Intra-rack travel plane automated storage and picking system and method

Abstract

Some embodiments provide an automated order fulfillment system comprising: a storage structure comprising: levels; a storage level change structure establishing a vertical path; a plurality of aisles comprising tracks configured for utilization by mobile robots to move along the aisles; storage locations configured to each store one of a plurality of containers; and a plurality of sets of intra-rack travel planes (IRTPs) interleaved distributed within the storage structure and spaced apart from one another along a first dimension of the storage structure, wherein each set of the plurality of sets of IRTPs comprises two or more IRTPs vertically spaced apart, wherein each IRTP is located in one of the levels; and workstations each configured to receive and dispense a plurality of containers, wherein the workstations are distributed along the storage structure, and wherein at least one IRTP in each of the plurality of sets of IRTPs is proximate to one or more of the workstations.

Description

Technical Field

[0001] This application claims priority to U.S. Provisional Application No. 63 / 627,520, filed January 31, 2024, which is incorporated herein by reference in its entirety. Technical Field

[0002] This invention relates in general to automated inventory control, storage, and picking. Background Technology

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

[0004] This document discloses embodiments of systems, apparatus, and methods related to automated inventory control, storage, and picking. This specification includes accompanying drawings, in which: Figure 1 A simplified block diagram perspective view of at least a portion of an exemplary automated order fulfillment system according to some embodiments is shown.

[0005] Figure 2 A simplified block diagram top view of a portion of an exemplary automated order fulfillment system according to some embodiments is shown.

[0006] Figure 3 A simplified block diagram side view of a portion of an exemplary automated order fulfillment system according to some embodiments is shown.

[0007] Figure 4 A simplified block diagram cross-sectional view of a portion of an exemplary automated order fulfillment system according to some embodiments is shown.

[0008] Figure 5 A simplified block diagram top cross-sectional view of a portion of an exemplary storage structure according to some embodiments is shown.

[0009] Figure 6 A simplified block diagram side view of a portion of an exemplary storage structure according to some embodiments is shown.

[0010] Figure 7 A simplified block diagram top cross-sectional view of a portion of an exemplary storage structure according to some embodiments is shown.

[0011] Figure 8 A simplified block diagram cross-sectional view of a portion of an exemplary automated order fulfillment system according to some embodiments is shown.

[0012] Figure 9A simplified block diagram cross-sectional view of a portion of an exemplary automated order fulfillment system according to some embodiments is shown.

[0013] Figure 10 A simplified perspective view of a portion of the storage structure of an order fulfillment system according to some embodiments is shown, wherein workstations are coupled to and / or incorporated into the storage structure.

[0014] Figure 11 A simplified cross-sectional top view of a portion of an exemplary storage structure according to some embodiments is shown.

[0015] Figure 12 A simplified block diagram cross-sectional view of a portion of an exemplary automated order fulfillment system according to some embodiments is shown.

[0016] Figure 13 A simplified block diagram of an exemplary order fulfillment system according to some embodiments is shown in a top cross-sectional view.

[0017] Figure 14 A simplified block diagram cross-sectional view of a portion of an exemplary automated order fulfillment system according to some embodiments is shown.

[0018] Figure 15 A top cross-sectional view of an exemplary storage structure according to some embodiments is shown.

[0019] Figure 16 A simplified flowchart of an exemplary process for automated order fulfillment according to some embodiments is shown.

[0020] Figure 17 A simplified flowchart illustrating an exemplary process of fulfilling an order through an order fulfillment system according to some embodiments is shown.

[0021] Figure 18 A simplified flowchart illustrating an exemplary process of fulfilling an order through an order fulfillment system according to some embodiments is shown.

[0022] Figure 19 Exemplary systems are shown, according to some embodiments, for implementing methods, techniques, apparatuses, devices, systems, servers, resources, and providing product order fulfillment, unpacking and transfer, consolidation, and inventory management.

[0023] The elements in the figures are shown for simplicity and clarity and are not necessarily drawn to scale. For example, the size and / or relative positioning of some elements in the figures may be exaggerated relative to other elements to aid in understanding the various embodiments. Additionally, for clarity of understanding of these various embodiments, common but well-known elements that are useful or necessary in commercially viable embodiments are generally not depicted. Certain actions and / or steps may be described or depicted in a particular sequence of occurrence, and those skilled in the art will understand that such specificity regarding the sequence is not actually necessary. Unless otherwise specified herein, the terms and expressions used herein have the ordinary technical meaning that those skilled in the art would assign to such terms and expressions. Detailed Implementation

[0024] The following description should not be considered limiting, but is merely for the purpose of describing the general principles of exemplary embodiments. References throughout this specification to “one embodiment,” “embodiment,” “some embodiments,” “implementation,” “some implementations,” “some applications,” or similar language refer to a specific feature, structure, or characteristic described in relation to that embodiment, which is included in at least one embodiment of the invention. Therefore, the phrases “in one embodiment,” “in an embodiment,” “in some embodiments,” “in some implementations,” and similar language appearing throughout this specification may (but not necessarily) all refer to the same embodiment.

[0025] The terms “top” and “bottom,” “upper” and “lower,” and “vertical” and “horizontal” used herein are for illustrative purposes only and are not intended to limit the description of the embodiments, as referenced items may be interchanged in position and orientation. Additionally, as used herein, the terms “substantially” and / or “about” mean that, for a given application, a specified dimension or parameter may vary within acceptable manufacturing tolerances. In one non-limiting embodiment, an acceptable manufacturing tolerance is ±0.25%. For the purposes of this disclosure, connections may be direct or indirect (e.g., via one or more other parts). In some cases, when reference is made to a first element being connected, attached, or coupled to a second element, the first and second elements may be directly connected, attached, or coupled to each other, or indirectly connected, attached, or coupled to each other. When a first element is referred to as being directly connected, attached, or coupled to a second element, there are no intermediate elements between the first and second elements (other than adhesives or welds that may be used to connect, attach, or join the first and second elements).

[0026] Automated order fulfillment systems have limited capabilities due to a variety of factors. These factors include resources, task completion time, congestion, and others. Embodiments of current automated order fulfillment systems and methods improve upon many of these factors. In part, some embodiments provide automated order fulfillment systems that significantly reduce the travel time of mobile robots operating to pick and transport items between storage areas and workstations, where items can be picked and aggregated to fulfill corresponding orders. Furthermore, some embodiments partially improve efficiency by buffering, temporarily storing, and sorting items supplied to workstations. Even further, some embodiments provide more item storage within the same footprint as previous systems by incorporating buffering and sorting within the storage structure, rather than outside of it.

[0027] Figure 1 A simplified block diagram perspective view of at least a portion of an exemplary automated order fulfillment system 100 according to some embodiments is shown. Figure 2 A simplified block diagram top view of a portion of an exemplary automated order fulfillment system 100 according to some embodiments is shown. Figure 3 A simplified block diagram side view of a portion of an exemplary automated order fulfillment system 100 according to some embodiments is shown. Figure 4 A simplified block diagram cross-sectional view (along the Y-axis and perpendicular to the X-axis) of a portion of an exemplary automated order fulfillment system 100 according to some embodiments is shown. See also Figures 1 to 4 The order fulfillment system 100 includes a storage structure 102 having a first horizontal dimension D1 (as shown along the X-axis) and sometimes referred to as length; a second horizontal dimension D2 (as shown along the Y-axis) and sometimes referred to as width; and a third dimension D3 (as shown along the Z-axis) and sometimes referred to as height. The storage structure is further assembled to include vertically spaced (e.g., as shown in the image). Figure 1The storage structure 102 includes multiple layers 104 (along the Z-axis) and separated by corresponding vertical distances, and multiple storage layer changing structures 106 spaced apart along a first dimension of the storage structure 102 and establishing vertical paths between the layers 104. The storage layer changing structures 106 can be configured for use by a mobile robot 110 to move vertically between the layers. The automated order fulfillment system 100 may further include one or more control circuits 101 and / or robot scheduling 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 these networks). In some embodiments, the control circuits 101 communicate with workstation 126, sensors, databases (e.g., inventory database, customer database, historical database, etc.), inventory management system, order receiving system, other systems of the order fulfillment system 100, or combinations of two or more of such systems.

[0028] The storage structure 102 further includes a plurality of aisles 112, each aisle extending through at least a corresponding portion of the storage structure and extending along at least a portion of a first dimension D1 of the storage structure. In some embodiments, at least some of the plurality of aisles, and typically each aisle 112, includes tracks, rails, and / or other such structures configured to be utilized and / or engaged by the mobile robot 110 for horizontal movement along the aisle. At least some of the aisles include storage locations 114 positioned on the level 104 and spanning at least one side and typically both sides of each aisle 112. Storage locations 114 may be configured to each store at least one of a plurality of containers that store one or more items to be picked to fulfill a fulfillment order to be fulfilled by the fulfillment system 100 and / or facilities.

[0029] In some embodiments, one or more sets of in-shelf access planes 122 (IRTPs) 120 may be staggered within the storage structure 102 and horizontally spaced apart from each other along a first dimension D1 of the storage structure. Each set of IRTPs 120 includes one or more IRTPs 122. When a set of 120 includes two or more IRTPs 122, the two or more IRTPs may be vertically spaced apart from each other, wherein each IRTP 122 is located in one of the hierarchies 104. In some embodiments, the IRTPs are horizontal plane structures, each horizontal plane structure including a horizontal plane surface extending over a region and configured to enable the mobile robot 110 to move on the IRTP in any horizontal direction (e.g., across the plane along the X and Y axes, such as...). Figure 1(As shown in the diagram). One or more of the IRTPs 122 may cooperate with one or more aisles 112, one or more hierarchical change structures 106, and / or one or more workstations 126 to enable the mobile robot 110 to traverse the order fulfillment system 100 between storage locations 106 and workstations 126, while controlling the flow of the mobile robot to improve throughput, reduce congestion, reduce mobile robot demand, and other such benefits. The mobile robot 110 may maneuver in the XY plane of each IRTP 122 to allow transitions between different aisles 112, different workstations 126, and / or other parts of the storage structure. Some embodiments may further include one or more passageways located at one or more ends and / or portions of one of the ends of the storage structure 102.

[0030] In some embodiments, the storage structure 102 includes at least one, and typically multiple, workstations 126, and / or cooperating therewith. Workstations 126 may be configured to receive and distribute multiple containers 302 (e.g., bins, boxes, bags, sub-bins, cartons, etc.) conveyed by a mobile robot 110. In some embodiments, the mobile robot 110 enters the workstation 126 while conveying at least one container 302 and holds the container on the mobile robot without releasing the container 302 as the mobile robot moves the container into, through, and out of the workstation 126. Workstations 126 may be distributed along the storage structure 102. In some embodiments, workstations 126 are distributed along one or more sides of the storage structure (e.g., at least on both sides extending over a first dimension D1). One or more other workstations may be located at one or more ends of the storage structure and / or detached from the storage structure.

[0031] In some embodiments, some or all of the workstations 126 may be positioned close to one group of IRTPs 122 in a plurality of groups 120. In some embodiments, at least one of the IRTPs 122 in the plurality of groups 120 is close to one or more of the workstations, and in some embodiments, is aligned with and cooperates with one or more of the workstations 126.

[0032] Further details of the workstation 126, storage structure 102, mobile robot 110, and planar structure (which may be utilized in at least some embodiments) are described, for example, in the following U.S. patents and patent applications: U.S. Patent No. 9,139,363, entitled "Automated System for Transporting Payloads," issued September 22, 2015; U.S. Patent No. 10,435,241, entitled "Storage and Retrieval System," issued October 8, 2019; U.S. Patent No. 11,142,398, entitled "Order Fulfillment System," issued October 12, 2021; and U.S. Patent No. 11,142,398, entitled "Automatic Storage and Retrieval System having Staging and Sequencing Buffer Locations and Segregated Storage," published March 30, 2023. U.S. Patent Application Publication No. 2023 / 0095494 entitled “Storage” (Attorney’s File No. 8842-157747-US_8182US03); U.S. Patent Application Publication No. 2022 / 0063910 entitled “Order Fulfillment System”, published March 3, 2022; and U.S. Patent Application Serial No. 18 / 268,204 entitled “Methods and Apparatus for Facilitating Transport of Items Between a Store and a Customer via a Customer Access Portal” (Attorney’s File No. 8842-156750-US_8154US01), each of which is incorporated herein by reference in its entirety.

[0033] See also Figures 1 to 4In some embodiments, each of the multiple sets of IRTPs 120 includes at least a first IRTP 122 located at a first level 104 and physically connected to at least one corresponding workstation 126 to establish a path to or from the corresponding workstation. For example, in some embodiments, the IRTP 122 may be positioned to be physically connected to at least one workstation via a set of tracks, rails, etc., extending directly from the IRTP to the workstation 126. In some embodiments, one or more of the workstations 126 may be multi-level workstations. For example, a first workstation level may be a feed or inbound workstation level used by the mobile robot 110 to enter the workstation, and a second workstation level vertically separated from the first workstation level may be used as an outbound or exit workstation level used by the mobile robot to leave the workstation. One or more workstation levels may be incorporated into the workstations with altered structures and may be configured to be engaged and used by the mobile robot 110 for autonomous propulsion between at least the first and second workstation levels. For multi-level workstations, multiple sets 120 of IRTPs 122 may include at least two IRTPs positioned close to at least one of the workstations, and in some embodiments, each aligned with and cooperating with a corresponding one of the multiple workstation levels. For example, the lower of the two IRTPs 122 may be assigned as an inbound IRTP and may cooperate with a lower workstation level 304 to provide a feed or inbound path from the lower IRTP to the corresponding workstation; and the higher of the two IRTPs 122 may be assigned as an outbound IRTP and may cooperate with a second or higher workstation level 305 to provide an outbound or exit path from the corresponding workstation to the higher IRTP. Alternatively or additionally, one or more workstations may be single-level workstations. A single IRTP may cooperate with a single workstation level to provide a path for the mobile robot to approach the workstation. For example, one or more workstations may be pass-through workstations, where a mobile robot enters at a single workstation level on one side of the pass-through workstation, travels across the width of the workstation at the single workstation level, and exits the workstation from the single workstation level. One or more workstations may include and / or may also utilize other workstations comprising one or more functionalities, such as, but not limited to: enabling one or more mobile robots to drive into and wait while performing a task at the workstation, and then exit; enabling one or more mobile robots to additionally or alternatively release a container at the workstation, and then the same or different mobile robots may later pick up the placed container; one or more workstations may also cooperate with one or more conveying systems to enable containers to be additionally or alternatively conveyed to and from the workstation; and / or other workstation functionalities and / or workstations (e.g., one or more workstations described in the patents and patent applications mentioned above and below).

[0034] As described above, each IRTP in group 120 may include one or more IRTPs 122, and typically includes a plurality of vertically spaced IRTPs 122. One or more or all of the IRTPs may be aligned with different levels 104 of the storage structure 102. In some embodiments, one or more of the IRTPs or each group 120 includes at least three IRTPs 122 that are each vertically aligned with each other (e.g., along the Z-axis), and each of the at least three IRTPs is located at a different level in the levels 104 of the storage structure 102. Similarly, in some embodiments, one or more of the IRTPs in multiple groups 120 each cooperate with one or more workstations 126. For example, one or more of the IRTPs in multiple groups 120 may include a first IRTP and a second IRTP of at least three IRTPs. The first IRTP and the second IRTP may each be aligned and coupled to one or more workstations 126 at different corresponding levels. For example, Figure 3 Exemplary multiple groups 120 are shown, each comprising four IRTPs 122a-122d. Each group 120's four IRTPs 122a-122d includes one or more IRTPs aligned with at least one workstation 126. For example, as... Figure 3 As shown, the multiple sets of IRTPs 120 include a first IRTP 122a (e.g., horizontally aligned along level 104_L1) coupled to and / or aligned to a first workstation level 304, and a second IRTP 122b (e.g., horizontally aligned along level 104_L2) coupled to and / or aligned to a second workstation level 305. One or more IRTPs may not be aligned to a workstation.

[0035] In some embodiments, one or more IRTPs are configured to extend along a second dimension D2 and, in some cases, at least substantially across a portion of the storage structure 102 in which they are positioned (e.g., the storage structure may have multiple distinct segments or portions with different second dimensions, and corresponding IRTPs positioned within those respective segments may have different dimensions corresponding to the corresponding second dimension of the portion of the storage structure in which they are positioned). In some embodiments, two or more IRTPs 122 of one or more sets 120 may extend along a corresponding second dimension D2 across the storage structure 102 to intersect with multiple aisles 112 at a corresponding level 104 where the corresponding IRTP is positioned, to establish an aisle-crossing movement path. Furthermore, one or more IRTPs 122 may extend along the second dimension, cooperating with a different workstation 126 at each of their opposite ends. For example... Figure 4An exemplary embodiment is shown, comprising a first IRTP 122a of a set of IRTPs coupled to two workstations 126a, 126b, wherein each of the two workstations 126a-126b is positioned at opposite ends 402a, 402b of the first IRTP 122a. As described above, in some embodiments, two or more IRTPs may be aligned with and / or cooperate with workstations. Similarly, Figure 4 An exemplary embodiment is shown to further include a second IRTP 122b of a set of IRTPs, which is connected to two workstations 126a, 126b, wherein each of the two workstations 126a-126b is located at opposite ends 402a, 402b of the second IRTP 122b.

[0036] Figure 5A simplified block diagram top cross-sectional view of a portion of an exemplary storage structure 102 according to some embodiments is shown. A hierarchy 104 containing at least one of IRTPs 122 includes and / or provides a two-dimensional (2D) mesh for mobile robot travel paths traversing the respective hierarchy. The 2D mobile robot travel paths may include a plurality of first-dimensional travel paths 504 along a plurality of aisles 112, each intersecting at a respective hierarchy with at least one, and typically a plurality of, second-dimensional travel paths 506, which traverse a plurality of IRTPs 122 spaced apart and separately positioned along a first dimension D1 of the storage structure 102. For example, a first mobile robot 110a may travel from a first storage location 114a along a first-dimensional travel path 504a_1 to intersect with a second-dimensional travel path 506a and another first-dimensional travel path 504a_2. Similarly, the second mobile robot 110b can travel from the second storage location 114b along a first-dimensional travel path 504b_1 to intersect with a second-dimensional travel path 506b and another first-dimensional travel path 504b_2. Thus, two or more or each of the IRTPs 122 in each of the multiple sets 120 extend along the second dimension D2 to intersect with corresponding subsets of aisles 112 along the corresponding levels in the hierarchy, establishing multiple access paths to and from the corresponding aisle subsets within the storage structure. Furthermore, storage hierarchy change structures 106, typically spaced apart at different locations along the first dimension D1 of the storage structure 102, can connect the 2D mesh and hierarchy of the mobile robot travel paths to establish a three-dimensional (3D) mesh of the mobile robot travel paths throughout the storage structure. Essentially any number of related 2D meshes of mobile robot travel paths (with the same or different dimensions) can be stacked to achieve the desired storage location capacity. Vertical movement (e.g., in the Z-axis direction) between 2D meshes is achieved by changing the structure 106 via the storage hierarchy to interconnect the 2D meshes (e.g., the XY axes). The 2D and 3D meshes or arrays of the mobile robot's travel path provide significantly reduced travel distances, reduced travel times, increased efficiency, and other such benefits. Some embodiments can further improve efficiency using fewer mobile robots 110.

[0037] At least refer to Figure 3In some embodiments, at least a subset of one or more storage hierarchy change structures 106 are positioned proximate to each workstation 126. These storage hierarchy change structures 106 proximate to the workstations provide inbound and / or outbound paths from other hierarchies to the IRTP hierarchy at the hierarchy cooperating with the corresponding workstation 126. In some embodiments, for each of the workstations 126, at least one inbound storage hierarchy change structure 106a is positioned on a first side 310 of the corresponding workstation 126 and / or on a first side of the IRTP of the corresponding group 120 aligned with the corresponding workstation, and an outbound storage hierarchy change structure 106b is positioned on a second side 311 of the corresponding workstation and / or on a second side of the IRTP of the corresponding group 120 aligned with the corresponding workstation. In some embodiments, the inbound storage hierarchy change structure 106a may be unidirectional and limited to movement of the mobile robot 110 toward the corresponding workstation. For example, the inbound storage hierarchy change structure 106a may be limited to movement of the mobile robot downwards within the storage structure. In some embodiments, the outbound storage hierarchy change structure 106b may be unidirectional and limited to the mobile robot 110 moving toward the corresponding workstation. For example, the inbound storage hierarchy change structure 106a may be limited to unidirectional upward movement of the mobile robot leaving the workstation. For example, two or more storage hierarchy change structures 106 of a first group may be positioned on a first side of the IRTP 122 of a group 120, and each of the two or more storage hierarchy change structures 106 of the first group may be dedicated to unidirectional movement (e.g., downward movement). Similarly, two or more storage hierarchy change structures 106 of a second group may be positioned on the other side of the IRTP 122 of a group 120, and each of the two or more storage hierarchy change structures 106 of the second group may be dedicated to unidirectional movement opposite to that of the first group (i.e., upward movement). Other storage hierarchy change structures 106 of the fulfillment system may similarly be limited to either upward or downward directional movement of the mobile robot 110. In some embodiments, one or more of the storage hierarchy change structures may provide bidirectional movement.

[0038] In some embodiments, by utilizing different tiers of IRTPs as inputs and outputs to corresponding workstations, the flow of mobile robot 110 can be improved and / or congestion reduced. In some embodiments, a first IRTP 122a may extend horizontally along a first tier 104 and be aligned with a workstation exit tier 305 of at least one and typically two workstations 126, such that at least a subset of mobile robots leaving one or two workstations onto the first IRTP 122a travel along at least a portion of the first IRTP toward a corresponding exit storage tier change structure 106b near the corresponding one or two workstations. Similarly, a second IRTP 122b of a set of two or more IRTPs may extend horizontally along a second tier 304 vertically spaced from the first IRTP 122a and be aligned with at least one workstation inbound tier 304 of at least one and typically two first workstations. At least a subset of the mobile robots can vertically enter the second IRTP from the corresponding inbound storage level 106a near the corresponding one or two workstations, and horizontally enter the first workstation, for example, from the second IRTP 122b.

[0039] See Figures 1 to 4 In some embodiments, control circuitry 101 is configured to wirelessly transmit instructions to mobile robot 110 to schedule the mobile robot between storage location 106 and workstation 126. In some embodiments, control circuitry 101 is further configured to define a buffer for two or more of the mobile robots 110 within storage structure 102 and near a designated one in workstation 126. For example, Figure 3Multiple groups of one or more mobile robots, 320a, 320b, according to some embodiments, are shown buffered in one or more aisles 112 near the respective workstation 126. When one or more mobile robots are ready to fulfill an order they have buffered, reach a threshold position in the order fulfillment queue, and / or within the expected order fulfillment time, the buffered mobile robot associated with the order may be instructed to move directly from the buffer aisle to the inbound IRTP, and / or engage the storage level change structure 106 and move vertically to the inbound IRTP to prepare to advance itself into the workstation 126 according to the order fulfillment queue. The buffering of mobile robot 110 can be used to enhance the scheduling of mobile robots in the temporary storage and sorting of containers transported by the mobile robots, in order to manage congestion, improve the speed of product delivery, improve the speed of order fulfillment, reduce the number of mobile robots, improve workstation utilization, reduce latency, improve the utilization of storage structure, improve efficiency, eliminate waiting constraints and dwell time between orders for fulfilling overlapping orders, enable skipping task assignments and / or reprioritizing task assignments when there is a threshold productivity improvement and / or simplification, improve the productivity of fulfillment system equipment, reduce costs, improve capacity, and other such benefits. Allowing workstations to operate along the storage structure and in cooperation with the IRTP enables mobile robots to be temporarily buffered directly within storage structure 102 to prepare for the fulfillment of corresponding fulfillment orders according to the order fulfillment queue. In some embodiments, a separate order fulfillment queue may be maintained for each workstation 126.

[0040] In some embodiments, when defining a buffer for mobile robot 110, control circuitry 101 may be configured to determine that one or more mobile robots are associated with a first fulfillment order, and while holding the corresponding container 302, buffer and temporarily stop on a first aisle 112 of storage structure 102, and near a first workstation 126 designated as fulfilling at least a portion of the first fulfillment order. In some cases, control circuitry may further determine that a second mobile robot 110 is also associated with the first fulfillment order, and based on the association with the first fulfillment order and the buffering of the first mobile robot, when buffering the second mobile robot, a buffering instruction may be transmitted to the second mobile robot to instruct the second mobile robot to proceed to the first aisle adjacent to the first mobile robot, to stop and wait in the first aisle while holding the corresponding container 302. This buffering of the second robot with the buffered first mobile robot consolidates the containers corresponding to the first fulfillment order before scheduling the containers to the workstation, allowing mobile robots associated with the first fulfillment order to be cooperatively scheduled to the workstation in an attempt to simplify the picking of items when fulfilling the first fulfillment order.

[0041] Figure 6 A simplified block diagram side view of a portion of an exemplary storage structure 102 according to some embodiments is shown. Figure 7 A simplified block diagram top cross-sectional view of a portion of an exemplary storage structure 102 according to some embodiments is shown. See also Figures 6 to 7 In some embodiments, in the buffered mobile robot 110, control circuitry 101 may instruct the mobile robot to reach one or more aisles 112 of one or more adjacent storage structure segments 602b of the storage structure 102 adjacent to the inbound storage level change structure 106a, and / or designate workstation 126 to the workstation segment 602a of the storage structure to which it is positioned and / or aligned. For example, control circuitry may determine that the first mobile robot 110a arrives before the fulfillment of a corresponding order, and may instruct the first mobile robot 110a to stop at a level consistent with the aisle 112a into which the first mobile robot 110a enters as the mobile robot descends along the inbound storage level change structure 106a. In some embodiments, control circuitry may instruct the first mobile robot to buffer in an aisle aligned with the inbound storage level change structure 106a used by the first mobile robot and / or in an aisle reached by the mobile robot. For example, see Figure 7In some embodiments, a mobile robot may be instructed to descend along a first inbound storage level change structure 106a to a corresponding first aisle 112a, a mobile robot may be instructed to descend along a second inbound storage level change structure 106a_2 to a corresponding second aisle 112, a mobile robot may be instructed to descend along a third inbound storage level change structure 106a_3 to a corresponding third aisle 112c, and so on. In other cases, the control circuitry may instruct the first mobile robot to move onto the IRTP 122 and laterally move into a designated aisle. As described above, in some embodiments, the control circuitry may organize queued mobile robots to line up with other mobile robots already buffered for the same fulfillment order (e.g., using one of the IRTP 122 to move across to the appropriate aisle before or after descending along the storage level change structure). In some embodiments, the control circuitry 101 may further instruct one or more other mobile robots (e.g., 110b, 110c) to move to make room for the first mobile robot 110a in the intended aisle 112a. Note that in some embodiments, the first dimension 702 (e.g., along the X-axis) of one or more of the IRTPs 122 may be smaller than a similar dimension 704 of the workstation segment 602a within which the IRTP is positioned. This dimensional difference can provide a gap between the storage tier change structure 106 and the IRTP to allow the mobile robot 110 to move vertically up and down without interference from the IRTP. In other embodiments, one or more of the IRTPs may have openings through which the mobile robot can pass during vertical movement. Furthermore, tracks, rails, and / or other such structures may extend across the gap between the storage tier change structure 106 and the IRTP to enable the mobile robot to move back and forth between the storage tier change structure 106 and the IRTP 122.

[0042] In some embodiments, instructing the mobile robot to buffer may depend on confirmations that: the fulfillment order has not been processed by the designated workstation when the mobile robot moves toward the designated workstation; the fulfillment order is later than a threshold position in the order fulfillment queue corresponding to the designated workstation; other such factors; or a combination of such factors. The threshold position in the order fulfillment queue may depend on the expected time it will take for the mobile robot associated with the order to reach the designated workstation, the predicted time to fulfill the fulfillment order at the workstation, and / or other such factors.

[0043] When an order is about to be fulfilled and / or fulfilled within a threshold time, one or more mobile robots that are buffered for the order and / or have reached their scheduled time to be dispatched to the workstation may be instructed to proceed directly to the inbound IRTP 122a without buffering. In some embodiments, the order fulfillment queue corresponding to the workstation may be evaluated by control circuitry. For example, the queue evaluation may include determining the expected fulfillment time of the order, comparing the expected fulfillment time with one or more time 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 in the order fulfillment queue, congestion conditions, mobile robot buffer locations within storage structure 102, the number of open buffer aisles and / or buffer areas of one or more IRTPs, other such factors, or a combination of two or more such factors.

[0044] Alternatively or alternatively, some embodiments utilize one or more aisles 104 located in workstation section 602a and vertically positioned above one or more IRTPs 122a, 122b, which are aligned with the first workstation. Figure 8 A simplified block diagram cross-sectional view of a portion of an exemplary automated order fulfillment system 100 according to some embodiments is shown, wherein a first workstation 126a is positioned aligned with and / or combined with a workstation segment 602a of a storage structure 102. Figure 9 A simplified block diagram cross-sectional view (along the Y-axis and perpendicular to the X-axis) of a portion of an exemplary automated order fulfillment system 100 according to some embodiments is shown. (See at least...) Figures 8 to 9In some embodiments, additionally or alternatively, one or more aisles 112a, 112b, 112c at multiple levels (e.g., levels 104_L1–104_L18) within workstation segment 602a (aligned with and / or located therein with the first workstation 126a) may be used for buffering and / or sorting one or more mobile robots 110. For example, a set of levels 802 along the first aisle 112a (e.g., four levels 104_L3–104_L6) may be used for buffering and / or sorting one or more mobile robots 110 intended to be dispatched to the first workstation 126a to fulfill one or more orders. Lower levels (e.g., levels 104_L1 and 104_L2) may correspond to inbound IRTP 122a and outbound IRTP 122b. As described above, some embodiments may also utilize inbound IRTPs for buffering and / or sorting one or more mobile robots. Additionally, or alternatively, one or more levels 104 of one or more adjacent segments 602b may be used to buffer and / or sort containers 302. In some embodiments, adjacent segments 602b of workstation segment 602a may not include IRTPs at lower levels (e.g., the two lower levels 104_L1 and 104_L2 at the bottom). Thus, these lower levels can be used as part of buffering and / or sorting. In some embodiments, the lowest level 104_L1 is aligned with the input to workstation 126a, and thus, the mobile robot 110 buffering and / or sorting in the aisle at the lowest level 104_L1 may move directly from the aisle at the lowest level 104_L1 to the lowest level IRTP 122a without engaging the storage level change structure 106. Therefore, when scheduling the mobile robot, the control circuit 101 may prioritize the lowest level 104_L1 aisle 112 of adjacent segment 106b over other levels.

[0045] Figure 10 A simplified perspective view of a portion of a storage structure 102 of an order fulfillment system 100 according to some embodiments is shown, wherein a workstation 126 is coupled to and / or incorporated into the storage structure 102. (See at least...) Figure 1 and Figures 7 to 10 As described above and further below, the mobile robot 110 can buffer at one or more locations. For example, Figure 10A buffer location “B” is shown within one or more aisles adjacent to workstation 126. As described above, in some embodiments, workstation 126 may be a multi-level workstation (e.g., two workstation levels 304, 305, three workstation levels, four workstation levels, or other associated number of workstation levels). Mobile robot 110 may be dispatched from buffer location B (e.g., one or more aisles in workstation segment 602a and / or one or more aisles in adjacent segment 602b). When the mobile robot is located at a level above inbound IRTP 122a, it may move from the corresponding aisle and engage the inbound storage level change structure 106a connected to the corresponding aisle, and self-propel itself down along the inbound storage level change structure 106a to the level where inbound IRTP 122a is located (e.g., in many embodiments, inbound IRTP 122a is the lowest level (104_L1) or a set of lowest levels, such as when the workstation includes multiple inbound workstation levels).

[0046] The mobile robot can move out of the inbound storage hierarchy change structure 106a S1 and onto the inbound IRTP 122a. In some embodiments, the workstation may have one or more access points 1002a, 1002b, and similarly include one or more entrances spanning the inbound IRTP 122a. Thus, the mobile robot can be scheduled to traverse the inbound IRTP 122a to align with a designated robot entrance among a plurality of robot entrances of the workstation 126a. The robot can then rotate to align with the orientation of the corresponding access point of the workstation. Depending on the sequence, the mobile robot can advance along the inbound IRTP 122a S2 to move through the corresponding workstation entrance and enter the workstation's entrance hierarchy 304 (e.g., the lowest workstation hierarchy), and cooperate with one or more workstation hierarchy change structures 1004 within the workstation S3. When the access point is clear (e.g., the previous mobile robot has moved out of alignment with the access point and the workstation), the mobile robot can vertically self-propel itself along the workstation hierarchy structure 1004 to position itself in alignment with the workstation's access point S4, so as to perform a specified workstation task relative to the positioned mobile robot. Workstation tasks may include picking one or more items from a product container 302p delivered by the mobile robot, inserting one or more items into a container (e.g., when the container is an order container, a merging task is being performed, an unpacking and transfer task is being performed, etc.), removing one or more items from an order in an order assignment task, inserting one or more containers into a container import task and cooperating with the mobile robot to import one or more containers into the storage structure 102, removing the mobile robot from the workstation, and / or other such tasks. Therefore, in some embodiments, two or more of the workstations 126 may be configured as multi-functional workstations to perform multiple different tasks, such as unpacking and transferring boxes, collections, or other such multiple items into one or more containers, importing at least a subset of multiple containers into a storage structure, picking individual items from multiple product containers, placing items into order containers, merging items from several containers into fewer containers, assigning fulfilled orders, other such tasks, or combinations of two or more such tasks. In some embodiments, the workstations and IRTPs are sized to facilitate collaboration with section 602. For example, in some embodiments, the section is modular, making it easy to assemble and fit within substantially any relevant area. For example, section 602 may have a width substantially equal to a fixed number of storage locations, such as 7 storage locations wide, 8 storage locations wide, 10 storage locations wide, 6 storage locations wide, or substantially any other relevant size.

[0047] Once the workstation task is completed, the S5 mobile robot can be instructed to leave the workstation through the workstation's exit, moving out of E1 and onto the exit IRTP 122b. Once on the exit IRTP 122b, the mobile robot can move away from the workstation along the exit path. For example, in some embodiments, each mobile robot leaving the workstation can move away from the workstation along the exit IRTP 122b to align with a predetermined exit storage level change structure 106b, rotate E2 to align with the orientation of the engaging exit storage level change structure 106b, move out of the exit IRTP 122b, and engage the E3 exit storage level change structure 106b. Once engaged, the mobile robot can vertically advance to assignment level 104 to initiate subsequently assigned tasks (e.g., returning a container being transported to one of storage locations, which may be close to a subsequent container to be picked by the mobile robot); transporting containers directly to different workstations (which may include buffering near different workstations); transporting containers to circulate towards and buffer relative to the same workstation in preparation for fulfilling subsequent orders at the same workstation; and / or other such subsequent tasks. Workstations provide access to the interior of container 302. In some embodiments, a worker and / or one or more automated picking systems (e.g., articulated arms or other such systems) can pick one or more items from containers located within access points or openings positioned at the workstation. In some embodiments, one or more workstations include multiple access points. Workstations and multi-access workstations may be implemented similarly to those described in U.S. Patent Nos. 9,139,363; 10,435,241; 11,142,398; U.S. Patent 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.

[0048] Furthermore, in some embodiments, control circuitry 101 may instruct other mobile robots (such as mobile robots conveying empty order containers 302x) to utilize inbound IRTP 122a to coordinate with other product containers 302p conveyed by one or more mobile robots in buffer and / or bypassing buffers to schedule the empty order containers to the workstation. Product containers 302p carry one or more items for fulfilling one or more fulfillment orders, while one or more order containers 302x may receive and combine one or more items picked from product containers 302p and inserted into the corresponding order containers at the workstation.

[0049] Figure 11 A simplified cross-sectional top view of a portion of an exemplary storage structure 102 according to some embodiments is shown. Figure 12 A simplified block diagram cross-sectional view (along the Y-axis and perpendicular to the X-axis) of a portion of an exemplary automated order fulfillment system 100 according to some embodiments is shown. (See at least...) Figures 11 to 12 In some embodiments, empty order containers 302x can be moved to workstation 126 based on a predetermined order container movement pattern. Similarly, in some embodiments, the workstation may have multiple access points 1002a, 1002b, one of which may be assigned to receive order containers, while one or more other access points 1002b may be assigned to receive product containers 302p. This configuration enables the picking of items from product containers and their movement into order containers to aggregate items for fulfilling orders. Mobile robots transporting order containers may be temporarily stored in one or more aisles (e.g., 112x and 112y). These temporary storage aisles may be different from the aisles used for buffering product containers. This allows for the smooth flow of empty order containers without disrupting buffering. In other cases, mobile robots transporting order containers may be staggered with mobile robots transporting product containers within buffer aisles. Mobile robots transporting order containers may be scheduled to move from temporary storage aisles and onto inbound IRTP 122a to rank alongside one or more other mobile robots transporting order containers. Typically, mobile robots are aligned with designated access points (e.g., access point 1002a). However, one or more mobile robots may make one or more turns on the inbound IRTP 122a according to the queue. Note that mobile robots conveying order containers may further pause or buffer in an aisle at a different level 104 from the inbound IRTP 122a, and engage the corresponding inbound storage level change structure 106a to vertically move themselves to the corresponding level of the inbound IRTP 122a. (Regarding...) Figure 10 The process is similar, with the mobile robot that delivers the order container moving into the entrance of the workstation, altering the structure of the workstation level to vertically advance itself to the appropriate workstation approach level, and positioning the order container to align with the corresponding access point 1002a.

[0050] In some embodiments, additionally or alternatively, other aisles and / or one or more IRTPs may be used to buffer mobile robots and / or to sequence mobile robots to achieve a desired order in which mobile robots move sequentially to the corresponding workstation 126. For example, in some embodiments, when buffering is defined, control circuitry 101 may be configured to transmit instructions to a third mobile robot and separate instructions to a fourth mobile robot, each associated with a second fulfillment order specified for performance at the first workstation, to travel through storage structure 102 (e.g., along one or more aisles, one or more IRTPs, and / or one or more storage hierarchies) to an IRTP 122 aligned with and connected to the first workstation 126, and to stop and wait without releasing the corresponding containers 302 delivered by the third and fourth mobile robots, and then continue to the first workstation after at least the third mobile robot has waited for the corresponding buffering period. In some embodiments, the size of one or more IRTPs 122 may be set to allow multiple mobile robots 110 to simultaneously position on and / or travel through the same IRTP. For example, the size of the first IRTP 122 may be configured such that two or more mobile robots (e.g., a third and a fourth mobile robot) can buffer on the first IRTP, allowing at least one additional mobile robot (e.g., a fifth mobile robot) to enter and travel on the first IRTP to approach and enter the first workstation, while the third and fourth mobile robots wait on the first IRTP and are not blocked from entering the first workstation by the third and fourth mobile robots. The buffering period may depend on one or more factors, such as, but not limited to: the position of the corresponding order in the order fulfillment queue, the expected average duration of order completion, the number of containers to be scheduled to the designated workstation when fulfilling a specified portion or all of the orders assigned to the workstation, the travel distance of the order containers to the designated workstation, the order fulfillment queue of one or more other fulfillment orders pending processing at the designated workstation before the relevant fulfillment order, the number of containers and mobile robots associated with an earlier fulfillment target in the order fulfillment queue, the expected rate of processing each of the containers at the designated workstation 126, other such factors, or a combination of two or more such factors.

[0051] In some embodiments, control circuitry 101 further schedules one or more mobile robots to sort and / or organize mobile robots approaching and entering a specific workstation 126. Sorting provides an ordered sequence of mobile robots. For example, this allows mobile robots fulfilling a single order to be arranged sequentially, one after another, to enter the same workstation designated for fulfilling at least the relevant portion of a single fulfillment order. For example, in some embodiments, control circuitry 101 may be configured to transmit instructions to a first mobile robot (which is conveying a container with items intended for fulfilling the first fulfillment order) to move onto a first IRTP 122 in the first group 120 of IRTPs, and, upon approaching the first workstation 126 coupled to the first IRTP, to position itself between a second and a third mobile robot already on the first IRTP, according to the order fulfillment order corresponding to the first fulfillment order and one or more other fulfillment orders designated for fulfillment via the first workstation. Alternatively or additionally, sorting may also be managed by releasing buffered mobile robots from the aisles associated with the inbound IRTP and / or feeding directly to one or more mobile robots without buffering. In some embodiments, sorting is performed within storage channels on multiple levels (e.g., first level 104_L1 and second level_L2) of the IRTP 122 that feeds toward the workstation.

[0052] In some embodiments, the order fulfillment system 100 may include multiple different zones or areas. For example, in some embodiments, the order fulfillment system 100 may include multiple different temperature zones in which different items may be temporarily stored, and which need to be kept at different temperatures while awaiting picking to fulfill different fulfillment orders.

[0053] Figure 13A simplified block diagram top cross-sectional view of an exemplary order fulfillment system 100 according to some embodiments is shown. The order fulfillment system may include multiple distinct zones 1302-1304. For example, the zones may include: a first temperature zone 1302, which is maintained at a first temperature and / or within a first temperature range (e.g., an ambient temperature range, such as +80℉ to +43℉); a second temperature zone 1303, which may be maintained at a second temperature and / or within a second temperature range, the temperature of which is lower than the first temperature range (e.g., a refrigeration temperature, such as +41℉ to +35℉); and a third temperature zone 1304, which may be maintained at a third temperature and / or within a third temperature range, the temperature of which is lower than the second temperature range (e.g., a freezing temperature, such as 34℉ to -10℉). Inner walls 1308, curtains, doors, and / or other structures may be included to separate these zones and to help maintain the desired temperature within the respective zones 1302-1304. As a non-limiting example, the order fulfillment system 100 may include an ambient temperature zone, a refrigeration temperature zone, and a freezing temperature zone. One or more temperature systems may work in conjunction with one or more in the zone to manage temperature (e.g., based on sensor feedback from one or more locations within the respective zone).

[0054] The order fulfillment system 100 includes one or more storage structures 102 extending within each zone and / or between two or more zones, and configured to allow a mobile robot 110 to traverse the storage structures at least within a corresponding zone, and in some embodiments, to move between different zones. One or more workstations 126 may be included in or cooperate with one or more of the different zones 1302-1304. For example, one or more workstations 126 may be distributed along a first zone 1302 (e.g., extending only along a first dimension D1), and one or more workstations 126 may be distributed along a second zone 1303 (e.g., extending only along the first dimension D1). In some embodiments, one or more zones may not include workstations (e.g., a frozen zone may not include workstations to avoid the picking machine or picking system operating within a third temperature range). The mobile robot 110 may be scheduled to pick one or more third temperature zone containers 302 and deliver the third temperature zone containers to workstations in the first temperature zone 1302 and / or the second temperature zone 1303.

[0055] Furthermore, one or more of the different zones 1302-1304 may include one or more sets of 120 IRTPs 122. In some embodiments, one or more IRTPs may extend horizontally between two or more of the different zones. For example, one or more IRTPs 122 of one or more sets of 120 may extend along a second dimension D2 between the first zone 1302 and the second zone 1303 to establish one or more horizontal transition paths for the mobile robot 110 between the first zone 1302 and the second zone 1303. Some embodiments include one or more passageways 1310, doors, curtains, openings, and / or other such structures within the wall 1308 that allow the mobile robot 110 to pass through a corresponding one of the IRTPs 122 between two different zones. Furthermore, passageways 1310 may be configured to reduce temperature variations, such as including doors that can be opened when one or more mobile robots pass through, curtains that reduce and / or restrict airflow between zones, other such structures, or combinations of two or more such structures. One or more transition paths between different zones can be configured to be utilized by the mobile robot 110 to transport at least a subset of a plurality of containers 302 between zones (e.g., between a first temperature zone 1302 and a second temperature zone 1303).

[0056] In some embodiments, one or more IRTPs 122x of one or more sets of 120x IRTPs may be confined to a single zone. For example, IRTP 122x may not extend between a first zone 1302 (e.g., an ambient temperature zone) and a third zone 1304 (e.g., a freezing temperature zone). As described above, one or more, and typically all, IRTPs 122 intersect with multiple different aisles 112 at the corresponding level 104 where the respective IRTP is located to establish a 2D aisle-crossing mobile robot travel or movement path. In some embodiments, storage structure 102 further includes multiple storage level change structures 106 in each of zones 1302-1304 to provide paths between multiple levels 104 within each zone and to establish one or more three-dimensional (3D) meshes for mobile robot travel paths in the different zones 1302-1304 of storage structure 102.

[0057] The execution system 100 further includes one or more workstations 126. One or more of the IRTPs 122, 122x may be positioned to align with and cooperate with at least one workstation 126. In some embodiments, one or more of the IRTPs 122 in one or more sets of 120 are coupled to two workstations 126 located at opposite ends of the respective IRTPs (e.g., opposite ends separated along a second dimension D2 (e.g., the Y-axis)).

[0058] although Figure 13Different zones 1302-1304 are shown to be horizontally adjacent, but in some embodiments, one or more portions or the entirety of a zone may be vertically separated from one or more other zones or one or more portions of another zone. For example, at least a portion of a first temperature zone may be vertically separated from at least a portion of a second temperature zone. Furthermore, in some embodiments, the vertically separated zones may include two or more levels. In some embodiments, a first portion of a first zone may include a first subset of levels 104, and a second portion of a second zone located below the first portion of the first zone may include a second subset of levels different from the first subset. One or more IRTPs may be included in one or more of the individual zones, and in some embodiments, one or more IRTPs may extend between two or more of the individual zones. As a non-limiting example, a first IRTP 122 in a first set of IRTPs may be vertically aligned and separated from a second IRTP, and the second IRTP may extend horizontally between the first and second temperature zones to establish a horizontal temperature transition path between the first and second temperature zones.

[0059] Figure 14 A simplified block diagram cross-sectional view (along the Y-axis and perpendicular to the X-axis) of a portion of an exemplary automated order fulfillment system 100 according to some embodiments is shown. The fulfillment system includes a storage structure 102 having a plurality of container storage locations 114 distributed along aisles 112. In some embodiments, the storage structure 102 may include a plurality of distinct zones 1402-1403. For example, the storage structure may include a first temperature zone 1402 and a second temperature zone 1403 maintained at a different temperature than the first temperature zone. One or more IRTPs 122 of one or more sets 120 may be included, wherein one or more and typically all IRTPs 122 intersect with a plurality of distinct aisles 112 at a corresponding level 104 where the respective IRTP is located, to establish a horizontal transition path between aisle and / or storage level changing structures 106.

[0060] In some embodiments, at least a first portion or all of the second temperature zone 1403 is vertically separated from at least a portion or all of the first temperature zone 1402. The second zone or a portion of the second temperature zone 1402 may include a first hierarchical subset of the hierarchy (e.g., 104_L13 to 104_L18), and a portion of the first temperature zone 1402 may include a second hierarchical subset different from the first hierarchical subset (e.g., 104_L1 to 104_L12). Furthermore, in some embodiments, one or more IRTPs in a set of IRTPs may be separated between different zones. For example, one or more IRTPs in a set of IRTPs (e.g., IRTPs 122a-122b) may be vertically aligned and vertically separated from one or more additional IRTPs (e.g., IRTPs 122c-122d) in that set of IRTPs (the first IRTP). The storage structure 102 may include additional separate zones that may be vertically and / or horizontally separated (e.g., similar to...). Figure 13 (As shown in the illustration). For example, the third zone may be adjacent to at least the first zone. Furthermore, in some embodiments, one or more of the IRTPs may extend between two horizontally adjacent zones when they are horizontally adjacent. For example, the IRTP may extend horizontally between the first and third temperature zones to establish a horizontal temperature transition path between the first and third temperature zones.

[0061] As described above and further below, the staggered distribution of the IRTP 122 and the distribution of workstations only along the first dimension significantly improve the operational efficiency of the fulfillment system 100. Some of these improvements are achieved by reducing the travel distance and / or time between the storage location 114 and the designated workstation 126. In many previous fulfillment systems employing mobile robots, the mobile robot typically needs to travel along an aisle to the end of the storage structure before it can move laterally, and then travel a considerable distance along the length of the storage structure along other aisles before reaching the designated workstation. Thus, the mobile robot typically overlaps the directional movement toward the end of the storage structure with the directional movement to the workstation.

[0062] The staggered distribution of IRTPs 122 and / or multiple sets of 120 within the storage structure along the first dimension D1 of the storage structure partially provides a travel path grid, enabling more direct scheduling between storage location 114 and designated workstations. Figure 15A top cross-sectional view of an exemplary storage structure 102 according to some embodiments is shown. The storage structure includes multiple sets 120 of IRTPs 122, which are staggered within the storage structure and horizontally spaced from each other along a first dimension D1 of the storage structure. Exemplary more direct mobile robot travel paths 1502-1508 are also shown, which do not require reaching the end of the storage structure or turning back; and other route optimizations that significantly improve efficiency, reduce fulfillment time, reduce traffic flow, shorten cycle time, enable an increase in the number of mobile robots available and / or improve performance with a smaller number of mobile robots, and other such benefits. Furthermore, the IRTPs provide more alternative routes between storage locations and workstations, which can reduce congestion, avoid congestion, limit delays, and other benefits.

[0063] Figure 16 A simplified flowchart of an exemplary process 1600 for automated order fulfillment according to some embodiments is shown. In step 1602, a first fulfillment order is determined, which will be fulfilled at a first workstation 126 among a plurality of workstations. In step 1604, a set of storage locations 114 among a plurality of storage locations within storage structure 102 is determined, these storage locations holding corresponding containers 302, each container storing one or more items to fulfill the first fulfillment order. In step 1606, control circuitry wirelessly transmits instructions to one or more mobile robots to schedule mobile robots between storage locations and workstations. In step 1608, one or more mobile robots 110 are scheduled to move longitudinally along aisle 112, vertically via storage hierarchy change structure 106, and laterally via IRTP 122 of a plurality of sets 120 within storage structure 102 to move containers between the determined storage locations and the first workstation. In some embodiments, scheduling may include, for example, scheduling a first mobile robot that delivers a first container to move across a first IRTP 122 in a first group of multiple IRTPs, and the IRTP 122 being located at a first level and physically connected to at least a first workstation along an established path via the first IRTP to or from the first workstation. In scheduling the mobile robot, some embodiments may schedule the first mobile robot to laterally traverse a third IRTP in a first group of IRTPs comprising at least three IRTPs, each vertically aligned at a different level in the hierarchy 104 of the storage structure 102, between a first aisle at a second level and a second aisle at a second level. In some embodiments, the first IRTP and the second IRTP in the first group of at least three IRTPs may be aligned with and connected to the first workstation. In step 1610, instructions are transmitted to buffer two or more of the mobile robots within the storage structure and near a designated one of the workstations.

[0064] Figure 17 A simplified flowchart of an exemplary process 1700 for fulfilling an order through an order fulfillment system according to some embodiments is shown. In step 1602, an aisle-crossing movement path is established via two or more IRTPs 122 in each group 120 of a plurality of different groups of IRTPs, which extend along a second dimension D2 across the storage structure 102 to intersect with a plurality of aisles 112 in the aisle at a corresponding level 104 where the respective IRTP 122 is located. In step 1704, at least a first IRTP 122 of the two or more IRTPs is connected to two workstations 126 of a plurality of workstations. In some embodiments, each of the two workstations is located at opposite ends of the first IRTP. In step 1706, a two-dimensional (2D) mesh of the mobile robot's travel path is established at each of the levels containing at least one IRTP 122. The two-dimensional mesh of the mobile robot's travel path may include multiple first-dimensional travel paths along multiple aisles 112, each of which intersects with multiple second-dimensional travel paths spanning one or more of a group of IRTPs 122 located at corresponding levels along a first dimension of the storage structure. In step 1708, a three-dimensional (3D) mesh of the mobile robot's travel path is established throughout the storage structure 102, which includes storage level change structures 106 spaced apart at different locations along a first dimension D1 of the storage structure, connecting the 2D mesh and levels of the mobile robot's travel path. In step 1710, for each workstation, at least the inbound storage level change structure of the storage level change structure is coordinated and positioned on a first side of the corresponding workstation, and the outbound storage level change structure of the storage level change structure is coordinated and positioned on a second side of the corresponding workstation. Some embodiments may utilize a robot capable of moving between xy meshes to stack as many xy meshes as desired. This results in faster movement due to 3D motion and / or shorter robot travel paths, and fewer robots.

[0065] Figure 18A simplified flowchart of an exemplary process 1800 for fulfilling an order through an order fulfillment system according to some embodiments is shown. In step 1802, a first mobile robot is determined to be associated with a first fulfillment order, and the first mobile robot, while holding a first container, buffers and temporarily stops on a first aisle 112 of storage structure 102 and approaches a first workstation 126 designated for fulfilling at least a portion of the first fulfillment order. In step 1804, a second mobile robot is determined to be associated with the first fulfillment order. In step 1806, while buffering the second mobile robot, a first instruction is transmitted to the second mobile robot, for example from control circuitry 101, to instruct the second mobile robot to proceed to the first aisle adjacent to the first mobile robot. In an optional step 1808, a second instruction is transmitted to a third mobile robot associated with the second fulfillment order designated for fulfillment at the first workstation, to instruct the third mobile robot to travel through the storage structure to a first IRTP aligned with and connected to the first workstation, stop and wait upon arrival at the first IRTP without releasing the container delivered by the third mobile robot, and then continue to the first workstation after the third mobile robot has waited for a corresponding buffer period.

[0066] In optional step 1810, a third instruction is transmitted to a fourth mobile robot, also associated with a second fulfillment order designated for fulfillment at the first workstation, instructing it to travel through the storage structure to the first IRTP, stop and wait on the first IRTP without releasing the corresponding container delivered by the fourth mobile robot, and then proceed to the first workstation after the third mobile robot has waited for a response buffer period. In step 1812, a fourth instruction is transmitted to a fifth mobile robot, instructing it to move to the first IRTP in the first group of IRTPs, and, upon approaching the first workstation, position itself between the two mobile robots already on the first IRTP according to the order fulfillment order.

[0067] According to example embodiments, a machine-readable, non-transient program storage device, such as a memory, may be provided, for example, to tangibly embody a machine-executable instruction program for performing operations. Any combination of one or more computer-readable media may be used as memory. The computer-readable medium may 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 may be, for example, but not limited to, electronic, magnetic, optical, electromagnetic, infrared, or semiconductor systems, devices, or apparatuses, or any suitable combination thereof. More specific examples (not an exhaustive list) of computer-readable storage media include: electrical connections having one or more lines, portable computer floppy 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 thereof.

[0068] Furthermore, the circuits, circuit systems, systems, devices, processes, methods, technologies, functions, services, servers, resources, etc., described herein can be used, implemented, and / or operated on many different types of devices and / or systems. Figure 19 An exemplary system 1900 is illustrated, which can be used to implement any component, circuit, circuit system, system, functionality, device, process, or apparatus of fulfilling system 100, and / or other systems or apparatus mentioned above or below, or portions of such circuits, circuit systems, functionality, systems, devices, processes, or apparatuses. For example, system 1900 can be used to implement some or all of fulfilling system 100, control circuit 101, mobile robot 110, mobile robot control circuit, workstation 126, inventory system, point-of-sale system, and / or other such components, circuit systems, functions, and / or apparatuses. However, the use of system 1900 or any portion thereof is certainly not essential.

[0069] For example, system 1900 may include one or more control circuitry or processor modules 1912, one or more memories 1914, and one or more communication links, paths, buses, or the like 1918. Some embodiments may include one or more user interfaces 1916, and / or one or more internal and / or external power supplies or power supply devices 1940. Control circuitry 1912 may be implemented by one or more processors, microprocessors, central processing units, logic circuits, local digital storage, firmware, software, and / or other control hardware and / or software, and may be used to perform or assist in performing the steps of the processes, methods, functions, and techniques described herein, as well as to control various communications, decisions, programs, content, lists, services, interfaces, logging, reporting, etc. Furthermore, in some embodiments, control circuitry 1912 may be part of a control circuitry system and / or control system 1910, which may be implemented by one or more processors, wherein the processors access one or more memories 1914, which may store instructions, code, etc., implemented by the control circuitry and / or processors to implement the intended functionality. In some applications, control circuitry and / or memory may be distributed across a communication network (e.g., LAN, WAN, Internet) to provide distributed and / or redundant processing and functionality. Again, system 1900 may be used to implement one or more, or portions thereof, of the components, circuits, systems, processes, etc., described above or below.

[0070] User interface 1916 allows a user to interact with system 1900 and receive information through the system. In some cases, user interface 1916 includes display 1922 and / or one or more user input units 1924, such as buttons, touchscreens, trackballs, keyboards, mice, etc., which may be part of system 1900 or wired or wirelessly connected to system 1900. Typically, system 1900 further includes one or more communication interfaces, ports, transceivers 1920, etc., which allow system 1900 to communicate via communication bus, distributed computer and / or communication network 103 (e.g., local area network (LAN), Internet, wide area network (WAN), etc.), communication link 1918, other networks or communication channels with other devices, and / or other such communications or combinations of two or more such communication methods. Furthermore, transceiver 1920 may be configured for wired, wireless, optical, fiber optic cable, satellite or other such communication configurations, or combinations of two or more such communications. Some embodiments include one or more input / output (I / O) ports 1934 that allow one or more devices to connect to system 1900. The I / O ports can be virtually any associated port or combination of ports, such as, but not limited to, USB, Ethernet, or other such ports. The I / O interface 1934 can be configured to allow wired and / or wireless communication connections with external components. For example, the I / O interface can provide wired and / or wireless communication (e.g., Wi-Fi, Bluetooth, cellular networks, RF, and / or other such wireless communications), and in some cases, may include any known wired and / or wireless interface devices, circuitry, and / or connection devices, such as, but not limited to, one or more transmitters, receivers, transceivers, or combinations of two or more of these devices.

[0071] In some embodiments, the system may include one or more sensors 1926 to provide information to the system and / or transmit sensor information to another component, such as control circuitry 101, mobile robot 110, workstation 126, 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, acoustic / 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 provide an exhaustive list of all possible sensors. Instead, it should be understood that these teachings will be suitable for sensing any of a variety of situations in a given application setting.

[0072] System 1900 includes examples of control systems and / or processor-based systems having control circuitry 1912. Again, control circuitry 1912 can be implemented by one or more processors, controllers, central processing units, logic circuits, software, etc. Furthermore, in some embodiments, control circuitry 1912 may provide multiprocessor functionality.

[0073] The memory 1914, accessible by the control circuitry 1912, typically includes one or more processor-readable and / or computer-readable media accessible by the control circuitry 1912, and may include volatile and / or non-volatile media such as RAM, ROM, EEPROM, flash memory, and / or other memory technologies. Furthermore, the memory 1914 is shown as being internal to the control system 1910; however, the memory 1914 may be internal memory, external memory, or a combination of internal and external memory. Similarly, some or all of the memory 1914 may be internal memory, external memory, or a combination of internal and external memory of the control circuitry 1912. External memory may be substantially any associated memory, such as, but not limited to, solid-state storage devices or drives, hard disk drives, one or more Universal Serial Bus (USB) flash drives or drives, Flash Secure Digital (SD) cards, other memory cards, and other such memories or combinations of two or more of these memories, and some or all of the memory may be distributed across multiple locations on the computer network 103. The memory 1914 can store code, software, executable files, scripts, data, content, lists, programming, programs, logs or historical data, user information, customer information, product information, etc. Although Figure 19 The diagram shows various components connected together via a bus, but it should be understood that the various components can actually be directly connected to the control circuit and / or one or more other components.

[0074] Some embodiments provide an automated order fulfillment system comprising: a storage structure having a first horizontal dimension and a second horizontal dimension, wherein the storage structure is configured to enable a mobile robot to travel through the storage structure, and wherein the storage structure includes: vertically spaced levels; a storage level changing structure spaced along the first dimension of the storage structure and establishing vertical paths between the levels, wherein the storage level changing structure is configured to be utilized by the mobile robot for vertical movement between the levels; and a plurality of aisles, each extending through at least a corresponding portion of the storage structure and extending along at least a portion of the first dimension of the storage structure, wherein each of the plurality of aisles includes a mechanism configured to be utilized by the mobile robot for horizontal movement along the aisle. The system includes: a track; storage locations positioned on a level and spanning at least one side of each of a plurality of aisles, wherein each storage location is configured to store one of a plurality of containers; and multiple sets of in-rack passage planes (IRTPs) staggered within the storage structure and horizontally spaced apart from each other along a first dimension of the storage structure, wherein each set of IRTPs comprises two or more vertically spaced IRTPs, wherein each IRTP is positioned in one of the levels; and workstations, each configured to receive and distribute a plurality of containers, wherein the workstations are distributed along the storage structure, and wherein at least one IRTP of each set of IRTPs is adjacent to one or more of the workstations.

[0075] Some embodiments provide a method for automating order fulfillment, comprising: determining a first fulfillment order to be fulfilled at a first workstation among a plurality of workstations; determining a set of storage locations within a storage structure that hold corresponding containers of stored items to fulfill the first fulfillment order, the storage structure including a first horizontal dimension and a second horizontal dimension; vertically spaced hierarchies; storage hierarchy change structures spaced along the first dimension of the storage structure to establish vertical paths between the hierarchies; a plurality of aisles, each extending along at least a portion of the first dimension of the storage structure, wherein the plurality of storage locations are positioned on a hierarchy spanning at least one side of each of the plurality of aisles; and a plurality of sets of in-rack passage planes (IRTPs). They are staggered within the storage structure, horizontally spaced apart from each other along a first dimension of the storage structure, and wherein each IRTP is located in one of the hierarchies, wherein each group of IRTPs comprises two or more IRTPs spaced vertically apart, and wherein multiple workstations are distributed along the storage structure, and wherein at least one IRTP in each of the multiple groups of IRTPs is close to one or more of the multiple workstations; and scheduling a mobile robot to travel longitudinally along the aisle, to travel vertically through the storage hierarchy, and to travel laterally through the multiple groups of IRTPs within the storage structure to move containers between a defined storage location and a first workstation, wherein each workstation is configured to receive and distribute containers to fulfill an order.

[0076] In some embodiments, the buffer for the container 302 delivered by the mobile robot 110 may be integrated into the storage structure 102 and / or the IRTP 122. The integration of the IRTP partially provides more alternative flow paths for the mobile robot traveling to and from workstation 126, which improves system performance. Some embodiments reduce the overall footprint while potentially increasing storage density and simplifying the supply chain and installation. The IRTP provides a more direct path between workstations and storage locations, offering faster scheduling and / or delivery times, greater freedom of movement for mobile robots, increased throughput, smaller time differences in mobile robot arrival times at workstations for easier managed sequencing, and other benefits.

[0077] Some embodiments may keep container 302 within the storage structure and avoid moving the container in or out of the system. The IRTP may work with general-purpose workstations 126 capable of performing a variety of different system activities or tasks (e.g., picking, allocating, offline importing inventory into containers, unpacking and transferring, consolidation, etc.). Furthermore, in some embodiments, one or more of the workstations 126 may allow one container to be moved out while another is moved in. For example, some workstations provide multi-level stations that allow containers to be moved into a workstation at one level and then out at a different level. Additionally, one or more of the workstations 126 may be multi-access workstations with two or more access points. Multi-functional workstations provide the ability to perform picking and allocating tasks on an order-by-order staggered basis, thus maintaining productivity by eliminating the need for operators to be reassigned to different workstations during peak periods.

[0078] This application incorporates by reference the entire contents of each of the following U.S. patent publications: U.S. Publication No. 2014 / 0288696, published September 25, 2014, U.S. Patent Application Serial No. 14 / 213,187, filed March 14, 2014, entitled "Automated system for transporting payloads" (Applicant Reference No. ALRT-001-101); and U.S. Patent Publication No. 2017 / 0313514, published November 2, 2017, U.S. Patent Application Serial No. 15 / 591,956, filed May 10, 2017, entitled "Order fulfillment system". The following patent applications have been filed: US Patent Publication No. 2019 / 0270591, published in September 2019, with US Patent Application Serial No. 16 / 419,910, filed on May 22, 2019, and entitled "Order Fulfillment System" (Applicant Reference No. ALRT-003-2); and US Patent Publication No. 2018 / 0134492, published on May 17, 2018, with US Patent Application Serial No. 15 / 816,832, filed on November 17, 2017, and entitled "Automated-service retail system and method". The method)""Applicant Reference No. ALRT-004-101"; U.S. Patent Publication No. 2018 / 0194556, published on July 12, 2018, with U.S. Patent Application Serial No. 15 / 867,373, filed on January 10, 2018, and entitled "Interchangeable automated mobile robots with a plurality of operating modes configuring a plurality of different robot task capabilities""Applicant Reference No. ALRT-007-101";U.S. Patent Publication No. 2018 / 0150793, published on May 31, 2018, with U.S. Patent Application Serial No. 15 / 826,045, filed on November 29, 2017, and entitled "Automated retail supply chain and inventory management system" (Applicant Reference No. ALRT-008-101); and U.S. Patent Publication No. 2018 / 0305123, published on October 25, 2018, with U.S. Patent Application Serial No. 15 / 956,346, filed on April 18, 2018, and entitled "Picking workstation with mobile robots & machine vision verification of each transfers performed by human operator". Operators) (Applicant Reference No. ALRT-009-102); U.S. Patent Publication No. 2018 / 0247257, published on August 30, 2018, with U.S. Patent Application Serial No. 15 / 903,993, filed on February 23, 2018, and entitled "Inventory Management System and Method" (Applicant Reference No. ALRT-018-101); U.S. Patent Publication No. 2018 / 0341908, published on November 29, 2018, with U.S. Patent Application Serial No. 15 / 987,736, filed on May 23, 2018, and entitled "Fully Automated Self-Service Store". The U.S. Patent Publication No. 2019 / 0047787, published on February 14, 2019, with U.S. Patent Application Serial No. 16 / 058,065, filed on August 8, 2018, and entitled "Universal gripper for tote and sub-tote transport" (Applicant Reference No. ALRT-022-101);U.S. Patent Publication No. 2020 / 071076, published on March 5, 2020, with U.S. Patent Application Serial No. 16 / 554,512, filed on August 28, 2019, and entitled "Tote handling for chilled or frozen goods" (Applicant Reference No. ALRT-032-101); and U.S. Patent Publication No. 2020 / 0156871, published on May 21, 2020, with U.S. Patent Application Serial No. 16 / 676,732, filed on November 7, 2019, and entitled "System having a robotic workstation". The following patent applications have been filed: U.S. Patent Publication No. 2020 / 0223630, published on July 16, 2020, with U.S. Patent Application Serial No. 16 / 742,119, filed on January 14, 2020, entitled "System having workstation with tote retention and release mechanism" (Applicant Reference No. ALRT-039-101); U.S. Patent Publication No. 2021 / 0300664, published on September 30, 2021, with U.S. Patent Application Serial No. 16 / 831,468, filed on March 26, 2020, entitled "Tote handling for chilled or frozen goods" (Applicant Reference No. ALRT-041-001); and a patent application filed on April 21, 2020, entitled "Transport..." U.S. Provisional Patent Application Serial No. 63 / 013,504, filed August 19, 2022, entitled "High Density Micro Fulfillment Center 'HD-MFC' with Nightly G2P Storage Batch Pick Replenishment from Store Floor and Method of Operating Same" (Applicant Reference No. ALRT-042-001); and U.S. Provisional Patent Application Serial No. 63 / 067,759, filed August 19, 2022, entitled "High Density Micro Fulfillment Center 'HD-MFC' with Nightly G2P Storage Batch Pick Replenishment from Store Floor and Method of Operating Same" (Applicant Reference No. ALRT-046-001).

[0079] Those skilled in the art should understand that various other modifications, alterations, and combinations can be made to the above embodiments without departing from the scope of the present invention, and such modifications, alterations, and combinations should be considered within the scope of the inventive concept.

Claims

1. An automated order fulfillment system, comprising: A storage structure having a first horizontal dimension and a second horizontal dimension, wherein the storage structure is configured to allow a mobile robot to travel through the storage structure, and wherein the storage structure includes: Vertically separated levels; A storage hierarchy alteration structure is provided, which is spaced apart along a first dimension of the storage structure and establishes vertical paths between the levels, wherein the storage hierarchy alteration structure is configured to be used by the mobile robot to move vertically between the levels; A plurality of passageways, each extending through at least a corresponding portion of the storage structure and along at least a portion of a first dimension of the storage structure, wherein each of the plurality of passageways includes a track configured for use by the mobile robot to move horizontally along the passageway; Storage locations, situated on the hierarchy and spanning at least one side of each of the plurality of aisles, wherein each storage location is configured to store one of a plurality of containers; and Multiple sets of internal rack passageways (IRTPs), wherein the multiple sets of IRTPs are staggered within the storage structure and horizontally spaced apart from each other along a first dimension of the storage structure, wherein each set of IRTPs comprises two or more vertically spaced IRTPs, wherein each IRTP is located in one of the levels; and Workstations, each configured to receive and distribute the plurality of containers, wherein the workstations are distributed along the storage structure, and wherein at least one IRTP in each of the plurality of IRTP groups is located near one or more of the workstations.

2. The order fulfillment system of claim 1, wherein each of the plurality of IRTPs includes a first IRTP located at a first level, the first IRTP being physically connected to at least one of the workstations to establish a path to or from the corresponding workstation.

3. The order fulfillment system of claim 2, wherein each group of IRTPs comprises at least three IRTPs, each vertically aligned at a different level in the hierarchy of the storage structure, wherein the first and second IRTPs of at least three IRTPs in each of the multiple groups of IRTPs are aligned with and connected to the corresponding workstation at a level.

4. The order fulfillment system of claim 1, wherein two or more IRTPs in each of the plurality of IRTPs extend along the second dimension across the storage structure to intersect with a plurality of aisles at a corresponding level where the respective IRTP is located to establish an aisle-crossing movement path, and at least a first IRTP of the two or more IRTPs is connected to two workstations in the workstations, wherein each of the two workstations is located at an opposite end of the first IRTP.

5. The order fulfillment system according to claim 4, further comprising: The storage layer includes at least one of the IRTPs, each comprising a two-dimensional (2D) mesh of a mobile robot travel path, the two-dimensional (2D) mesh comprising a plurality of first-dimensional travel paths along the plurality of aisles, each intersecting with a plurality of second-dimensional travel paths spanning one or more of the IRTPs in different groups of the plurality of groups of IRTPs, the IRTPs being positioned at the respective layer spaced apart along the first dimension of the storage structure, and the storage layer changing structure being spaced apart at different locations along the first dimension of the storage structure, connecting the 2D mesh of the mobile robot travel path to the layer, and establishing a three-dimensional (3D) mesh of the mobile robot travel path throughout the storage structure.

6. The order fulfillment system of claim 4, wherein for each of the workstations, the storage hierarchy change structure includes at least an inbound storage hierarchy change structure located on a first side of the corresponding workstation and an outbound storage hierarchy change structure located on a second side of the corresponding workstation.

7. The order fulfillment system according to claim 6, wherein: The first IRTP extends horizontally along a first level of the hierarchy and is aligned level-by-level with at least one exit level of the first workstation of the two workstations, such that at least a subset of the mobile robots leaving the first workstation onto the first IRTP travel along at least a portion of the first IRTP toward a corresponding exit storage level closer to the first workstation, changing their structure accordingly; and The second IRTP of the two or more IRTPs extends horizontally along a second level that is vertically spaced from the first IRTP in the hierarchy, and is aligned with at least one inbound level of the first workstation, such that at least a subset of the mobile robot changes structure vertically from a corresponding inbound storage level near the first workstation into the second IRTP, and horizontally from the second IRTP into the first workstation.

8. The order fulfillment system according to claim 1, further comprising: The control circuitry is configured to wirelessly transmit instructions to the mobile robot to schedule the mobile robot between the storage location and the workstation, and to define a buffer for two or more of the mobile robots within the storage structure and near a designated one of the workstations.

9. The order fulfillment system of claim 8, wherein when the buffer is defined, the control circuit is configured to: The first mobile robot is identified as being associated with the first fulfillment order, and while holding the first container, it is buffered and temporarily stopped in the first aisle of the storage structure and close to the first workstation in the workstation designated as fulfilling at least a portion of the first fulfillment order; The second mobile robot is identified as being associated with the first fulfillment order; as well as While buffering the second mobile robot, a first instruction is transmitted to the second mobile robot to instruct the second mobile robot to move to a first passageway adjacent to the first mobile robot.

10. The order fulfillment system of claim 9, wherein when the buffer is defined, the control circuit is configured to: A second instruction is transmitted to a third mobile robot and a third instruction is transmitted to a fourth mobile robot, each associated with a second fulfillment order designated for execution at the first workstation, to travel through the storage structure to a first IRTP aligned and connected to the first workstation, and to stop and wait without releasing the corresponding containers delivered by the third and fourth mobile robots, and then proceed to the first workstation after the third mobile robot has waited for a corresponding buffer period.

11. The order fulfillment system of claim 10, wherein the size of the first IRTP is set such that at least a fifth mobile robot can enter and travel on the first IRTP to approach and enter the first workstation, while the third and fourth mobile robots wait on the first IRTP and are not blocked from entering the first workstation by the third and fourth mobile robots.

12. The order fulfillment system of claim 9, wherein the control circuit is further configured to transmit a second instruction to a third mobile robot in the mobile robots, causing it to move to a first IRTP in a first group of IRTPs, and, upon approaching a first workstation connected to the first IRTP, to position itself between a fourth mobile robot and a fifth mobile robot already located on the first IRTP, according to the order fulfillment sequence.

13. The order fulfillment system of claim 1, wherein the storage structure includes a first temperature zone and a second temperature zone, the second temperature zone being maintained within a second temperature range lower than a first temperature within the first temperature zone, and a third temperature zone being maintained within a third temperature range lower than the second temperature range; At least one first IRTP in the first group of the plurality of IRTPs extends horizontally between the first temperature zone and the second temperature zone to establish a horizontal first temperature transition path between the first temperature zone and the second temperature zone, and is configured to be used by the mobile robot to transport at least a subset of the plurality of containers between the first temperature zone and the second temperature zone.

14. The order fulfillment system of claim 13, wherein at least a first portion of the second temperature zone is vertically separated from at least a second portion of the third temperature zone, and wherein, The first portion of the second temperature zone includes a first-level subset of the hierarchy, and the second portion of the third temperature zone includes a second-level subset that is different from the first-level subset; and In the first group of IRTPs, at least the second IRTP is vertically aligned with and separated from the first IRTP, and the second IRTP extends horizontally between the first temperature zone and the third temperature zone to establish a horizontal second temperature transition path between the first temperature zone and the third temperature zone.

15. The order fulfillment system of claim 1, wherein two or more of the workstations are configured as multi-functional workstations that perform at least the following: unpacking and transferring item boxes into one or more of the plurality of containers, importing at least a subset of the plurality of containers into the storage structure, picking individual items from the plurality of containers, and assigning fulfilled orders.

16. The order fulfillment system of claim 1, wherein each IRTP in each of the plurality of IRTPs extends along the second dimension to intersect with a corresponding subset of the plurality of aisles along the corresponding level of the hierarchy to establish a plurality of passageways to and from the corresponding subset of the storage structure within the storage structure.

17. An automated order fulfillment method, comprising: Determine the first fulfillment order to be fulfilled at the first of the multiple workstations; A set of storage locations is defined within a storage structure, wherein the storage locations hold corresponding containers for stored items to fulfill a first fulfillment order; the storage structure includes a first horizontal dimension and a second horizontal dimension; and vertically spaced hierarchical levels. The storage hierarchy changes its structure, which is spaced apart along a first dimension of the storage structure to establish vertical paths between the hierarchy; A plurality of aisles, each extending along at least a portion of a first dimension of the storage structure, wherein the plurality of storage locations are located on the hierarchy spanning at least one side of each of the plurality of aisles; And multiple sets of internal rack passage planes (IRTPs) are staggered within the storage structure, horizontally spaced apart from each other along a first dimension of the storage structure, and each IRTP is located in one of the levels, wherein each set of IRTPs includes two or more IRTPs that are vertically spaced apart, and wherein the plurality of workstations are distributed along the storage structure, and wherein at least one IRTP in each set of IRTPs is close to one or more of the plurality of workstations; as well as A mobile robot is dispatched to travel longitudinally along the plurality of aisles, vertically via the storage hierarchy change structure, and horizontally via multiple sets of IRTPs within the storage structure to move containers between the determined storage location and the first workstation, wherein each of the plurality of workstations is configured to receive and distribute the containers to fulfill orders.

18. The method of claim 17, wherein scheduling the mobile robot comprises: A first mobile robot is scheduled to transport a first container to move across a first IRTP in a first group of multiple IRTPs located at the first level, the first IRTP being physically connected to at least the first workstation along an established path via the first IRTP to or from the first workstation.

19. The method of claim 18, wherein scheduling the first mobile robot comprises scheduling the first mobile robot to laterally traverse between a first aisle at a second level and a second aisle at a second level, traversing a third IRTP of a first set of IRTPs comprising at least three IRTPs, each aligned at a different level in the storage structure, wherein the first IRTP and the second IRTP of the at least three IRTPs in the first set of IRTPs are aligned with and connected to the corresponding workstation.

20. The method of claim 17, further comprising: A cross-aisle movement path is established via two or more IRTPs in each of the plurality of IRTPs, the IRTPs extending along the second dimension across the storage structure to intersect with a plurality of aisles at the corresponding level where the respective IRTP is located, and at least a first IRTP of the two or more IRTPs is connected to two workstations of the plurality of workstations, wherein each of the two workstations is located at an opposite end of the first IRTP.

21. The method of claim 20, further comprising: At each of the layers containing at least one of the IRTPs, a two-dimensional (2D) mesh of mobile robot travel paths is established, the 2D mesh comprising a plurality of first-dimensional travel paths along the plurality of passageways, each intersecting with a plurality of second-dimensional travel paths of one or more of the plurality of sets of IRTPs positioned at the respective layer and spaced apart along the first dimension of the storage structure. A three-dimensional (3D) mesh of the mobile robot's travel path is established throughout the storage structure, the storage structure including storage level changing structures spaced apart at different locations along a first dimension of the storage structure, the storage level changing structures connecting the 2D mesh of the mobile robot's travel path to the levels.

22. The method of claim 20, further comprising: For each of the plurality of workstations, at least the inbound storage hierarchy change structure of the storage hierarchy change structure located on the first side of the corresponding workstation and the outbound storage hierarchy change structure of the storage hierarchy change structure located on the second side of the corresponding workstation shall cooperate.

23. The method of claim 17, further comprising: Commands are wirelessly transmitted from the control circuit to the mobile robot to schedule the mobile robot between the storage location and the plurality of workstations; as well as Within the storage structure and near one of the plurality of workstations, a buffer is designated to define two or more of the mobile robots.

24. The method of claim 17, wherein the buffer is defined as: The first mobile robot is identified as being associated with the first fulfillment order, and while holding the first container, it is buffered and temporarily stopped in the first aisle of the storage structure, and close to the first workstation among the plurality of workstations designated as fulfilling at least a portion of the first fulfillment order; The second mobile robot is identified as being associated with the first fulfillment order; as well as While buffering the second mobile robot, a first instruction is transmitted to the second mobile robot to instruct the second mobile robot to move to the first passageway adjacent to the first mobile robot.

25. The method of claim 24, wherein the buffer is defined as: A second instruction is transmitted to a third mobile robot and a third instruction is transmitted to a fourth mobile robot, each associated with a second fulfillment order designated for execution at a first workstation, to travel through the storage structure to a first IRTP aligned with and connected to the first workstation, and to stop and wait without releasing the corresponding containers delivered by the third and fourth mobile robots, and then proceed to the first workstation after the third mobile robot has waited for a corresponding buffer period.

26. The method of claim 24, further comprising: A second instruction is transmitted to the third mobile robot in the mobile robot group, causing it to move to the first IRTP in the first group of IRTPs, and when approaching the first workstation connected to the first IRTP, it positions itself between the fourth and fifth mobile robots that are already on the first IRTP, according to the order fulfillment sequence.

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