Automated storage and retrieval system and method with staging, sequencing and buffering system and method

Abstract

Some embodiments provide an automated order fulfillment system comprising: mobile robots to transport containers each containing a product; a storage structure comprising storage locations to store the containers; a first workstation; a first buffer sequence structure positioned between the storage structure and the first workstation, cooperating with the storage structure and the first workstation, the first buffer sequence structure comprising a plurality of buffer lanes, the plurality of buffer lanes comprising: a one-way buffer lane to which each of a first group of mobile robots transporting a container is directed and instructed to stop and wait without releasing the container before proceeding to the first workstation; a second buffer lane in which each of a second group of mobile robots is directed to pass through to the first workstation without stopping; and a one-way return lane into which at least one of the first group of mobile robots and the second group of mobile robots will enter after leaving the first workstation.

Description

[0001] Cross-references to related applications This application claims the benefit of U.S. Provisional Application No. 63 / 626,974, filed January 30, 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 move 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 control systems used in implementing inventory management. This specification includes accompanying drawings, in which: Figure 1 This shows a perspective view of an exemplary order fulfillment facility that displays a storage structure according to some embodiments.

[0005] Figure 2 A simplified side view of an exemplary buffer sequence structure that collaborates between the transport plane of the storage structure and the workstation, according to some embodiments, is shown.

[0006] Figure 3 A simplified perspective view of an exemplary buffer sequence structure that collaborates between the transport plane of the storage structure and the workstation, according to some embodiments.

[0007] Figure 4 A simplified block diagram top view of a portion of an order fulfillment facility according to some embodiments is shown, the order fulfillment facility having a storage structure that cooperates with multiple buffer sequence structures.

[0008] Figure 5 A simplified block diagram side view of an exemplary buffer sequence structure that collaborates with multiple transport planes and workstations according to some embodiments is shown.

[0009] Figure 6 A simplified block diagram side view of an exemplary buffer sequence structure that collaborates with multiple transport planes and workstations according to some embodiments is shown.

[0010] Figure 7 A simplified block diagram partial perspective view of an exemplary buffer sequence structure according to some embodiments is shown, which collaborates with multiple exemplary transport planes and exemplary workstations implemented within an exemplary fulfillment facility.

[0011] Figure 8A simplified flowchart illustrates an exemplary process of fulfilling product orders through an automated order fulfillment system according to some embodiments.

[0012] Figure 9 A simplified flowchart illustrates an exemplary process of fulfilling product orders through an automated order fulfillment system according to some embodiments.

[0013] Figure 10 A simplified flowchart illustrates an exemplary process of fulfilling product orders through an automated order fulfillment system according to some embodiments.

[0014] Figure 11 A simplified flowchart illustrates an exemplary process of fulfilling product orders through an automated order fulfillment system according to some embodiments.

[0015] Figure 12 A simplified flowchart illustrates an exemplary process of fulfilling product orders through an automated order fulfillment system according to some embodiments.

[0016] Figure 13 A simplified flowchart illustrating an exemplary process of management performance according to some embodiments is shown.

[0017] Figure 14 Exemplary systems are shown according to some embodiments for use in implementing methods, techniques, apparatuses, devices, systems, servers, resources, and providing product order fulfillment, unpacking and transfer, consolidation, and inventory management.

[0018] 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 of the elements in the figures may be exaggerated relative to other elements. Furthermore, to facilitate less obstructed observation of these various embodiments, common but well-known elements that are useful or necessary in commercially viable embodiments are often not depicted. Certain actions and / or steps may be described or depicted in a particular order of occurrence, and those skilled in the art will understand that such specificity regarding the sequence is not actually required. Except where otherwise set forth in this document, the terms and expressions used herein have the ordinary technical meaning that those skilled in the art would attribute to such terms and expressions as set forth above. Detailed Implementation

[0019] Embodiments of the present technology will now be described with reference to figures, which generally relate to automated storage and retrieval systems with temporary and sorting locations, and further to automated storage and retrieval systems with dedicated routing paths for mobile robots. The described embodiments simplify software complexity, for example, by simplifying or limiting the need for traffic management. Furthermore, as will be described, the embodiments aim to achieve efficient transport of mobile robots to and from storage locations, where sequence constraints, scheduling constraints, and congestion points are simplified.

[0020] It is understood that this embodiment may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be exhaustive and complete, and will fully express the invention to those skilled in the art. In fact, the embodiments are intended to cover alternatives, modifications, and equivalents of these embodiments, which are included within the scope and spirit of the invention as defined by the appended claims. Furthermore, specific details are set forth in the following detailed description to provide an understanding of these embodiments.

[0021] The terms “top” and “bottom,” “upper” and “lower,” and “vertical” and “horizontal” as used herein are for illustrative purposes only and are not intended to limit the description of the embodiments, as the items mentioned may be interchanged in position and orientation. Furthermore, as used herein, the terms “substantially” and / or “about” mean that, for a given application, the specified dimensions or parameters may vary within acceptable manufacturing tolerances. In one non-limiting embodiment, an acceptable manufacturing tolerance is ±0.25%.

[0022] For the purposes of this disclosure, the connection may be a direct connection or an indirect connection (e.g., via one or more other parts). In some cases, when the first element is referred to as a connection, attachment, or coupling to the second element, the first element and the second element may be directly connected, attached, or coupled to each other, or indirectly connected, attached, or coupled to each other. When the first element is referred to as a direct connection, attachment, or coupling to the second element, there are no intervening elements between the first element and the second element (other than possible adhesives or welds used for connecting, attaching, or coupling the first element and the second element).

[0023] Figure 1This is a perspective view of an exemplary order fulfillment facility 100 showing a storage structure 102 according to some embodiments. In some embodiments, the order fulfillment facility 100 may include a plurality of shelving units 104 or storage locations 106. Each of the storage units 104 may comprise a yz array of storage locations 106 arranged in horizontal rows at a plurality of levels 105, and one or more storage level changing structures 107, passageways, aisles, towers, or the like extending vertically along an aisle 108. A mobile robot 130 (sometimes referred to as a "robot" and a drone) may travel in the z-direction between storage levels within the storage level changing structures 107 (e.g., unidirectional upward level changing structures 107a and unidirectional downward level changing structures 107b). Typically, multiple storage level changing structures 107 may cooperate with one or more aisles 108 at multiple different levels 105, enabling a mobile robot 130 to self-propel vertically upward (e.g., via a one-way upward level changing structure 107a) and vertically downward (e.g., via a one-way downward level changing structure 107b) to move between levels 105 and / or transport planes 112, platforms, or the like. In some embodiments, pairs of storage locations 104 are arranged facing each other and separated by aisles 108, wherein storage locations 106 are spaced apart along each side of the aisle 108 at each of the multiple levels 105. The aisle 108 may have a width such that a mobile robot 130 traveling within the aisle 108 can transfer containers back and forth between storage locations 106 on either side of the aisle 108. In some embodiments, the storage structure 102 includes a three-dimensional array of multiple different storage locations 106, each configured to receive one of a plurality of different containers, each configured to receive one or more items. Multiple storage locations 106 can all be located along one of multiple different vertically spaced storage levels 105 that can be accessed by multiple mobile robots 130.

[0024] In some embodiments, the storage structure 102 includes one or more transport planes 112 or other such transport structures spaced apart at different vertical levels 105 of the storage structure 102. The transport planes 112 may be arranged individually or in groups (e.g., in pairs) and typically extend between aisles 108 at a single level to allow the robot 130 to maneuver horizontally in the xy plane of each transport plane, typically traveling between different aisles 108 at the same level. In some embodiments, one or more of the transport planes 112, or suitable support structures, may also extend into the corresponding aisles to allow technicians to enter the aisles 108 to maintain components within the aisles. In some embodiments, the transport planes 112 facilitate the transport of the mobile robot 130 between aisles and / or between aisles and workstations 115. One or more of the transport planes 112 may be designated unidirectional (e.g., a first transport plane at a first level is unidirectional along the +x direction, while a second transport plane at a second level is unidirectional along the -x direction).

[0025] One or more equipment at workstation 115 is configured to receive one or more mobile robots 130. For example, a first mobile robot at the workstation may carry one or more containers (such as product containers) and combine with a subsequent mobile robot containing items to fulfill product requests to form an order. A second mobile robot at the workstation may carry one or more other containers (such as order containers) and combine with a subsequent mobile robot, as needed, containing one or more items from one or more product containers to fulfill product requests to form an order with one or more order containers. One or more worker and / or robot picking systems at the corresponding workstation 115 may transfer items from product containers to order containers. In some embodiments, the transfer is guided by an inventory control system at workstation 115. Containers may have substantially any relevant size and / or shape that can be picked and transported by at least one of the mobile robots and / or used by the workstation.

[0026] The order fulfillment facility 100 further includes a plurality of mobile robots 130 that transport one or more containers (e.g., one or more product bins, order bins, bags, sub-bins, etc.) to and from workstation 115 and storage location 106. The mobile robots 130 may be self-guided and / or rail-guided to move vertically through the storage structure and horizontally within aisle 108 to position and transport containers to and from storage location 106. For example, a track system including horizontal rails may be attached to storage location 104 at a vertical level. The horizontal rails provide access to storage shelves on either side of aisle 108 at a given level. The vertical level change structure 107 enables the mobile robots to travel vertically in the z-direction between levels of the storage structure.

[0027] In some embodiments, storage structure 102 further includes one or more buffer sequence structures 150, all positioned between and cooperating with both storage structure 102 and one or more workstations 115. Transport planes 112, aisles 108, buffer sequence structures 150, and workstations cooperate to enable mobile robot 130 to traverse the order fulfillment facility 100 between storage locations 106 and workstations 115, while robot flow control improves throughput, reduces congestion, reduces mobile robot demand, and provides other such benefits. Mobile robot 130 can maneuver in the xy-plane of each transport plane 112, allowing transitions between different aisles 108 and between different workstations 115 via buffer sequence structures 150. Fulfillment facility 100 further includes one or more control circuits 101 and / or robot routing control circuitry that wirelessly communicate via one or more wireless and / or wired distributed communication networks 103 (e.g., wireless local area network (LAN), wired LAN, wide area network (WAN), cellular network, Wi-Fi, Bluetooth, Ethernet, other such communication networks, or combinations of two or more of such networks). The one or more control circuits 101 may include one or more buffer control processors and a buffer control memory communicatively coupled to the one or more buffer control processors and storing executable code configured, when executed by the buffer control processors, to identify the storage location 106 of container 204 and the workstation 115 for receiving the storage container based on one or more items within the container used to fulfill the order. Additionally, in some embodiments, when controlling the flow of mobile robot 130 to the corresponding workstation 115, the control circuitry determines that mobile robot 130 passes through a buffer sequence structure 150.

[0028] In some embodiments, in managing flow, congestion, and improving the overall efficiency of the order fulfillment facility 100, control circuitry 101 may be configured to track the movement of container 204 and / or mobile robot 130 (e.g., via one or more sensors at mobile robot 130, storage structure 102, buffer sequence structure 150, workstations, and / or other such locations) to determine the sorting, buffering, and / or routing of container 204 and / or mobile robot 130 between storage location 106 and workstation 115 via buffer sequence structure 150. A challenge in discrete picking designs is providing efficient flow of sorted items, as well as a stable flow of items to and from locations within the fulfillment facility 100, ensuring an orderly and stable flow of items from any location within the fulfillment facility 100 to any workstation 115 and / or from a workstation to any location within the fulfillment facility 100. In some embodiments, the buffer sequence structure 150 provides pathways, paths, frames, and the like, which can be used to enhance the routing of mobile robots in terms of temporary storage and sorting of containers transported by the mobile robots, so as to facilitate congestion management, improve the speed of product delivery, improve the speed of order fulfillment, reduce the number of mobile robots, enhance workstation utilization, reduce latency, improve the utilization of storage structures, and other benefits.

[0029] Further details regarding the workstations, storage structures, and mobile robots that may be used are described, for example, in the following U.S. patents and patent applications: U.S. Patent No. 9,139,363, published September 22, 2015, entitled "Automated System for Transporting Payloads"; U.S. Patent No. 10,435,241, published October 8, 2019, entitled "Storage and Retrieval System"; U.S. Patent No. 11,142,398, published October 12, 2021, entitled "Order Fulfillment System"; and U.S. Application Publication No. 30, 2023, entitled "Automatic Storage and Retrieval System having Staging and Sequencing Buffer Locations and Segregated Storage". U.S. Patent Application Publication No. 2023 / 0095494 (Attorney File No. 8842-157747-US_8182US03), entitled “Order Fulfillment System,” published March 3, 2022; and U.S. Patent Application Serial No. 18 / 268,204 (Attorney File No. 8842-156750-US_8154US01), entitled “Methods and Apparatus for Facilitating Transport of Items Between a Store and a Customer via a Customer Access Portal,” wherein each of these patents and applications is incorporated herein by reference in its entirety.

[0030] Figure 2 A simplified side view of an exemplary buffer sequence structure 150, which collaborates between a transport plane 112 of a storage structure 102 and a workstation 115 according to some embodiments, is shown. Figure 3 A simplified perspective view is shown of an exemplary buffer sequence structure 150 that collaborates between a transport plane 112 of a storage structure 102 and a workstation 115, according to some embodiments. Figure 4A simplified block top view of a portion of an order fulfillment facility 100 according to some embodiments is shown. The order fulfillment facility 100 has a storage structure 102 that cooperates with a plurality of buffer sequence structures 150. (Refer to...) Figures 1 to 4 The buffer sequence structure 150 includes a plurality of buffer walkways 202. These buffer walkways provide a path for the mobile robot 130 to move between the transport plane 112 and the workstation, while also sequencing and / or buffering the mobile robot within the buffer sequence structure 150. In some embodiments, the buffer walkways include one or more (and typically, more) one-way inbound or supply buffer walkways 202a-202b toward the workstation 115; and one or more (and typically, more) one-way buffer walkways (sometimes referred to below as “outbound” buffer walkways) used by the mobile robot 130 to transport the container 204 away from the workstation and toward storage location 106 within the transport plane 112 and / or storage structure 102, another workstation 115 and / or other locations within the facility. The size of buffer aisle 202 may depend on one or more factors, such as, but not limited to, the size of the mobile robots, the projected order fulfillment rate, the projected maximum number of mobile robots to be buffered within buffer aisle 202a, other such factors, or a combination of two or more of such factors. Container 204 improves buffering efficiency, eliminates waiting constraints and dwell time between orders for fulfilling overlapping orders, enables skipping task assignments and / or prioritizing task assignments when threshold productivity gains and / or simplifications are available, improves fulfillment facility equipment productivity, reduces costs, increases capacity, and other such benefits.

[0031] In some embodiments, while buffering containers 204 carried by mobile robots, control circuitry 101 may utilize buffer walkways to temporarily halt and store mobile robots 130 until the products within containers 204 are ready to be processed for the corresponding order at workstation 115. The buffering of the mobile robots and the containers 204 carried by them allows control over the transport and sequencing of containers 204 based on orders being fulfilled at the respective workstations. By allowing containers to be picked up and temporarily held until other containers containing the products of an order are also ready to be released to a specific workstation, container routing efficiency can be partially improved. In this regard, in some embodiments, a first group of one or more mobile robots 130 carrying containers 204 may be directed and instructed to stop and wait, without releasing the corresponding containers until they proceed to the intended workstation 115.

[0032] Note that some mobile robots 130 are directed to pass through buffer sequence structure 150, while others are directed to temporarily stop within one of the supply buffer aisles 202a. While the mobile robots wait within the buffer sequence structure, one or more containers 204 transported by the mobile robots remain on the mobile robots until the order for which the transport container 204 is located is at a predefined stage and / or position in the order fulfillment queue. Therefore, in some embodiments, buffer sequence structure 150 may maintain one or more inbound through-pass or bypass buffer aisles 202b, at which the mobile robots do not stop and wait, but instead pass directly through buffer sequence structure 150. Some embodiments provide one or more bypass buffer aisles 202b, at which each of the second group of mobile robots is directed to pass through one or more bypass buffer aisles 202b to the corresponding workstation 115 without stopping.

[0033] In some embodiments, the buffer walkway may include one or more outbound return walkways 202c, which may be dedicated to mobile robots 130 moving away from workstation 115 and / or the workstation side 206 of the buffer sequence structure 150. In some cases, the return walkway 202c may be a dedicated one-way return walkway into which at least one of the first group of mobile robots and at least one of the second group of mobile robots will enter after leaving the workstation and / or moving away from the workstation side 206 of the buffer sequence structure. One or more supply buffer walkways 202a may be vertically spaced from each other, vertically spaced from one or more bypass buffer walkways 202b, and vertically spaced from the return walkway 202c. Similarly, one or more bypass walkways 202b may be vertically separated from each other and vertically spaced from one or more return walkways 202c, while one or more return walkways 202c may be vertically separated from each other.

[0034] In some embodiments, each of the buffer sequence structures 150 may further include one or more workstation-side vertical change structures 220-221 positioned between some or all of the plurality of buffer walkways 202 and one or more workstations 115, and cooperating with some or all of the plurality of buffer walkways 202 and one or more workstations 115. The workstation-side vertical change structures 220-221 provide a vertical path that enables the mobile robot 130 to vertically self-propelled to and from the workstations 115. In some embodiments, the buffer sequence structure 150 includes one or more supply workstation-side vertical change structures 220 used by a mobile robot moving toward one or more workstations 115 to supply the container 204 to one or more workstations; and one or more workstation-side return vertical change structures 221 that provide a path for the mobile robot 130 moving away from one or more workstations 115.

[0035] In some embodiments, one or more of the supply workstation-side vertical changing structures 220 may be configured and / or used as unidirectional downward supply workstation-side vertical changing structures 220, which constrain vertical movement in a unidirectional downward direction. Similarly, in some embodiments, one or more of the workstation-side return vertical changing structures 221 may be configured and / or used as unidirectional upward workstation-side return vertical changing structures 221, which constrain vertical movement in an upward direction. However, in other embodiments, one or more of the vertical workstation-side vertical changing structures 220-221, or a portion of one of the vertical workstation-side vertical changing structures 220-221, may allow bidirectional movement, or may be divided into a portion that allows only downward movement and another portion that allows only upward movement. The supply workstation-side vertical changing structures 220 provide a supply path from the buffer walkway to the workstation. A mobile robot 130 moving through the buffer sequence structure 150 and toward workstation 115 (whether buffered to wait within one of the supply buffer aisles 202a or passing through one of the bypass buffer aisles 202b) can leave the corresponding buffer aisle, engage the supply workstation-side vertical alteration structure 220, and propel itself vertically toward workstation 115 in accordance with the expected fulfillment sequence and / or queue. The supply workstation-side vertical alteration structure 220 can cooperate with at least one (and typically all) of the buffer aisles 202a and at least one (and typically all) of the bypass aisles 202b. Furthermore, the supply workstation-side vertical alteration structure 220 cooperates with one or more workstations 115 and provides at least a portion of the supply path between the buffer sequence structure 150 and one or more workstations 115. In some embodiments, the supply vertical hierarchy change structure 220 enables the mobile robot 130 to propel itself vertically downwards and / or upwards to a hierarchy corresponding to the input workstation supply hierarchy 240 of the assigned workstation 115. Rails, guides, platforms, and / or other such structures may connect buffer walkways 202a and bypass walkways 202b to the supply workstation-side vertical hierarchy change structure 220, and / or connect the supply vertical hierarchy change structure 220 to one or all of the workstation supply hierarchy 240 and / or exit hierarchy 242, enabling the mobile robot to transition from the buffer walkways and bypass walkways to the supply workstation-side vertical hierarchy change structure 220 and the assigned workstation 115.

[0036] Similarly, the workstation-side return vertical hierarchy change structure 221 can cooperate with one or more workstations 115 and at least one (and typically all) of a plurality of return paths 202c to provide at least a portion of the return path between the workstation 115 and the return path 202c. In some embodiments, the return vertical hierarchy change structure 221 enables the mobile robot 130 to self-propel itself vertically upward and / or downward to a corresponding level in one of the return paths 202c. Tracks, rails, platforms, and / or other such structures can connect the return vertical hierarchy change structure 221 to the workstation exit level 242 and one or more return paths 202c, enabling the mobile robot to transition from the return vertical hierarchy change structure 221 to the assigned return path 202c. In some embodiments, based on the intended destination of the container 204 and / or product carried by the respective mobile robot 130, the control circuitry 101 communicates the mobile robot's route to the corresponding one of the return paths 202c. In some embodiments, for example, control circuitry 101 identifies a specific storage location within a storage structure to which container 204 will return, and the level 105 to which that return storage location is located. Based on the level 105 of the specific storage location, control circuitry 101 may identify a corresponding return path 202c of the level 105 that is vertically closest to the specific storage location, and guide the mobile robot to propel vertically from workstation 115 to the identified return path 202c to move along a route through buffer sequence structure 150 to the specific storage location where container 204, carried by the mobile robot, returns. Alternatively or additionally, control circuitry 101 may select the return path 202c based on congestion within the storage structure, one or more transport planes, and / or other potentially congested areas. For example, the control circuitry may identify the initial transport plane 112 within the vertical threshold of the level 105 of the storage structure 102 in which the container will return, but select a different transport plane and alternative route based on congestion proximity and / or based on the initial transport plane and / or other issues associated with the initial route that will utilize the initial transport plane.

[0037] In some embodiments, one or all of the buffer return aisles 202c are vertically positioned to be vertically aligned with a corresponding one of the transport planes 112, such that the mobile robot 130 can pass directly through the buffer sequence structure 150 via the corresponding one of the return aisles 202c without stopping, and move directly horizontally from the buffer sequence structure 150 to the corresponding one of the transport planes 112 at the desired level. This allows the mobile robot 130 to then laterally transition along the storage structure 102 on the transport plane to the desired aisle 108. As described above, in some embodiments, the storage structure 102 may include one or more storage level changing structures 107. The mobile robot may move from the transport plane 112 to engage the storage level changing structure 107 at the desired aisle 108, vertically self-propelling itself to climb up or down to the desired level 105 corresponding to the storage location indicated by the mobile robot 130.

[0038] Mobile robot 130 is configured to move autonomously through storage structure 102, buffer sequence structure 150, workstation 115, and / or other parts of order fulfillment facility 100. One or more control circuits 101 and / or one or more routing control circuits or systems may communicate with mobile robot 130 to provide routing instructions to one or more mobile robots 130, which are implemented by mobile robot 130, coordinating the movement of the mobile robots to provide a desired robot sequence to a specific workstation 115 based on the corresponding order, so that the items contained in container 204 arrive at workstation 115 in sequence to fulfill at least a portion of the order assigned to the corresponding workstation. For example, when an order to be fulfilled includes four different items, and these four different items are held in four different containers 204, control circuit 101 may direct four different mobile robots 130 to four different storage locations 106 within storage structure 102 to pick one of the four containers. Next, the four mobile robots can move to the first buffer sequence structure 150 of multiple buffer sequence structures based on a single workstation 115, which will collect the four different items of the order. Because the containers are in different storage locations, the mobile robots 130 typically arrive at the buffer sequence structure 150 at different times. Utilizing the buffer, the first three mobile robots 130 to arrive at the buffer sequence structure 150 can be directed to one or more of the supply buffer aisles 202a to stop and wait until all four mobile robots assigned to the order are at the buffer sequence structure (and the order reaches a threshold position within the order fulfillment queue and / or buffer queue), and then the four mobile robots are released from the buffer sequence structure so that the four mobile robots arrive at the assigned workstation 115 in sequence, allowing the four items of the order to be picked one after another in sequence as the four mobile robots 130 move sequentially into and through the assigned workstation 115. In some embodiments, the release of the four mobile robots may include directing the last arriving mobile robot to bypass buffer lane 202b, so that the last arriving mobile robot does not buffer but instead simply crosses the bypass buffer lane. In other embodiments, the last arriving mobile robot associated with an order may additionally be directed to supply buffer lane 202a to stop and wait until the order reaches a threshold position in the order fulfillment queue.

[0039] Workstation 115 provides access to the interior of container 204. In some embodiments, worker 302 and / or one or more automated picking systems (e.g., articulated arms or other such systems) can pick one or more items from a container located in an access location or opening within the workstation. In some embodiments, one or more workstations include a plurality of access locations 304a-304b. Workstations and multi-retrieval workstations may be similar to those described in: U.S. Patent Nos. 9,139,363; 10,435,241; 11,142,398; U.S. Application Publication No. 2023 / 0095494; and U.S. Provisional Application Serial No. 63 / 626,967 (Attorney's File No. 8842-157459-USPR_8291US01), entitled "Retail Fulfillment Dispense and Decant Systems and Methods," each of which is incorporated herein by reference in its entirety. Furthermore, in some embodiments, the workstation may be a multi-level workstation having one or more workstation supply levels 240 and one or more workstation departure levels 242. Furthermore, in some embodiments, the workstation includes a workstation vertical change structure or passageway, which is engaged and used by a mobile robot to advance vertically to position a corresponding container at a retrieval location, move the corresponding container downward away from the retrieval location to vertically align with one of one or more workstation exit levels 242, and advance away from workstation 115. As a non-limiting example, in some embodiments, the workstation includes a single workstation supply level 240 and a single workstation exit level 242 (e.g., see...). Figure 2 As another non-limiting example, a workstation may include three workstation provisioning tiers 240 and one workstation exiting tier 242 (see, for example, see...). Figures 3 to 5 ).

[0040] Figure 5A simplified block diagram side view of an exemplary buffer sequence structure 150 cooperating with multiple transport planes 112 and workstations 115 according to some embodiments is shown. In managing and controlling the flow of containers through the fulfillment facility, control circuitry 101 may be configured in some embodiments to identify a first set of containers 204, each containing items, for example, associated with a first fulfillment order, and further identify and / or assign a first set of mobile robots to pick up each of the first set of containers. Instructions may be communicated to each of the mobile robots in the first set (which has a corresponding location within the fulfillment facility) and enable the mobile robots to autonomously route through storage facilities and / or storage structures 102 to pick up the corresponding container in the first set of containers 204. In some embodiments, control circuitry 101 may further identify a first mobile robot 130a in the first set of mobile robots associated with a first fulfillment order and arriving at the buffer sequence structure 150 before one or more other mobile robots in the first set of mobile robots, and command the first mobile robot to buffer itself within the buffer sequence structure 150. In some embodiments, the buffer command may direct a first mobile robot to a first buffer aisle 202a_l and stop the first mobile robot within the first buffer aisle 202a_l, holding the corresponding container and waiting, while one or more other mobile robots in the first group of mobile robots are positioned for routing to the workstation. Similarly, in some embodiments, control circuitry 101 may identify a second mobile robot 130b in the first group of mobile robots transporting a second container associated with a first fulfillment order, and the first mobile robot 130a buffering in the first buffer aisle 202a_l (and / or being routed to a buffer sequence structure and buffering itself), while holding the first container. Based on the association of the first mobile robot 130a with the first fulfillment order and its buffering in the first buffer aisle 202a_l, the control circuit 101 may, in some embodiments, guide the second mobile robot 130b to the first buffer aisle 202a_l while the first mobile robot is waiting in the first buffer aisle 202a_l, and cause the second mobile robot to wait behind the first mobile robot in the first buffer aisle 202a_l, while holding the second container on the second mobile robot without releasing it. This allows the second mobile robot 130b (and the second container) to be aligned with the first mobile robot 130a (and the first container) while waiting for one or more other mobile robots and / or for the first fulfillment order to be ready for processing at the assigned workstation.

[0041] In some embodiments, control circuitry 101 may be further configured to, after a buffer period, direct both the first mobile robot 130a and the second mobile robot 130b to leave the first buffer aisle 202a_l and continue to the assigned first workstation 115, during which at least the first mobile robot waits on the first buffer aisle. The buffer period may depend on one or more factors, such as, but not limited to: the duration for which one or more other mobile robots in the first group are in place within the facility; the estimated time for movement through the facility and / or buffer sequence structure; an order fulfillment queue of one or more other fulfillment orders awaiting processing at the first workstation prior to the first fulfillment order; the number of containers and mobile robots associated with earlier fulfillment orders in the order fulfillment queue; and the estimated rate at which each of the containers at the first workstation 115 is processed, other such factors, or combinations of two or more of such factors.

[0042] As another example, in some embodiments, the control circuit 101 may be further configured to identify that the third mobile robot 130c and / or the third container transported by the third mobile robot are associated with a second fulfillment order, which is different from the first fulfillment order and will be fulfilled by a workstation 115 cooperating with the buffer sequence structure 150. Based on the order fulfillment queue, while the first mobile robot 130a is waiting on the first buffer aisle 202a_1, and based on the fact that the third mobile robot 130c is associated with a different second fulfillment order, the control circuit 101 may direct the third mobile robot 130c to a second buffer aisle 202a_2, which is different from the first buffer aisle, and cause the third mobile robot 130c to wait in the second buffer aisle 202a_2 while keeping the third container on the third mobile robot without releasing the third container.

[0043] As described above, in some cases, the mobile robot can be guided to the bypass buffer lane 202b to directly traverse the buffer sequence structure without stopping and waiting for the buffer period to be reached. Still referring to... Figure 4In some embodiments, control circuitry 101 may identify a fourth mobile robot 130d and / or a fourth container carried by the fourth mobile robot as associated with a fourth fulfillment order to be fulfilled by workstation 115 in cooperation with buffer sequence structure 150. Based on the order fulfillment queue, while the first mobile robot 130a is waiting on the first buffer aisle 202a_l, and based on the association of the fourth mobile robot 130d with a different fourth fulfillment order, control circuitry 101 may direct the fourth mobile robot 130d to a first bypass buffer aisle 202b_l, which is different from the first and second buffer aisles, and cause the fourth mobile robot 130d to pass directly through buffer sequence structure 150 while carrying the fourth container, and proceed directly to workstation 115, and / or be positioned in the workstation queue of one or more other mobile robots leading to the workstation, to enter workstation 115 and be processed at workstation 115.

[0044] The buffer sequence structure 150 can further optimize container movement by limiting the distance traveled by the containers. For example, in some cases, the control circuitry 101 can identify that a container already at the buffer sequence structure and / or workstation contains at least a portion of the items available to fulfill an order awaiting subsequent fulfillment. In this regard, the control circuitry can avoid returning the container to the storage structure 102, instead rerouting it back to one of the buffer sequence structures 150 associated with the workstation 115 intended for fulfilling the subsequent order. In this respect, the container travel can be significantly reduced, thereby shortening the fulfillment time, reducing congestion, and other such benefits.

[0045] Figure 6A simplified block diagram side view of an exemplary buffer sequence structure 150 cooperating with multiple transport planes 112 and workstations 115 according to some embodiments is shown. As described above, in some embodiments, the buffer sequence structure 150 includes one or more supply-side vertical hierarchy change structures 230 on the storage structure side 208 of the buffer storage structure. One or more supply-side vertical hierarchy change structures 230 can be used to allow a mobile robot to move vertically into and align with different buffer aisles. Note that in some embodiments, the buffer sequence structure is configured with a single supply-side vertical hierarchy change structure 230 positioned between the storage structure and the multiple buffer aisles 202, which can partially reduce the area or footprint of the buffer sequence structure. Furthermore, the flow of the mobile robot 130 within the supply-side vertical hierarchy change structure 230 can be constrained such that the supply-side vertical hierarchy change structure allows unidirectional flow of the mobile robot (e.g., vertically upward). Control circuitry 101 is configured to recognize that a fifth container 204e, transported by the fifth mobile robot 130e and leaving the first workstation 115, remains identified as the first item or product in a fifth fulfillment order awaiting subsequent fulfillment, and to recognize that the fifth fulfillment order will be fulfilled by the first workstation. Based on the order fulfillment queue and / or the predicted timing of fulfilling the fifth fulfillment order, control circuitry may further identify that the fifth mobile robot 130e is available to fulfill at least a portion of the fifth fulfillment order, and reroute the fifth mobile robot 130e to the buffer sequence structure 150 without returning the fifth container 204e to the storage structure 102. A return instruction may be communicated to the fifth mobile robot 130e to proceed to the first return path 202c_l and travel through the buffer sequence structure to enter the supply-side vertical hierarchy change structure 230. When routing the fifth mobile robot 130e to workstation 115 while fulfilling the fifth fulfillment order, the fifth mobile robot 130e can use the supply-side vertical hierarchy change structure 230 to advance vertically to the third buffer lane 202a_3 (or, depending on the order fulfillment queue, the bypass lane) among multiple buffer lanes, and the fifth mobile robot 130e does not return to the storage structure 102.

[0046] Return to reference Figure 1As described above, fulfillment facility 100 may include multiple buffer sequence structures 150, each cooperating with one or more workstations 115. Furthermore, the buffer sequence structures typically cooperate with one or more transport planes 112, enabling mobile robots to move laterally (e.g., in the x and y axes) to the aisles 108 of assigned buffer sequence structures 150, workstations 115, and / or storage structures 102. In some embodiments, one or more transport planes may be positioned between storage structure 102 and one or more supply-side vertical hierarchy change structures 230, each cooperating with one of the buffer sequence structures 150. Some embodiments further improve efficiency, reduce travel, reduce congestion, and / or other such benefits by routing containers between buffer sequence structures 150 and workstations 115 without returning containers to storage structure 102. Buffer sequence structures 150 enable one or more mobile robots 130 to be temporarily buffered according to the order fulfillment queue of a particular workstation 115 in preparation for order fulfillment. Typically, a separate order fulfillment queue is maintained for each workstation 115 and / or buffer sequence structure 150.

[0047] Figure 7 A simplified block diagram partial perspective view of exemplary buffer sequence structures 150a-150c according to some embodiments is shown, which cooperate with a plurality of exemplary transport planes 112a-112d and exemplary workstations 115a-115c (shown as transparent) implemented within an exemplary fulfillment facility 100. Each workstation cooperates with one of the buffer sequence structures 150a-150c. One or more transport planes 112a-112d or transport planes may extend laterally (e.g., along the x and y axes) to provide a horizontal planar surface on which a mobile robot 130 may be positioned above a storage structure 102 (…). Figure 7 Transport between one or more of the buffer sequence structures 150a-150c (not shown in the diagram) and the storage structure 102. Furthermore, in some embodiments, one or more transport planes 112a-112d may extend laterally to cooperate with two or more or all of the buffer sequence structures 150a-150c to provide a lateral path to the mobile robot between two or more of the buffer sequence structures 150a-150c and / or the storage structure 102. Additionally, in some embodiments, transport planes 112a-112d may be positioned between the storage structure 102 (not shown in the diagram) and one or more of the buffer sequence structures 150a-150c and the storage structure 102. Figure 7 (Not shown in the text) and the corresponding supply-side vertical hierarchy change structure 230 of the first buffer sequence structure. As described above, in some embodiments, control circuitry 101 may guide the routing of one or more mobile robots to reduce flow, improve fulfillment efficiency, reduce congestion, and / or other such benefits by partially reducing the transport of container 204 back to the storage structure.

[0048] At least refer to Figures 1 to 2 In some embodiments, control circuitry 101 may be configured to identify a container 204 carrying a product transported by mobile robot 130 leaving first workstation 115a, and the product is identified as being in a second fulfillment order pending subsequent fulfillment. In some cases, control circuitry further identifies that the second fulfillment order will be fulfilled by a second workstation 115c, different from the first workstation 115a. An order fulfillment queue corresponding to the second workstation 115c may be evaluated. This queue evaluation may include determining the expected fulfillment timing of the second fulfillment order, comparing the expected fulfillment timing with one or more timing thresholds (e.g., buffer wait thresholds, order fulfillment duration thresholds, etc.), the number of orders in the order fulfillment queue, the expected and / or estimated duration of one or more orders fulfilling the order fulfillment queue, congestion levels, mobile robot buffer positions within a buffer sequence structure, the number of open buffer lanes, the number of unoccupied open mobile robot buffer positions, other such factors, or combinations of two or more of such factors.

[0049] The control circuit 101 can transmit a return command to the mobile robot 130, causing the robot to leave workstation 115a, engage the one-way workstation-side return vertical change structure 221, propel itself vertically, and move forward to a return path 202c-1 (e.g., assigned by the control circuit, or the default return path) to enter one of the transport planes (e.g., the second transport plane 112b). In some cases, the selected return path 202c-1 may be vertically aligned with the assigned second transport plane 112b. The return command may further include instructing the mobile robot 130 to travel along the second transport plane 112b to a second buffer sequence structure 150c that cooperates with the second transport plane 112b and the second workstation 115c, without the mobile robot 130 returning to the storage structure 102. Furthermore, the control circuitry can direct the mobile robot to a special buffer aisle (e.g., buffer aisle 202a_l) to temporarily stop and wait while holding the container; or, when a second order is to be fulfilled and the mobile robot is not waiting, direct the mobile robot to a bypass buffer aisle of the second buffer sequence structure. Again, this direct route for the mobile robot between workstations to the same or different buffer sequence structures 150 can improve efficiency, reduce fulfillment time, improve mobile robot utilization, reduce mobile robot demand, reduce congestion, and / or other such benefits. In some embodiments, one or more aisles within the storage structure may be located at a level 105 aligned with the transport plane 112.

[0050] In some embodiments, one or more of the return aisles 202c may be unidirectional return aisles in which control circuitry constrains the movement of the mobile robot toward the workstation side 206 of the transport plane 112 and away from the buffer sequence structure 150. Furthermore, in some embodiments, the return aisle 202c may be vertically positioned to align with one of the transport planes 112, providing a direct horizontal path through the buffer sequence structure 150 to the transport plane. The return aisle 202c selected for a particular mobile robot 130 may depend on one or more factors, such as, but not limited to, the intended next destination of the container 204 transported by the mobile robot (e.g., storage location 106, buffer aisles in the same or different buffer sequence structures, unpacking and transfer stations, other stations and / or other locations of fulfillment facilities), congestion, things blocking potential routes, the location of subsequent containers to be transported by the mobile robot, other such factors, or combinations of two or more of such factors. In some embodiments, for example, when determining the route for a first mobile robot to be moved away from the workstation, control circuitry 101 may be configured to identify a storage location 106 within storage structure 102, where a subsequent container is located and will be picked up by the first mobile robot 130 of a plurality of mobile robots. Based on the location of the subsequent container to be picked up, in some embodiments, control circuitry may be configured to identify a storage level 105 within storage structure 102, where the subsequent container is located. Control circuitry may identify a first return path 202c among a plurality of return paths that are vertically closest to the identified storage level 105, and based on the first return path that is vertically closest to the identified storage level, convey a first return instruction in a return instruction to route the first mobile robot to the first return path 202c. Furthermore, in some embodiments, one or more mobile robots 130 may stop and buffer in one or more return paths 202c to wait for outward movement onto transport plane 112 (e.g., waiting for gaps in the flow of mobile robots moving along a particular transport plane), wait for routing, wait due to congestion, other such factors, or a combination of two or more of such factors.

[0051] Using return instructions and a predetermined route, in some embodiments, after leaving the workstation, the first mobile robot can move to the return workstation-side vertical change structure 221, self-propelled to the level aligned with the first return path 202c, and proceed along the first return path and through the buffer sequence structure 150. In some cases, the route may guide the first mobile robot to move vertically upward or downward to the predetermined transport plane 112 using the supply-side vertical level change structure 230. However, in other cases, the route may continue horizontally from the assigned return path 202c directly to the transport plane 112 vertically aligned with the assigned return path. When the first mobile robot is at the level of the assigned transport plane, whether moving directly from the assigned return path 202c or after vertically moving through the supply-side vertical level change structure 230, the first mobile robot can proceed to the assigned transport plane 112 and continue along the predetermined route, whether lateral or transverse, before moving across to the storage structure 102. In some embodiments, a first mobile robot may engage a storage level change structure 107 on the storage structure side 310 of the transport plane 112 and vertically advance to a desired level 105 within the storage structure. The mobile robot may then advance horizontally from the storage level change structure 107 along the aisle to a desired storage location 106, where a first container transported by the first mobile robot may be moved from the mobile robot to the desired storage location. The first mobile robot may then be routed to perform another task, such as, but not limited to, picking another container 204, picking empty order containers or bins, moving to an unpacking and transfer station, and / or other such actions.

[0052] In some embodiments, control circuitry 101 may further manage order fulfillment based on the priority of received orders. Priority may be defined based on one or more factors, such as, but not limited to: the time of order receipt, one or more items requested in the order, the expected duration of order fulfillment, the availability of the requested items, the location of the corresponding one or more items in the order within storage structure 102, the number of mobile robots 130, the number of available mobile robots 130, the occupancy of one or more buffer sequence structures 150 (e.g., the number of mobile robots buffering and waiting in one or more buffer aisles 202a and / or the amount of open space within one or more buffer aisles of one or more buffer sequence structures available for receiving mobile robots), the number of empty buffer aisles 202a within one or more buffer sequence structures, the number of workstations in operation and / or expected to be operational in a predicted future time period, the customer or entity submitting the order, the customer level associated with the customer submitting the order, whether a higher priority request was submitted with the order (e.g., based on payment, points or other rewards, coupons, etc.), other such factors, or a combination of two or more factors. In addition, the control circuit 101 may modify the order priority over time based on one or more of the above factors, changes in one or more of the above factors and / or other factors (e.g., changing the position of the item based on other orders, congestion, need to introduce additional items into the storage structure, etc.).

[0053] In some embodiments, control circuitry 101 may be configured to identify a first container 204, transported by a first mobile robot in a first group of mobile robots, buffered and waiting in a first buffer aisle 202a of a first buffer sequence structure 150, and the first container holding a plurality of first products, wherein at least one of the plurality of first products is routed to a first workstation to fulfill a first fulfillment order. Control circuitry may further identify a second fulfillment order pending and / or queued in an order fulfillment queue for fulfillment orders to be fulfilled after the fulfillment of the first fulfillment order, and the second fulfillment order comprising at least one of the first products. In some embodiments, based at least in part on the fact that the first mobile robot is already present at the first buffer sequence structure 150 and transporting first products, control circuitry may be configured to reprioritize the second fulfillment order to adjust its position within the queue of fulfillment orders. This reprioritization may enable routing of the first mobile robot such that the first container is not returned to a storage structure, but instead re-buffered to one of one or more buffer storage structures associated with the intended workstation assigned to fulfill the second fulfillment order. Similarly, based on the repricing of the second order, the control circuitry can, when other containers are needed and when different containers are directed to the fulfillment workstation, direct one or more additional mobile robots to pick up one or more additional containers 204 from the corresponding one or more storage locations 106 and / or other workstations, other buffer sequence structures and / or other areas of the fulfillment facility, so as to complete the fulfillment of the second order in accordance with the repricing.

[0054] In some embodiments, the mobile robot and / or control circuitry 101 may route the mobile robot to induce recharging of the mobile robot's power storage system. Some or all of the mobile robots include a rechargeable power storage system, which may include a rechargeable battery, capacitor, supercapacitor, supercapacitor, and / or other such rechargeable storage devices. Some or all of the vertical change structures include charging rails that may be engaged by the mobile robot 130's recharging system to draw power from and recharge the rechargeable power storage system (e.g., battery, supercapacitor, etc.) during ascent and / or descent. When power storage falls below a threshold for recharging, the mobile robot and / or control circuitry and / or their own mobile robot control circuitry may guide the mobile robot to the vertical change structure. For example, in some embodiments, the supply-side vertical hierarchy change structure 230, the supply-workstation-side vertical change structure 220, and / or other vertical change structures may include charging rails. The control circuit 101 and / or the mobile robot control circuit can be configured to detect that the charging level of the first mobile robot 130 has a predefined relationship with the charging threshold, and guide the first mobile robot to the bypass path 202b of the buffer sequence structure 150 to pass through the bypass buffer path and enter the supply workstation side vertical change structure 220, and engage the first charging rail of the supply workstation side vertical change structure 220, while simultaneously recharging the first mobile robot. In some embodiments, the first mobile robot may be directed to move vertically along the workstation-side vertical change structure to a vertical level corresponding to the return path 202c, and to enter and pass through the return path 202c to engage the supply-side vertical level change structure 230. While engaging the second charging rail of the supply-side vertical level change structure, allowing the first mobile robot to further recharge, it advances vertically through the supply-side vertical level change structure until, depending on the position of the first mobile robot and its associated corresponding order in the order fulfillment queue, the first mobile robot is vertically aligned with the same or different buffer path 202a or bypass buffer path 202b. This recharging loop can be implemented when routing the first mobile robot to the first workstation to fulfill a corresponding fulfillment order, without requiring the first mobile robot to return to the storage structure.

[0055] When organizing different products for a single fulfillment order, some embodiments utilize different buffer lanes 202. In some embodiments, control circuitry 101 may identify a first mobile robot in a first group of mobile robots intended for fulfilling a first fulfillment order, transporting a first product within a first container associated with a first product group, and identify a second mobile robot in the first group of mobile robots, transporting a container carrying a second product associated with a second product group different from the first product group. Control circuitry may be configured to: while the first mobile robot is buffering and waiting in the first buffer lane, and based on the second product being associated with a different second product group, direct the second mobile robot to a second buffer lane, and stop and wait in the second buffer lane while holding the second container without releasing it. For example, different products may be associated with different product groups (e.g., some products may not be combined with other products (e.g., chemical products and edible products), frozen products, warm products, etc.), and control circuitry may organize the mobile robots within the different buffer lanes 202a of the buffer sequence structure 150 in part based on the different groups.

[0056] In some embodiments, when products are aggregated to fulfill an order, one or more mobile robots 130 may transport an order container to a workstation to receive one or more products picked from other containers transported to the workstation. Multiple product containers transported by multiple different mobile robots may traverse the workstation, while a single order container transported by a single mobile robot may remain at the workstation while different items are picked from the multiple product containers and placed into the order container. For example, when the workstation includes multiple access locations 304a-304b, the order container may be positioned at and maintained at a first access location while multiple different mobile robots move corresponding different product containers to align with a second access location, exposing the interiors of the different product containers so that a worker or picking system can pick one or more items from the order from the product containers and place them into the order container maintained at the first access location. In some embodiments, the control circuitry may be configured to: while queuing order containers, direct each of a group of mobile robots (which, in fulfilling different corresponding orders, transport order containers scheduled to receive items at workstation 115) to one of a set of buffer aisles, and direct each of the group of mobile robots from the set of buffer aisles into the workstation to position the corresponding order container with the access location of workstation 115. For example, in some embodiments, a set of one or more least oriented inbound or supply buffer aisles of a buffer sequence structure may be used as order container buffer aisles to queue one or more mobile robots transporting order containers to the workstation. In some embodiments, the mobile robot assigning such order containers may leave the workstation similarly to other mobile robots, while simultaneously routing back to one of the aisles 202c to move the order container to an order picking location within fulfillment facility 100, to storage location 106 to await subsequent picking, and / or to other locations within the fulfillment facility. In other embodiments, when those mobile robots are routed to one or more predefined locations for order bins, the mobile robot distributing the order container may be routed to a predefined return path 202c intended for the mobile robot transporting the order container.

[0057] In some embodiments, the buffer sequence structure 150 can be configured to streamline container movement and reduce congestion by buffering the mobile robot 130 while the container 204 is held on the mobile robot. In this respect, the mobile robot does not necessarily have to release the container it is carrying into a temporary storage location. Based on the movement rate of the container 204, the buffer duration is typically found to be relatively short. The time it takes to release the container 204 from the mobile robot 130 into the temporary storage location, and the subsequent time for the mobile robot to pick up the container from the temporary storage location, often results in additional delays and / or wasted time, which can often lead to the use of more mobile robots, increase the complexity of routing multiple mobile robots, and other such factors. By holding the container 204 on the mobile robot 130 while the mobile robot is buffered in the buffer aisle 202a, routing can be greatly simplified while still achieving the intended buffering and temporary storage to improve and streamline order fulfillment. Furthermore, the construction cost of the buffer sequence structure 150 can be reduced because the buffer sequence structure does not have additional structures for additional temporary storage locations, and the buffer sequence structure 150 can have a significantly smaller ground area footprint than other systems that include container storage areas. The buffer sequence structure 150 can be constructed with a width approximately equal to the width of the mobile robot 130 when carrying container 204. The buffer sequence structure does not necessarily need to include additional width for the temporary storage location of receiving container 204. In addition, the buffer sequence structure 150 enables the temporary storage and sorting of containers when collecting product containers for a given fulfillment order, and the release of the corresponding mobile robots from those buffers that transport those containers to the workstation as a group of containers constituting a given order. The temporary storage and sorting provide buffering, which partially alleviates the criticality of product container arrival and queuing, and simplifies product container arrival and queuing.

[0058] Figure 8 A simplified flowchart illustrates an exemplary process 800 for fulfilling a product order via an automated order fulfillment system according to some embodiments. In step 802, a mobile robot 130 directs at least one container 204, each containing one or more products, through a storage structure 102 and / or order fulfillment facility 100 accessible to the mobile robot. In step 804, each of the first group of one or more mobile robots transporting the containers is directed to a first buffer passageway 202a of a first buffer sequence structure 150, which is located between the storage structure 102 and at least a first workstation 115 and cooperates with both the storage structure 102 and at least the first workstation 115. The first buffer sequence structure 150 may include multiple buffer passageways in order to route the respective container 204 to the first workstation.

[0059] In step 806, each of the first group of mobile robots 130 may be instructed to stop and wait in the first buffer walkway 202a without releasing the corresponding container 204 before proceeding to the first workstation 115. In step 808, each of one or more mobile robots in the second group of a plurality of robots may be instructed to a second buffer walkway (e.g., a bypass walkway 202b) to cross the second buffer walkway to the first workstation 115 without stopping in the second bypass buffer walkway 202b. In step 810, after leaving the first workstation 115, at least one of the first group of mobile robots 130 and at least one of the second group of mobile robots 130 may be instructed to a return walkway 202c. In some embodiments, the first buffer walkway 202a is vertically spaced from the second buffer walkway 202b and the return walkway 202c, and the second buffer walkway 202b is vertically spaced from the return walkway 202c. When directing at least one of the first group of mobile robots and at least one of the second group of mobile robots to the return path, some embodiments direct at least one of the first group of mobile robots and at least one of the second group of mobile robots to return along at least part of the self-propulsion of the vertical hierarchy change structure 221 located between the first workstation and the return path and cooperating with the first workstation and the return path, providing a vertical return path between the first workstation and the return path 202c.

[0060] Figure 9A simplified flowchart of an exemplary process 900 for fulfilling a product order through an automated order fulfillment system according to some embodiments is shown. In step 902, a first mobile robot in a group of one or more mobile robots may be directed to a first buffer path 202a_l of a first buffer sequence structure 150. In step 904, the first mobile robot may be instructed to stop and wait in the first buffer path. In step 906, a first mobile robot 130 in the first group of mobile robots may be identified as associated with a first fulfillment order and buffers and waits in the first buffer path 202a_l while holding a first container 204. In step 908, a second mobile robot 130 may be identified as associated with the first fulfillment order. In step 910, while the first mobile robot is waiting in the first buffer path, the second mobile robot may be directed to the first buffer path 202a_l and stopped and waits in the first buffer path together with the first mobile robot while holding a second container on the second mobile robot without releasing the second container. In some embodiments, the guidance of the second mobile robot to the first buffer aisle 202a_l may depend on the confirmation that, as the second mobile robot moves toward the first buffer sequence structure, the first fulfillment order is not processed by the first workstation, and that the first fulfillment order is at or after a threshold position in the order fulfillment queue corresponding to the first workstation. The threshold position in the order fulfillment queue may depend on the estimated time it will take for the second mobile robot to reach the first buffer aisle, and the predicted time for fulfilling the first fulfillment order at the first workstation. Some embodiments include step 912, in which a third mobile robot is identified as associated with a second fulfillment order, which is different from the first fulfillment order. In step 914, while the first mobile robot is waiting on the first buffer aisle 202a_l, and based on the association of the third mobile robot with the second fulfillment order, the third mobile robot may be guided to the second buffer aisle 202a-2, and the third mobile robot may be stopped and wait on the second buffer aisle while the third container is held on the third mobile robot without being released. Again, in some embodiments, the guidance of the third mobile robot to the second buffer aisle may depend on the expected processing time at the first workstation for the second fulfillment order. In step 916, after the buffer period, both the first and second mobile robots may be directed to leave the first buffer path 202a_l and continue to the first workstation 115, during which at least the first mobile robot waited in the first buffer path. In step 918, the third mobile robot may be directed to leave the second buffer path 202a_2 and proceed to the first workstation to prepare for fulfilling the second fulfillment order at the first workstation.Furthermore, in some embodiments, the release of the third mobile robot from the second buffer walkway 202a_2 may depend at least in part on the position of the second fulfillment order in the order fulfillment queue corresponding to the first workstation.

[0061] Figure 10 A simplified flowchart illustrates an exemplary process 1000 for fulfilling a product order via an automated order fulfillment system according to some embodiments. In step 1002, a first container, transported by a first mobile robot and intended for fulfillment of a first fulfillment order by a first workstation 115, is identified as holding a first product, which is similarly identified in a second fulfillment order subsequently fulfilled after the fulfillment of the first fulfillment order. In step 1004, it is identified that the second fulfillment order will be fulfilled by the first workstation 115. In step 1006, when the first mobile robot is routed to the first workstation for fulfilling the second fulfillment order, a return instruction is communicated to the first mobile robot, causing it to proceed via a return vertical hierarchy change structure 221 to a first return path 202c after leaving the first workstation as part of the fulfillment of the first fulfillment order, to enter a supply-side vertical hierarchy change structure 230, without returning to the storage structure. In some embodiments, the supply-side vertical hierarchy change structure 230 may be located between the storage structure 202 and a plurality of buffer paths 202 of a buffer sequence structure. In step 1008, the first mobile robot moves forward to the first return path in accordance with the return command, enters the supply-side vertical level change structure 230, and moves vertically to the second buffer path without returning to the storage structure.

[0062] In step 1010, it is identified that a second container, transported by a second mobile robot among a plurality of mobile robots, holds the second product during the fulfillment of a third fulfillment order at the first workstation, and the second product is identified as being in a fourth fulfillment order to be fulfilled subsequently after the third fulfillment order. In step 1012, it is identified that the fourth fulfillment order will be fulfilled by a second workstation different from the first workstation. In step 1014, a second return instruction is communicated to the second mobile robot, causing the second mobile robot to move forward to a return path to enter a transport plane vertically aligned with the return path, and to travel along the transport plane to a second buffer sequence structure cooperating with the second workstation, without the second mobile robot returning to the storage structure.

[0063] Figure 11A simplified flowchart illustrates an exemplary process 1100 for fulfilling a product order via an automated order fulfillment system according to some embodiments. In step 1102, a first container, transported by a first mobile robot in a first group of mobile robots, is identified as being buffered and waiting in a first buffer aisle of a first buffer sequence structure 150, and the first container holds a plurality of first products, wherein at least one of the plurality of first products is routed to a first workstation cooperating with the first buffer sequence structure to fulfill a first fulfillment order. In step 1104, a second fulfillment order is identified as being queued in an order fulfillment queue to be fulfilled after the fulfillment of the first fulfillment order, and the second fulfillment order includes at least one of the first products. In step 1106, based on the fact that the first mobile robot is already present at the first buffer sequence structure and transporting first products, the priority of the second fulfillment order is re-determined to adjust its position within the order fulfillment queue.

[0064] Figure 12 A simplified flowchart of an exemplary process 1200 for fulfilling a product order through an automated order fulfillment system according to some embodiments is shown. In step 1202, a first storage location 106 is identified within a storage structure 102 for a subsequent container to be picked up by a first mobile robot at a first workstation cooperating with a first buffer sequence structure. In step 1204, a storage level within the storage structure in which the subsequent container is located is identified. In step 1206, a return path among a plurality of return paths of the first buffer sequence structure that is vertically closest to the identified storage level is identified. In step 1208, the first mobile robot routes to the return path based on the return path that is vertically closest to the identified storage level.

[0065] Figure 13 A simplified flowchart of an exemplary process 1300 for managing fulfillment according to some embodiments is shown. In step 1302, an order is received for fulfillment. Order receipt may include new orders and order updates (e.g., changes to the ordered items, quantity, shipping time, completion time, etc.). In some embodiments, the receiving process may perform inventory checks and consolidation planning (e.g., bag planning, order container planning, etc.). In some embodiments, in step 1304, the result may include one or more order container-level orders added to an unassigned order pool (e.g., planned to the order container order level). Typically, the orders have not yet been assigned to workstations and have not yet been bound to product containers. In some embodiments, the inventory check considers the existing quantity against the demand for one or more products and / or orders. When the existing inventory quantity is insufficient to meet the order receiving request, an alternative process may be implemented.

[0066] In step 1306, the fulfillment order is assigned to one or more workstations 115 for fulfillment. In some embodiments, the assignment process selects specific available product containers as needed to fulfill the corresponding order and creates a task (e.g., mobile robot picking) for each product container. In some embodiments, available product containers include containers that are not currently assigned to another workstation or have been assigned to the same workstation, or containers when picking from a container is completed at another workstation. The order fulfillment queue may depend on one or more factors. In some embodiments, reserved product containers and / or orders assigned to workstations may be based in part on ((order line threshold + average order size) / 2) * number of workstations. Tasks may be created, but specific mobile robots may not yet be assigned. In some embodiments, when picking products at a workstation, the number of order lines assigned to the workstation may be checked. When the corresponding order fulfillment queue is below a configurable threshold, some embodiments assign another order to the workstation. Order selection may include optimization logic to select the order with the least system overhead for the workstation receiving the order. In some embodiments, orders with earlier shipping times may be assigned higher priority. Alternatively, some embodiments prioritize orders whose inventory matches product containers already assigned to the same workstation (with sufficient stock and not yet picked). These product containers can be recycled within the buffer sequence structure 150, avoiding round trips to the storage structure. Orders with a large number of candidate product bins in the same area as the workstation can reduce processing time, reduce TP movement, improve efficiency, and offer other benefits.

[0067] In step 1308, unassigned container tasks are identified. Unassigned tasks may include, for example, tasks that have not yet been assigned to a mobile robot. Whenever a mobile robot completes a task, or if the mobile robot is idle, the system may find the next optimal task based on: a cost function (e.g., a weighted priority of task type (self-pickup vs. employee pickup vs. order picking vs. replenishment, etc.); the location of the next container assignment relative to the mobile robot's current location; the number of mobile robots already serving the destination workstation (this may increase the maximum number of mobile robots assigned to the workstation or "overrunning," where it is incorporated into the total cost rather than a fixed threshold); and / or other task-type specific costs (e.g., picking tasks vs. replenishment tasks). (etc.). In some embodiments, a task may include a user request 1310, which may include a user input mechanism that generates demand-driven tasks (such as distribution, replenishment, import, inspection, etc.); and a system request 1312, which is for any system-generated task (such as temporary movement) triggered by other activities. In step 1314, the mobile robot is assigned a task. In some embodiments, task assignment may include the assignment of container tasks to the mobile robot, which may include a container picking location and a destination location. Some embodiments generate and assign active routes in step 1316, and / or track the active routes of the mobile robot.

[0068] The buffer sequence structure 150 can improve equipment productivity (e.g., reduce mobile robot cycle time), reduce system implementation costs per site (e.g., fewer mobile robots to meet capacity), increase maximum capacity (e.g., fulfill a higher number of orders per day), and other such benefits. The use of an appropriately sized buffer sequence structure 150 and / or facility can expand the work pool. The system can be more selective in assigning mobile robots to tasks. Sequencing, as a subset of buffering capacity, allows upstream activities to work as efficiently as possible, regardless of work sequence, eliminates waiting constraints on overlapping orders and dwell time between orders, enables skip-task assignment when significant productivity gains are available, and / or other such benefits. In addition to buffering and sequencing containers 204 originating from storage location 106, the buffer sequence structure 150 further allows for container recycling when inventory will meet subsequent orders scheduled to the same or different workstations.

[0069] According to an example embodiment, a non-transient program storage device capable of being read by a machine, such as a memory, may be provided, for example, which tangibly embodies a program capable of being executed by a machine to perform operations including: calculating routes for mobile robots and containers to temporarily store and sort mobile robots and containers, as disclosed above and below.

[0070] Any combination of one or more computer-readable media can be used as a memory. A computer-readable medium can be a computer-readable signal medium or a non-transient computer-readable storage medium. A non-transient computer-readable storage medium does not include propagating signals and can be, for example, but not limited to, electronic, magnetic, optical, electromagnetic, infrared, or semiconductor systems, devices, or apparatuses, or any suitable combination of the foregoing. More specific examples of computer-readable storage media (a non-exhaustive list) will include the following: electrical connections having one or more wires, portable computer disks, hard disks, random access memory (RAM), read-only memory (ROM), erasable programmable read-only memory (EPROM or flash memory), optical fiber, portable optical disc read-only memory (CD-ROM), optical storage devices, magnetic storage devices, or any suitable combination of the foregoing.

[0071] Furthermore, the circuits, circuit systems, systems, devices, processes, methods, technologies, functionalities, services, servers, mobile robots, resources, etc., described herein can be utilized, implemented, and / or operated on many different types of devices and / or systems. Figure 14 An exemplary system 1400 is shown, which can be used to implement any or a portion of any of the components, circuits, circuit systems, systems, functionalities, devices, processes, or apparatuses mentioned above or below, of fulfillment facility 100, control circuitry 101, mobile robot 130, workstation 115, and / or other systems or apparatuses mentioned above or below. For example, system 1400 can be used to implement some or all of control circuitry 101, mobile robot 130, workstation 115, point-of-sale system, inventory system, database, customer computing system, purchasing system, customer file system, product file system, and / or other such components, circuit systems, functionalities, and / or apparatuses. However, the use of system 1400 or any part thereof is certainly not required.

[0072] By way of example, system 1400 may include one or more control circuitry or processor modules 1412, one or more memories 1414, and one or more communication links, paths, buses, or the like 1418. Some embodiments may include one or more user interfaces 1416, and / or one or more internal and / or external power supplies or power supply devices 1440. Control circuitry 1412 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 steps of the processes, methods, functionalities, and techniques described herein, and to control various communications, decisions, programs, content, lists, services, interfaces, logging, reporting, etc. Furthermore, in some embodiments, control circuitry 1412 may be part of a control circuitry system and / or control system 1410, which may be implemented by one or more processors accessing one or more memories 1414, which may store instructions, code, and the like, implemented by the control circuitry and / or processor to perform the intended functionality. In some applications, control circuitry and / or memory may be distributed across communication network 103 (e.g., LAN, WAN, Internet) to provide distributed and / or redundant processing and functionality. Again, system 1400 may be used to implement one or more of the above or below components, circuits, systems, processes, and the like, or portions thereof.

[0073] User interface 1416 allows a user to interact with system 1400 and receive information through the system. In some cases, user interface 1416 includes display 1422 and / or one or more user inputs 1424, such as buttons, touchscreens, trackballs, keyboards, mice, etc., which may be part of system 1400 or connected to system 1400 via wired or wireless means. Typically, system 1400 further includes one or more communication interfaces, ports, transceivers 1420 and the like, which allow system 1400 to communicate via a communication bus, a distributed computer and / or communication network 103 (e.g., local area network (LAN), Internet, wide area network (WAN), etc.), a communication link 1418, other networks or communication channels with other devices, and / or other such communications or combinations of two or more of such communication methods. Furthermore, transceiver 1420 may be configured for wired, wireless, optical, fiber optic, satellite or other such communication configurations, or combinations of two or more of such communications. Some embodiments include one or more input / output (I / O) ports 1434 that allow one or more devices to be coupled to system 1400. The I / O ports can be substantially any associated port or combination of ports, such as, but not limited to, USB, Ethernet, or other such ports. The I / O interface 1434 can be configured to allow wired and / or wireless communication coupling to external components. For example, the I / O interface can provide wired and / or wireless communication (e.g., Wi-Fi, Bluetooth, cellular networks, RF, and / or other such wireless communications), and in some cases, can include any known wired and / or wireless interface devices, circuitry, and / or connection devices, such as, but not limited to, one or more transmitters, receivers, transceivers, or combinations of two or more of such devices.

[0074] In some embodiments, the system may include one or more sensors 1426 to provide information to the system and / or to provide sensor information to another component (such as control circuitry 101, mobile robot 130, workstation 115, other such systems, or combinations of two or more such systems). Sensors may include virtually any relevant sensor, such as motion sensors, distance measurement sensors (e.g., optical units, sound / ultrasonic units, etc.), optical-based scanning sensors for sensing and reading optical patterns (e.g., barcodes), radio frequency identification (RFID) tag reader sensors capable of reading RFID tags near the sensor, accelerometers, gyroscopes, and other such sensors. The examples above are intended to be illustrative and are not intended to represent an exhaustive list of all possible sensors. Instead, it will be understood that these teachings will be adapted to any of the wide variety of situations requiring sensing in a given application setting.

[0075] System 1400 includes an example of a control and / or processor-based system having control circuitry 1412. Again, control circuitry 1412 can be implemented by one or more processors, controllers, central processing units, logic circuits, software, and the like. Furthermore, in some embodiments, control circuitry 1412 may provide multiprocessor functionality.

[0076] The memory 1414, accessible by the control circuitry 1412, typically includes one or more processor-readable and / or computer-readable media accessible by at least the control circuitry 1412, and may include volatile and / or non-volatile media such as RAM, ROM, EEPROM, flash memory, and / or other memory technologies. Furthermore, the memory 1414 is shown as being within the control system 1410; however, the memory 1414 may be internal memory, external memory, or a combination of internal and external memory. Similarly, some or all of the memory 1414 may be internal memory, external memory, or a combination of internal and external memory of the control circuitry 1412. External memory may be substantially any associated memory, such as, but not limited to, solid-state storage devices or drives, hard disk drives, flash drives or drives of one or more Universal Serial Bus (USB) devices, Flash Secure Digital (SD) cards, other memory cards, and other such memories or combinations of two or more such memories, and some or all of the memory may be distributed across multiple locations on one or more communication and / or computer networks. The memory 1414 can store code, software, executable files, scripts, data, content, lists, programming, programs, logs or historical data, user information, customer information, product information, and the like. Although Figure 14 The diagram shows various components connected together via a bus, but it is understood that the various components may actually be directly connected to the control circuit and / or one or more other components.

[0077] In some embodiments, the automated order fulfillment system includes: a plurality of mobile robots configured to transport at least one container, each containing at least one product; a storage structure accessible by the mobile robots and including storage locations configured to store the containers; a first workstation; a first buffer sequence structure located between and cooperating with both the storage structure and the first workstation, the first buffer sequence structure including a plurality of buffer lanes, the plurality of buffer lanes including: a one-way buffer lane, in which each of the first group of mobile robots transporting the containers is directed and instructed to stop and wait without releasing the corresponding container before proceeding to the first workstation; a second buffer lane, in which each of the second group of mobile robots is directed to pass through the second buffer lane to the first workstation without stopping; and a one-way return lane, in which at least one of the first group of mobile robots and at least one of the second group of mobile robots will enter the one-way return lane after leaving the first workstation.

[0078] Some embodiments provide a method for fulfilling product orders through an automated order fulfillment system, the method comprising: directing a plurality of mobile robots to transport at least one container containing at least one product through a storage structure accessible by the mobile robots and including storage locations configured to store the container; directing each of one or more mobile robots in a first group of the plurality of mobile robots to transport the corresponding container to a first buffer lane of a first buffer sequence structure located between the storage structure and the first workstation and cooperating with both the storage structure and the first workstation, wherein the first buffer sequence structure includes a plurality of buffer lanes; instructing each of the first group of mobile robots to stop and wait in the first buffer lane without releasing the corresponding container before proceeding to the first workstation; directing each of one or more mobile robots in a second group of the plurality of mobile robots to a second buffer lane to pass through the second buffer lane to the first workstation without stopping in the second buffer lane; and directing at least one of the first group of mobile robots and at least one of the second group of mobile robots to a return lane after leaving the first workstation.

[0079] Some embodiments provide an automated order fulfillment system comprising a plurality of mobile robots configured to transport bins, each containing at least one product; a storage structure accessible by the mobile robots and including storage locations configured to store bins received from the mobile robots; a first workstation; and a first buffer sequence tower positioned between and cooperating with both the storage structure and the first workstation, the first buffer sequence tower including a plurality of vertically separated buffer walkways, wherein the plurality of buffer walkways include: a first set of unidirectional buffer walkways, each of the plurality of mobile robots in the first set being directed and instructed to stop and wait for a corresponding buffer duration within a correspondingly assigned buffer walkway in the first set of buffer walkways, and upon stopping in the corresponding buffer walkway before proceeding to the first workstation. The system does not release the corresponding hopper; a second set of buffer walkways in a plurality of buffer walkways, wherein each of the second set of mobile robots in a plurality of mobile robots is directed to one of the second set of buffer walkways when advancing to the first workstation, and is directed to pass through the corresponding one of the second set of buffer walkways without stopping in the corresponding buffer walkway; and a plurality of dedicated one-way return walkways vertically spaced among the plurality of buffer walkways; and a return vertical hierarchy changing tower located between the first workstation and each of the plurality of buffer walkways and cooperating with the first workstation and each of the plurality of buffer walkways, wherein a return instruction is communicated to each of the plurality of mobile robots, which, as they leave the first workstation in sequence, are directed to enter the return vertical hierarchy changing tower and, according to the vertical hierarchy of the destination location within the storage structure, travel vertically to the assigned different return walkway among the plurality of return walkways. In some embodiments, a control circuit may be included, communicatively coupled to a plurality of mobile robots, and may include at least one buffer control processor and a buffer control memory storing executable code configured, when executed by the buffer control processor, to: identify a first mobile robot in a first group of mobile robots transporting a first bin as associated with a first fulfillment order in a plurality of different fulfillment orders, and buffer and wait in a first buffer aisle among a plurality of buffer aisles; identify a second mobile robot in the first group of mobile robots as associated with the first fulfillment order based on a second product to be included in a second bin transported by a second mobile robot in the first fulfillment order; and, based on the association of both the first and second mobile robots with the first fulfillment order, guide the second mobile robot to a first buffer aisle, while the first mobile robot stops in the first buffer aisle, and cause the second mobile robot to stop and wait behind the first mobile robot in the first buffer aisle, while holding the second bin on the second mobile robot without releasing the second bin.

[0080] The control circuitry can be configured to: identify a first mobile robot transporting a first product from a first bin associated with a first product group; identify a third mobile robot in the first group of mobile robots associated with a first fulfillment order and transporting a third bin carrying a third product associated with a second product group different from the first product group; while the first mobile robot buffers and waits in a first buffer aisle, and based on the second product being associated with a different second product group, guide the third mobile robot to a second buffer aisle in the first group of buffer aisles, and stop and wait in the second buffer aisle while holding the third bin on the third mobile robot without releasing the third bin. In some embodiments, the control circuitry can be configured to guide each of the third group of mobile robots, which transports order bins scheduled to receive products at a workstation when fulfilling the corresponding order, to one of the third group of lowest-level buffer aisles in the plurality of buffer aisles, and to allow each of the third group of mobile robots to enter the first workstation from the third group of lowest-level buffer aisles to position the corresponding order bin with the order bin location of the first workstation.

[0081] Some embodiments provide a method for fulfilling product orders through an automated order fulfillment system, comprising: assigning a plurality of mobile robots, each associated with a different fulfillment order and each transporting a corresponding bin carrying products, to a first workstation; directing each of the plurality of mobile robots in a first group to one of a plurality of vertically separated unidirectional buffer lanes in a first buffer sequence tower corresponding to the first workstation, and causing each of the first group of mobile robots to stop within its assigned buffer lane and wait for a corresponding buffer duration, while stopping in the corresponding buffer lane before proceeding as planned to the first workstation. When moving to the first workstation, each of the second group of mobile robots is directed to one of the second group of buffer walkways, and each of the second group of mobile robots passes through the corresponding one of the second group of buffer walkways without stopping in the corresponding buffer walkway; and when the multiple mobile robots leave the first workstation in sequence, a return instruction is transmitted to each of the multiple mobile robots to change the assigned different return walkways in the multiple dedicated unidirectional return walkways of the tower entering the first buffer sequence tower via the return vertical hierarchy according to the vertical hierarchy of the destination location within the storage structure.

[0082] This application is incorporated herein by reference in its entirety of each of the following U.S. patent publications: U.S. Publication No. 2014 / 0288696, published September 25, 2014, which has U.S. Application Serial No. 14 / 213,187, filed March 14, 2014, entitled "Automated system for transporting payloads" (Applicant reference No. ALRT-001-101); U.S. Patent Publication No. 2017 / 0313514, published November 2, 2017, which has U.S. Application Serial No. 15 / 591,956, filed May 10, 2017, entitled "Order fulfillment system" (Applicant reference No. ALRT-003-101); and U.S. Patent Publication No. 2014 / 0288696, filed September 25, 2019. 2019 / 0270591, which has U.S. Application Serial No. 16 / 419,910 filed on May 22, 2019, entitled "Order Fulfillment System" (Applicant Reference No. ALRT-003-2); U.S. Patent Publication No. 2018 / 0134492 published on May 17, 2018, which has U.S. Application Serial No. 15 / 816,832 filed on November 17, 2017, entitled "Automated-service retail system and method" (Applicant Reference No. ALRT-004-101); and U.S. Patent Publication No. 2018 / 0134492 published on July 12, 2018. 2018 / 0194556, which has a U.S. Application Serial No. 15 / 867,373 (Applicant Reference No. ALRT-007-101) filed on January 10, 2018, entitled "Interchangeable automated mobile robots with a plurality of operating modes configuring apllurality of different robot task capabilities"; and U.S. Patent Publication No. 2018 / 0194556 published on May 31, 2018.2018 / 0150793 contains U.S. Application Serial No. 15 / 826,045, filed November 29, 2017, entitled "Automated retail supply chain and inventory management system" (Applicant reference No. ALRT-008-101); U.S. Patent Publication No. 2018 / 0305123, published October 25, 2018, contains U.S. Application Serial No. 15 / 956,346, filed April 18, 2018, entitled "Picking workstation with mobile robots & machine vision verification of each transfer performed by human operators" (Applicant reference No. ALRT-009-102); and U.S. Patent Publication No. 2018 / 0305123, published August 30, 2018. US Patent Publication No. 2018 / 0247257, which includes US Application Serial No. 15 / 903,993, filed February 23, 2018, entitled "Inventory Management System and Method" (Applicant Reference No. ALRT-018-101); US Patent Publication No. 2018 / 0341908, published November 29, 2018, which includes US Application Serial No. 15 / 987,736, filed May 23, 2018, entitled "Fully Automated Self-Service Store" (Applicant Reference No. ALRT-022-101); and US Patent Publication No. 2019 / 0047787, published February 14, 2019, which includes a Universal Gripper for Tote and Sub-Bottling Carrying, filed August 8, 2018. U.S. application series No. 16 / 058,065 (applicant reference No. ALRT-023-001) concerning “sub-tote transport”; and U.S. Patent Publication No. 2020 / 071076, published on March 5, 2020, which has a U.S. application series No. filed on August 28, 2019, entitled “Tote handling for chilled or frozen goods”.16 / 554,512 (Applicant Reference No. ALRT-032-101); U.S. Patent Publication No. 2020 / 0156871, published May 21, 2020, which has a U.S. Application Serial No. 16 / 676,732, filed November 7, 2019, entitled "System having robotic workstation" (Applicant Reference No. ALRT-034-101); U.S. Patent Publication No. 2020 / 0223630, published July 16, 2020, which has a U.S. Application Serial No. 16 / 742,119, filed January 14, 2020, entitled "System having workstation with tote retention and release mechanism" (Applicant Reference No. 16 / 554,512). ALRT-039-101); U.S. Patent Publication No. 2021 / 0300664, published on September 30, 2021, which contains U.S. Application Serial No. 16 / 831,468 (Applicant Reference No. ALRT-041-001), filed March 26, 2020, entitled "Tote handling for chilled or frozen goods"; U.S. Provisional Application Serial No. 63 / 013,504 (Applicant Reference No. ALRT-042-001), filed April 21, 2020, entitled "Transport Rack Cartridge"; and U.S. Provisional Application Serial No. 63 / 013,504 (Applicant Reference No. ALRT-042-001), filed August 19, 2020, entitled "High Density Micro Fulfillment Center 'HD-MFC' with Nighttime G2P Storage Batch Picking Replenishment from Store Floor and Method of Operation thereof". The U.S. provisional application series No. 63 / 067,759 (applicant reference No. ALRT-046-001) concerns "Nightly G2P Storage Batch Pick Replenishment from Store Floor and Method of Operating Same".

[0083] Those skilled in the art will recognize that various other modifications, alterations, and combinations can be made with respect to the embodiments described above without departing from the scope of the invention, and such modifications, alterations, and combinations will be considered to be within the scope of the inventive concept.

Claims

1. An automated order fulfillment system, comprising: Multiple mobile robots configured to transport at least one container, each containing at least one product; A storage structure that can be accessed by the mobile robot and includes a storage location configured to store the container; First workstation; A first buffer sequence structure is positioned between the storage structure and the first workstation and cooperates with both the storage structure and the first workstation. The first buffer sequence structure includes a plurality of buffer channels, the plurality of buffer channels including: A one-way buffer walkway is provided, and each of the first group of mobile robots transporting containers is directed and instructed to stop and wait in the one-way buffer walkway without releasing the corresponding container before proceeding to the first workstation. A second buffer path, in which each of the second group of mobile robots is guided to cross the second buffer path to the first workstation without stopping; and A one-way return path is provided, in which at least one of the first group of mobile robots and at least one of the second group of mobile robots will enter the one-way return path after leaving the first workstation.

2. The order fulfillment system according to claim 1, wherein, The one-way buffer lane is vertically spaced from the second buffer lane and the one-way return lane, and the second buffer lane is vertically spaced from the one-way return lane.

3. The order fulfillment system according to claim 2, wherein, The first buffer sequence structure further includes: The vertical hierarchy is changed, and it is positioned between the first workstation and the one-way return path and cooperates with the first workstation and the one-way return path to provide a return path between the first workstation and the one-way return path.

4. The order fulfillment system according to claim 1, wherein the order fulfillment system further comprises: A control circuit communicatively coupled to the plurality of mobile robots, wherein the control circuit includes at least one buffered control processor and a buffered control memory, the buffered control memory storing executable code configured, when executed by the buffered control processor, to: The first mobile robot in the first group of mobile robots is identified as being associated with the first fulfillment order, and buffers and waits in the one-way buffer lane while holding the first container; Identify the association between the second mobile robot and the first fulfillment order; as well as While the first mobile robot waits in the one-way buffer lane, the second mobile robot is directed to the one-way buffer lane and waits behind the first mobile robot in the one-way buffer lane, while the second container is held on the second mobile robot without being released.

5. The order fulfillment system according to claim 4, wherein, The control circuit is further configured to, after a buffer period, instruct both the first mobile robot and the second mobile robot to leave the one-way buffer path and continue to the first workstation, during which at least the first mobile robot waits on the one-way buffer path.

6. The order fulfillment system according to claim 4, wherein, The control circuit is further configured to: Identify the association between the third mobile robot and the second fulfillment order; While the first mobile robot waits on the one-way buffer lane, and based on the association of the third mobile robot with the second product order, the third mobile robot is directed to the third buffer lane and made to wait in the third buffer lane, while the third container is held on the third mobile robot without being released.

7. The order fulfillment system according to claim 1, wherein the first buffer sequence structure further comprises: A single supply-side vertical hierarchical change structure is positioned between the storage structure and the plurality of buffer aisles; A control circuit, communicatively coupled to the plurality of mobile robots, includes at least one buffered control processor and a buffered control memory, the buffered control memory storing executable code configured, when executed by the buffered control processor, to: The first container, which is transported by the first mobile robot and leaves the first workstation, is identified as the first product in a second fulfillment order pending subsequent fulfillment. The second fulfillment order will be fulfilled by the first workstation; as well as When the first mobile robot is routed to the first workstation during the fulfillment of the second fulfillment order, a return instruction is transmitted to the first mobile robot so that the first mobile robot moves forward to the one-way return path to enter the supply-side vertical hierarchy change structure, and moves vertically through the supply-side vertical hierarchy change structure to the third buffer path among the plurality of buffer paths, while the first mobile robot does not return to the storage structure.

8. The order fulfillment system according to claim 7, wherein the order fulfillment system further comprises: Second buffer sequence structure; as well as A first transport plane is positioned between the storage structure and the supply-side vertical hierarchy change structure of the first buffer sequence structure; The control circuit is further configured to: The second container, which is carried by the second mobile robot among the plurality of mobile robots and leaves the first workstation, holds the second product, and the second product is identified as being in a third fulfillment order pending subsequent fulfillment; Identify that the second fulfillment order will be fulfilled by a second workstation different from the first workstation; as well as The second return command is transmitted to the second mobile robot, causing the second mobile robot to move forward to the one-way return path, enter the first transport plane aligned with the one-way return path, and travel along the first transport plane to the second buffer sequence structure cooperating with the second workstation, without the second mobile robot returning to the storage structure.

9. The order fulfillment system according to claim 1, wherein the order fulfillment system further comprises: A control circuit, communicatively coupled to the plurality of mobile robots, includes at least one buffered control processor and a buffered control memory, the buffered control memory storing executable code configured, when executed by the buffered control processor, to: The first container, carried by the first mobile robot in the first group of mobile robots, is identified and buffered and waited in the one-way buffer aisle, and the first container holds a plurality of first products, wherein at least one of the plurality of first products is routed to the first workstation to fulfill a first fulfillment order; Identify that a second fulfillment order is queued in the order fulfillment queue to be fulfilled after the fulfillment of the first fulfillment order, and that the second fulfillment order includes at least one of the first products; as well as Based on the fact that the first mobile robot is already present in the first buffer sequence structure and is transporting the first product, the priority of the second fulfillment order is re-determined to adjust its position within the fulfillment order queue.

10. The order fulfillment system according to claim 1, wherein the order fulfillment system further comprises: Multiple return lanes, including the one-way return lane; A control circuit, communicatively coupled to the plurality of mobile robots, includes at least one buffered control processor and a buffered control memory, the buffered control memory storing executable code configured, when executed by the buffered control processor, to: Identify a first storage location within the storage structure for a subsequent container to be picked up by a first mobile robot among the plurality of mobile robots; Identify the storage hierarchy within the storage structure, where the subsequent container is located; Identify the first return path among a plurality of return paths including the one-way return path, which is closest to the identified storage level in vertical orientation; as well as Based on the first return path that is closest to the identified storage level in the vertical orientation, a first return instruction in the return instruction is conveyed to route the first mobile robot to the first return path.

11. A method for fulfilling product orders through an automated order fulfillment system, the method comprising: Multiple mobile robots are guided to transport at least one container containing at least one product through a storage structure that can be entered by the mobile robots and includes storage locations configured to store the containers. When routing the corresponding container to the first workstation, each of the first group of one or more mobile robots among the plurality of mobile robots is instructed to transport the corresponding container to a first buffer lane of a first buffer sequence structure located between the storage structure and the first workstation and cooperating with both the storage structure and the first workstation, wherein the first buffer sequence structure includes a plurality of buffer lanes; Instruct each of the first group of mobile robots to stop and wait in the first buffer walkway, without releasing the corresponding container before proceeding to the first workstation; Each of one or more mobile robots in the second group of the plurality of mobile robots is directed to the second buffer walkway to cross the second buffer walkway to the first workstation without stopping in the second buffer walkway; as well as Guide at least one of the first group of mobile robots and at least one of the second group of mobile robots to the return path after leaving the first workstation.

12. The method according to claim 11, wherein, The first buffer lane is vertically spaced from the second buffer lane and the return lane, and the second buffer lane is vertically spaced from the return lane.

13. The method according to claim 12, wherein, Directing at least one of the first group of mobile robots and at least one of the second group of mobile robots to the return path further includes: The system guides at least one of the first group of mobile robots and at least one of the second group of mobile robots to self-propel along at least part of a return vertical hierarchy change structure located between the first workstation and the return path and cooperating with the first workstation and the return path, the return vertical hierarchy change structure providing a vertical return path between the first workstation and the return path.

14. The method of claim 11, further comprising: The first mobile robot in the first group of mobile robots is identified as being associated with the first fulfillment order, and buffers and waits in the first buffer aisle while holding the first container; Identify the association between the second mobile robot and the first fulfillment order; as well as While the first mobile robot is waiting in the first buffer aisle, the second mobile robot is directed to the first buffer aisle and stopped and waited together with the first mobile robot in the first buffer aisle, while the second container is held on the second mobile robot without being released.

15. The method of claim 14, further comprising: After the buffer period, both the first mobile robot and the second mobile robot are directed to leave the first buffer aisle and continue to the first workstation, during which at least the first mobile robot waited in the first buffer aisle.

16. The method of claim 14, further comprising: Identify the association between the third mobile robot and the second fulfillment order; as well as While the first mobile robot is waiting on the first buffer lane, and based on the association of the third mobile robot with the second fulfillment order, the third mobile robot is directed to the third buffer lane and stopped and waited on the third buffer lane, while the third container is held on the third mobile robot without being released.

17. The method of claim 11, further comprising: A first container, transported by a first mobile robot and intended for use in the fulfillment of a first fulfillment order, holds a first product, which is identified as being in a second fulfillment order to be fulfilled subsequently after the fulfillment of the first fulfillment order. The second fulfillment order will be fulfilled by the first workstation; as well as When the first mobile robot is routed to the first workstation while fulfilling the second fulfillment order, a return instruction is transmitted to the first mobile robot. After leaving the first workstation as part of the fulfillment of the first fulfillment order, the first mobile robot is made to move forward to the return path via the return vertical hierarchy change structure to enter the supply-side vertical hierarchy change structure located between the storage structure and the plurality of buffer paths, and move vertically to the third buffer path among the plurality of buffer paths of the first buffer sequence structure, without the first mobile robot returning to the storage structure.

18. The method of claim 17, further comprising: The second container, carried by the second mobile robot among the plurality of mobile robots, holds the second product, and the second product is identified as being in the third fulfillment order pending subsequent fulfillment; The third fulfillment order will be fulfilled by a second workstation different from the first workstation; as well as The second return command is transmitted to the second mobile robot, causing the second mobile robot to move forward to the return path, enter the transport plane vertically aligned with the return path, and travel along the transport plane to the second buffer sequence structure cooperating with the second workstation, without the second mobile robot returning to the storage structure.

19. The method of claim 11, further comprising: The first container, carried by the first mobile robot in the first group of mobile robots, is identified as being buffered and waiting in the first buffer aisle, and the first container holds a plurality of first products, wherein at least one of the plurality of first products is routed to the first workstation to fulfill a first fulfillment order; The second fulfillment order is identified as being queued in the order fulfillment queue of the order to be fulfilled after the fulfillment of the first fulfillment order, and the second fulfillment order includes at least one of the first products; as well as Based on the fact that the first mobile robot is already present in the first buffer sequence structure and is transporting the first product, the priority of the second fulfillment order is re-determined to adjust its position within the order fulfillment queue.

20. The method of claim 11, further comprising: Identify a first storage location within the storage structure for a subsequent container to be picked up by a first mobile robot among the plurality of mobile robots; Identify the storage hierarchy within the storage structure, where the subsequent container is located; Identify the second return path among multiple return paths of the first buffer sequence structure that is vertically closest to the identified storage level in the vertical orientation; as well as The first mobile robot is routed to the second return path based on the second return path that is closest to the identified storage level in the vertical orientation.

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