transported to the vicinity of the customer carrier associated with the order or to an unloading point at the customer carrier. At steps 515 and 520, the sub-boxes are removed from their respective order boxes and positioned above containers or bags at the customer carrier. At step 525, one or more items associated with the order are released from the sub-box into containers or bags by opening at least one bottom section of the sub-box. At step 530, if the order has not yet been completed, one or more of steps 515, 520, and 525 may be repeated until the sub-boxes associated with the order have unloaded the ordered items into consecutive containers or bags. At step 535, when the order items held in the sub-bin have been picked and it is determined that the order is completed at least with respect to the items stored in the sub-bin, in some embodiments the process may proceed to step 540, or in some cases, return to step 515 if incomplete. In step 540, the sub-bin may be returned to the bin, and the sub-bin and order bin may be imported back into the system for storage to fulfill additional orders and / or other functions.

[0137] In some embodiments, order fulfillment process 500 may include receiving customer-supplied (e.g., reusable) bags or containers from the customer and arranging them at a carrier for sequential receipt of ordered items from sub-bins. As described above with respect to at least the above order fulfillment process 400, in some approaches, order fulfillment process 500 may also include cleaning and / or disinfection steps to clean, disinfect, and / or decontaminate one or more sub-bins (e.g., sub-bins that come into contact with customer-supplied containers or bags). In some approaches, both the bin and the sub-bins may be disinfected after the order is unloaded to the customer (e.g., when the unloading step occurs externally). Order fulfillment process 500 may also include one or more other steps described above with respect to order fulfillment process 400. For example, the bottom section of the sub-bin may be opened and closed as described above.

[0138] Figure 23A simplified flowchart of an exemplary order fulfillment process 600 according to some embodiments is shown, which unloads orders into shopping carts, trolleys, mobile shelves, and / or other transport devices. In some embodiments, order fulfillment process 600 may be used in any of the systems described above (e.g., systems 100, 200, 300) and may have steps similar to those described above with respect to order fulfillment processes 400 and 500.

[0139] At step 605, one or more items associated with the order are picked and placed into one or more sub-boxes. The one or more sub-boxes are already nested within the order box, or the sub-boxes can be inserted into and / or nested within one or more order boxes. Typically, the workstation's control circuitry and / or central control circuitry obtains identification information for one or more order boxes and / or sub-boxes and associates them with the order. At step 610, the one or more sub-boxes nested within the one or more order boxes are transported to the order unloading station or order unloading location. At step 615, one or more shopping carts are transported to the order unloading station. Optionally, bags or containers are also transported to the order unloading station and arranged in an open configuration in the shopping cart (or on a wheeled shelf, trolley, and / or other such transport device).

[0140] At steps 620 and 625, the sub-box is removed from its corresponding order box and positioned above the shopping cart, or above a container or bag within the shopping cart. At step 630, one or more items associated with the order are released directly from the sub-box into the shopping cart or a container or bag within the shopping cart by opening at least one bottom door of the sub-box. At step 635, steps 620, 625, and 630 may be repeated until the sub-box associated with the order has unloaded the ordered items into one or more shopping carts, or into a series of containers or bags within one or more shopping carts, wheeled shelves, trolleys, etc. At step 640, the order is determined to be complete, at least for the ordered items held in the sub-box. At step 645, the empty sub-box is processed. The handling of empty sub-boxes may include one or more of the following: returning one or more sub-boxes to their respective order boxes and importing the empty sub-boxes and order boxes back into the system for storage or fulfilling additional orders; cleaning and / or disinfecting one or more sub-boxes; transporting one or more sub-boxes to a sub-box storage area for later use (e.g., receiving one or more items at an unpacking and transfer station); other such handling; or a combination of two or more of such handling.

[0141] In some embodiments, the order fulfillment process 600 may further include step 650, in which a filled shopping cart containing the ordered items and / or a bag containing the ordered items may be provided to the customer, transported to the customer, and the bag and / or container may be provided to the customer, and / or other such actions may occur. In some approaches, the method may include processing and receiving payment from the customer for the ordered items in the shopping cart at a point-of-sale cash register.

[0142] In some embodiments, order fulfillment process 600 may include receiving customer-supplied (e.g., reusable) bags or containers from the customer and arranging them in an open configuration in a shopping cart to sequentially receive ordered items from sub-boxes. As described above at least with respect to order fulfillment process 400, in some approaches, order fulfillment process 600 may also include a sterilization step to ensure that any sub-boxes that have come into contact with the customer-supplied containers or bags are decontaminated. In some approaches, both the cartons and sub-boxes may be sterilized after the order is unloaded. Order fulfillment 600 may also include many other steps described above with respect to order fulfillment process 400. For example, the bottom section of the sub-box may be opened and closed as described above.

[0143] Those skilled in the art will recognize that one or more steps in processes 400, 500, and 600 may be omitted, repeated once or multiple times, implemented in a different order, and / or other such modifications. Similarly, some or all steps in processes 400, 500, and 600 may be implemented as part of one or more other processes in processes 400, 500, and 600.

[0144] Furthermore, the circuits, circuit systems, systems, devices, processes, methods, techniques, functions, services, servers, resources, etc., described herein can be used, implemented, and / or operated on many different types of devices and / or systems. Figure 24 An exemplary system 700 is shown that can be used to implement any component, circuit, circuit system, system, function, device, process, or apparatus of the order fulfillment system 300, and / or other systems or apparatus mentioned above or below, or portions of such circuits, circuit systems, functions, systems, devices, processes, or apparatuses. However, the use of system 700 or any part thereof is certainly not necessary.

[0145] For example, system 700 may include one or more control circuitry or processor modules 712, one or more memories 714, and one or more communication links, paths, buses, etc. 718. Some embodiments may include one or more user interfaces 716, and / or one or more internal and / or external power supplies or power supply devices 740. Control circuitry 712 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 control various communications, decisions, programs, content, lists, services, interfaces, logging, reporting, etc. Furthermore, in some embodiments, control circuitry 712 may be part of a control circuitry system and / or control system 710 (e.g., centralized control system 380), which may be implemented by one or more processors that access one or more memories 714, which may store instructions, code, etc., implemented by the control circuitry and / or processor to implement 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 700 can be used to implement one or more of the components, circuits, systems, processes, etc. described above or below, or portions thereof.

[0146] User interface 716 allows a user to interact with system 700 and receive information through the system. In some cases, user interface 716 includes display 722 and / or one or more user inputs 724, such as buttons, touchscreens, trackballs, keyboards, mice, etc., which may be part of system 700 or wired or wirelessly connected to system 700. Typically, system 700 further includes one or more communication interfaces, ports, transceivers 720, etc., which allow system 700 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 718, other networks, or communication channels with other devices, and / or via other such communications or combinations of two or more such communication methods. Furthermore, transceiver 720 may be configured for wired, wireless, optical, fiber optic, satellite, or other such communication configurations, or combinations of two or more such communications. Some embodiments include one or more input / output (I / O) ports 734, which allow one or more devices to connect to system 700. The I / O port 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 734 can be configured to allow wired and / or wireless communication with 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 device, circuitry, and / or connection device, such as, but not limited to, one or more transmitters, receivers, transceivers, or combinations of two or more of such devices.

[0147] In some embodiments, the system may include one or more sensors 726 to provide information to the system and / or to another component (such as a centralized control system 380, a bin transfer system 312, an output / discharge system 320, a picking station 315, an input system 328). Figure 19 (and other such systems) transmit sensor information. Sensors can include virtually any relevant sensor, such as, but not limited to: optical-based scanning sensors for sensing and reading optical patterns (such as barcodes), radio frequency identification (RFID) tag reader sensors capable of reading RFID tags near the sensor, distance measurement sensors (such as optical units, acoustic / ultrasonic units, etc.), weight sensors, motion sensors, imaging systems, and 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.

[0148] System 700 includes examples of control systems and / or processor-based systems having control circuitry 712. Again, control circuitry 712 can be implemented by one or more processors, controllers, central processing units, logic circuits, software, etc. Furthermore, in some embodiments, control circuitry 712 can provide multiprocessor functionality.

[0149] The memory 714, accessible by the control circuitry 712, typically includes one or more processor-readable and / or computer-readable media accessible by the control circuitry 712, and may include volatile and / or non-volatile media such as RAM, ROM, EEPROM, flash memory, and / or other memory technologies. Furthermore, the memory 714 is shown as being internal to the control system 710; however, the memory 714 may be internal memory, external memory, or a combination of internal and external memory. Similarly, some or all of the memory 714 may be internal memory, external memory, or a combination of internal and external memory of the control circuitry 712. External memory may be substantially any relevant 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 714 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 24 Various components are shown connected together via a bus, but it is understood that the various components can actually be directly connected to the control circuit and / or one or more other components.

[0150] Some embodiments provide an order fulfillment system comprising: sub-bins; and order bins, wherein each order bin is sized to receive and store a plurality of sub-bins within the sub-bins, each sub-bin being positioned along the length of the respective order bin and adjacent to at least one of other sub-bins among the plurality of sub-bins. One or more of the sub-bins may include a body comprising: a first lateral side and a second lateral side extending along the length of the respective sub-bin; a first end side and a second end side extending along the width of the respective sub-bin from both the first lateral side and the second lateral side and between the first lateral side and the second lateral side; and a base. The first lateral side and the second lateral side, the first end side and the second end side, and the base define an internal cavity of the respective sub-bin. The base may include: a first door pivotally fixed to a first lateral side, wherein the first door pivots relative to the first lateral side between a closed position and an open position, wherein in the closed position, the first door closes at least a portion of the internal cavity at the base, and in the open position, the first door exposes the internal cavity through the base; and a first latch mechanically cooperating with the first door, wherein the first latch moves between a latched position and an unlocked position, wherein the first latch holds the first door in the closed position in the latched position and, when actuated, shifts to the unlocked position to release the first door so that the first door can be moved to the open position.

[0151] Some embodiments provide a method for order fulfillment, comprising: inserting a sub-box into an order box such that the sub-box is nested within the order box; transporting a product box, an order box, and a sub-box storing one or more items to a workstation; at the workstation, picking a first ordered item from one or more items stored in the product box and placing the first ordered item into a first sub-box nested within the first order box; removing the first sub-box from the first order box; positioning the first sub-box above a container; and releasing the first ordered item from the first sub-box into the container by opening at least one bottom door of the first sub-box.

[0152] Those skilled in the art will recognize that various other modifications, alterations, and combinations can be made with respect 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. Given the foregoing description, many alternative embodiments of the invention will become apparent to those skilled in the art. Therefore, this specification is to be understood as merely exemplary and intended to teach those skilled in the art the best mode for carrying out the invention. Substantial changes to the details of the structure may occur without departing from the spirit of the invention, and exclusive use of all modifications falling within the scope of the appended claims is reserved. In this specification, embodiments have been described in a manner that enables the writing and illustration of a clear and concise description, but it will be appreciated that embodiments and related portions of embodiments may be combined or separated in various ways without departing from the invention. It is intended that the invention be limited to the scope claimed by the appended claims and applicable legal rules.

Claims

1. An order fulfillment system, comprising: Sub-material bin; as well as An order bin, wherein each order bin is sized to receive and store a plurality of sub-bins from the sub-bins, each sub-bin being positioned along the length of the corresponding order bin and adjacent to at least one of the other sub-bins from the plurality of sub-bins; Each of the sub-bins includes a body, the body comprising: A first lateral side and a second lateral side extending along the length of the respective sub-box, a first end side and a second end side extending along the width of the respective sub-box from both the first lateral side and the second lateral side and between the first lateral side and the second lateral side, and a base, wherein the first lateral side and the second lateral side, the first end side and the second end side and the base define the internal cavity of the respective sub-box; The base includes: A first door, pivotally fixed to the first lateral side, wherein the first door pivots relative to the first lateral side between a closed position and an open position, wherein in the closed position, the first door closes at least a portion of the internal cavity at the base, and in the open position, the first door exposes the internal cavity through the base; and A first latch, which mechanically cooperates with the first door, wherein the first latch moves between a latched position and an unlocked position, wherein the first latch holds the first door in the closed position in the latched position and, when actuated, changes to the unlocked position to release the first door so that the first door can be moved to the open position.

2. The system according to claim 1, wherein, Each of the sub-bins further includes an actuator fixed to the body and mechanically coupled to the first latch, which, upon activation, moves the first latch from the latched position to the unlocked position and actuates the first door to the open position.

3. The system according to claim 2, wherein, Each of the sub-bins further includes: The first leader within the body; The actuator includes a trigger movably fixed to the first handle, the actuator being biased in an unactuated position to hold the first latch in the latched position, and being movable to an actuated position in response to an external force on the trigger to cause the first latch to move to the unlatched position.

4. The system according to claim 2, wherein, Each of the sub-bins further includes: The cavity opening is separated from the base by height from the first lateral side and the second lateral side, and has a cavity opening area; The first lateral side and the second lateral side extend along the height of the corresponding sub-box between the cavity opening and the base and are tapered, such that the area of ​​the base is smaller than the area of ​​the cavity opening.

5. The system according to claim 2, further comprising: An order unloading station includes an unloading robot, wherein the unloading robot includes a sub-bin gripper controlled to engage a first sub-bin and remove the first sub-bin from a first order bin, position the first sub-bin at an unloading location and activate an actuator of the first sub-bin to open a first door and release at least one ordered item into a container positioned aligned with the first door.

6. The system according to claim 5, further comprising: A release sensor is communicatively connected to the unloading robot, wherein the release sensor detects that the container is aligned with a threshold of the first door, and the unloading robot triggers the actuator to open the first latch and release the first door from the closed position to the open position.

7. The system of claim 6, wherein the order unloading station further comprises a blow-bag system that is activated to blow air after the first sub-box has been removed from the first order box and the container is positioned and aligned with the first sub-box, so as to align the container with the first door.

8. The system according to claim 1, further comprising: A sub-box transport robot separate from the order box and the sub-boxes, wherein the sub-box transport robot engages at least one of the plurality of sub-boxes and inserts and positions the sub-boxes into the order box to nest at least one of the sub-boxes within each of the order box.

9. The system according to claim 8, wherein, The first door includes an extension pin; and Each of the order bins includes a guide positioned along a portion of the inner surface of the first bin, wherein when one of the sub-bins in the open position is inserted into a corresponding one of the order bins, the protruding pin engages the guide to guide the first door to the closed position when the corresponding sub-bin is nested into the corresponding one of the order bins.

10. A method for order fulfillment, comprising: Insert the sub-material box into the order material box, so that the sub-material box is nested inside the order material box; Transport the product bins containing one or more items, the order bins, and the sub-bins to the workstation; At the workstation, a first ordered item is picked from the one or more items stored in the product bin, and the first ordered item is placed into a first sub-bin nested within the first order bin; Remove the first sub-box from the first order box; Place the first sub-box on top of the container; as well as The first ordered item is released from the first sub-box into the container by opening at least one bottom section of the first sub-box.

11. The method according to claim 10, wherein, During the transportation step, the product bin, the order bin, and the sub-bin are transported to the workstation via at least one mobile robot from a plurality of robots controlled by a robot control circuit.

12. The method according to claim 10, wherein, The step of inserting the sub-box into the order box such that the sub-box is nested within the order box is performed by one or more robots among a plurality of robots controlled by robot control circuitry.

13. The method according to claim 10, wherein, The step of releasing the first ordered item from the first sub-bin into the container includes: moving a first latch, mechanically coupled to the at least one bottom section, from a latched position to an unlocked position via an actuator fixed to the body of the first sub-bin and mechanically coupled to the first latch.

14. The method according to claim 13, wherein, The step of actuating the actuator to move the first latch to the unlatched position includes: moving a trigger of the actuator movably fixed at a first handle of the sub-bin, the actuator being biased in the unactuated position to hold the first latch in the unlatched position, and being movable to an actuated position in response to an external force applied to the trigger to cause the first latch to move to the unlatched position.

15. The method of claim 13, wherein: The steps of removing the first sub-box from the first order box and placing the first sub-box above the container are performed by an unloading robot, wherein the sub-box holder of the unloading robot engages the first sub-box and removes the first sub-box from the first order box, and positions the first sub-box above the container; and The step of releasing the first ordered item from the first sub-bin into the container is performed when the unloading robot actuates the actuator for the first sub-bin to move the first latch to the unlocked position to open the at least one bottom section.

16. The method of claim 15, further comprising sensing a threshold alignment of the container with the first sub-bin via a release sensor communicatively coupled to the unloading robot, and in response to the sensing, triggering the unloading robot to actuate the actuator to move the first latch to the unlatched position to open the at least one bottom section.

17. The method of claim 15, further comprising, when the first sub-box is positioned and aligned with the container, blowing air into the container via a blower system to align the container with the first sub-box.

18. The method of claim 10, further comprising, after the picking step and before the step of removing the first sub-box from the first order bin, transporting the first order bin and the first sub-box to the order unloading location via a first robot of a plurality of robots.

19. The method of claim 10, further comprising, after the release step, sterilizing the first sub-box before nesting the first sub-box back into the first box.

20. The method of claim 10, wherein, The container is located at the customer carrier, and the method further includes transporting the first order box and the first sub-box to the customer carrier after the picking step and before the step of removing the first sub-box from the first order box; wherein during the release step, the first ordered item is released from the first sub-box into the container at the customer carrier.

21. The method according to claim 10, wherein, The container is located in the shopping cart, and the method further includes transporting the first order box and the first sub-box to the shopping cart after the picking step and before the step of removing the first sub-box from the first order box; wherein during the release step, the first ordered item is released from the first sub-box into the container in the shopping cart.

22. The method of claim 21, further comprising, after the release step, providing the shopping cart to the customer.

23. The method of claim 10, further comprising, after the release step, closing and latching the at least one bottom section of the first sub-box by inserting the first sub-box back into the first order box.

24. The method according to claim 23, wherein, The steps of closing and latching the at least one bottom section are performed via an extendable pin positioned on the at least one bottom section engaging a guide positioned along a portion of the inner surface of the first hopper. When the first sub-hopper is nested into the first order hopper, the guide guides the extendable pin to move the at least one bottom section from an open position to a closed position.

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