Order preparation system and procedure

Abstract

A logistics facility that enables flexible and agile order preparation, comprising a plurality of input stations (10), a plurality of output stations (20), a fleet of mobile shuttles, each shuttle (42) with a locomotion device that enables it to move between the input stations (10) and the output stations (20), and a receptacle intended to receive an item (61), and a control unit, wherein, to prepare an order that includes at least two items (61, 62), the control unit is configured to direct a first shuttle (42) to a first input station (10) to pick up a first item (61), direct a second shuttle (42) to a second input station (10) to pick up a second item (62), and direct the first and second shuttles (42) to a determined output station (20) to unload the first and second items (61, 62) at said output station (20).

Description

Technical Field

[0001] This presentation concerns a logistics installation that allows for the preparation of orders in a flexible and agile manner.

[0002] Such a logistics facility can be used to prepare e-commerce orders as well as wholesale orders, for B2B sales for example, or for restocking stores. It is particularly suitable for the clothing or fashion industry; however, it could also be used in other sectors requiring such logistics facilities (cultural goods, DIY, food, etc.). Previous technique

[0003] The logistics facilities used so far were developed at a time when e-commerce was non-existent or still marginal: as a result, they were designed to handle large flows of items, essentially corresponding to wholesale sales, characterized by large volumes and generally well-controlled deadlines.

[0004] Thus, a typical order preparation process involves aggregating orders over a fairly long period, typically around ten hours, to reach a sufficiently large number of items, for example, 10,000 items. Once this volume, commonly referred to as the "bulk," is reached, a primary sorter subdivides this volume into a plurality of smaller secondary volumes, taking care not to split any order between multiple volumes. Secondary sorters are then used to further subdivide these secondary volumes into even smaller tertiary volumes, again ensuring that no order is split. Such subdivisions are then carried out successively until final volumes are small enough for an operator to complete the order preparation manually. This final step generally consists of distributing the items from each final volume into a bin according to the orders received.

[0005] This process is therefore particularly well-suited for handling large volumes. While it can certainly handle smaller orders such as online orders, this comes with several drawbacks.

[0006] Firstly, such a process cannot respond in real time to online orders since a period of about ten hours is needed to accumulate the volume necessary to start the sorting, which can be a problem when a 24-hour delivery is desired.

[0007] This process is also quite rigid, as it is difficult to adapt to variations in order flow, such as between day and night, or between peak sales periods (like the holiday season) and quieter periods. Indeed, the entire system, and in particular the primary sorter designed for 10,000 items, must be activated even if only about a hundred items have been ordered during that period. Similarly, such a system is difficult to adapt in the event of significant market gains or losses (such as the opening of new stores) since the primary sorter's capacity cannot be changed. This type of system is also difficult to adapt to different order structures, for example, when orders containing a small number of items are received simultaneously with orders containing a large number of items.Furthermore, sorting machines are designed to sort objects of a given size, but also of a given weight and potentially other given characteristics such as fragility, which reduces the possibility of diversifying the nature or size of the items.

[0008] Another drawback of the current process is its difficulty in automatizing, since the final order consolidation step involves sorting the orders into lockers by operators. Finally, this process is unable to handle the problem of order returns, which have become much more frequent since the rise of e-commerce.

[0009] There is therefore a real need for an order picking system and process that are free, at least in part, from the drawbacks inherent in the aforementioned known method. A shuttle-based order picking system and process are disclosed in US 9,463,927 B1. Description of the invention

[0010] This presentation concerns an order preparation facility, comprising a plurality of entry stations, a plurality of exit stations, a first fleet of mobile shuttles configured to perform a first order consolidation phase, each shuttle comprising a locomotion device, enabling the shuttle to move between the entry stations and the exit stations, and a receptacle intended to receive an item, and a control unit, in which, in order to prepare an order including at least two items, the control unit is configured to direct a first shuttle to a first entry station to pick up a first item, direct a second shuttle to a second entry station to pick up a second item, and direct the first and second shuttles to a given exit station to unload the first and second items at said exit station. The order preparation facility includes a second fleet of shuttles configured to provide a second phase of dispatching of the shipments of items.

[0011] Thus, in such a system, each item is handled by a separate shuttle, and order consolidation is achieved by grouping the relevant shuttles—each having picked up an item from the order at the entry stations—at the same exit station. Specifically, the order in which items are removed from stock is irrelevant, since each item can be handled individually by a different shuttle. The order of items required for the order, if any, can be reconstructed by imposing an order of arrival for the shuttles at the exit station. This provides an additional degree of flexibility in managing stock and thus facilitates the removal of items.

[0012] Therefore, no further sorting is required: each order can be prepared virtually in real time, without any prior sorting. Consequently, thanks to this system, orders can be processed almost immediately, according to the order queue, without needing to accumulate orders until a predetermined volume is reached. Thus, for example, orders can be prepared overnight, during off-peak hours, without delay.

[0013] This system also offers great flexibility because, since each item is handled individually, it is sufficient to open a greater or lesser number of entry and exit stations, as well as activate a greater or lesser number of shuttles, to respond to demand in real time. This system therefore benefits from a better proportionality between the flow of items and the resources deployed to process it. Similarly, when acquiring new markets, for example when opening new stores, the additional investment is limited to the purchase of new shuttles and / or entry or exit stations, without the need to replace existing equipment.

[0014] This system can also be adapted to a wide variety of objects: it is simply a matter of modifying the size and / or geometry of the shuttle receptacle to accommodate a new object, without needing to modify or reprogram the shuttle itself. This receptacle can take many forms: it could be a bin, for example, but it could also be a simple flat platform, possibly equipped with fastening devices such as clamps. If necessary, the fleet of shuttles can also include several different types, equipped with receptacles of varying sizes and / or geometries, in order to simultaneously process, within the same system, items of different types, possibly sold under different brands.

[0015] Furthermore, this system significantly reduces the need for operators, potentially limiting their role to simple point-to-point item transfers between stations and shuttles, or vice versa. The system can even be fully automated by robotizing these transfer operations.

[0016] Finally, returns can easily be handled using the same shuttle system. In such a case, for example, an output station will be a station capable of reintroducing items into the stock.

[0017] In some embodiments, the control unit is configured to allocate, for orders containing fewer than 5 items, as many shuttles as there are items in the order. This avoids shuttles making multiple round trips for the same order, thus saving time in order processing. However, this option is preferred for orders with a small number of items, for example, fewer than 10 items or a number representing less than 15% of the total number of shuttles in the shuttle fleet; this option can also be used for certain types of orders, such as online orders.

[0018] In some embodiments, for a given order, the control unit is configured to initiate the unloading of items at the output station only when all items in that order have been picked by shuttles. This ensures that the order is complete before unloading begins, preventing the output station from being idled if the order is canceled. It also avoids, for example, starting the packaging process if the order is canceled. Again, this option is preferred for orders with a small number of items or, more generally, for online orders.

[0019] In some embodiments, the installation includes a waiting area, with the control unit configured to direct at least one shuttle to the waiting area when waiting conditions are met. Such an area allows shuttles that must wait for a specific condition to be stored in a designated space, so as not to impede the movement of other shuttles. This waiting area may be a single zone; it may also be divided into several zones distributed throughout the installation. These waiting areas may be predetermined and possibly marked with physical markers, or they may be established and then dissolved during operation by the control unit.

[0020] In some embodiments, the control unit is configured to direct at least one shuttle that has picked up an item from a given order to the waiting area if at least one other item from that order has not yet arrived at an entry station. This allows entry stations to be freed up quickly after items have been picked and keeps the exit station free for as long as possible before it is actually used. Such a waiting period can be systematic, particularly when the order includes several items, except perhaps in the case of a bulk order.

[0021] In some embodiments, the control unit is configured to direct at least one shuttle that has picked up an item from a given order to the waiting area if no exit station is available to receive the items from that order. This allows the entry stations to be quickly freed up after the items have been picked, even if no exit station is available.

[0022] In some embodiments, the control unit is configured to order the unloading of items from a given order in a predetermined order. This may, for example, be the order of the items on the order form. In such a case, the control unit can control the shuttles so that their arrival order at the output station corresponds to this predetermined order.

[0023] In some embodiments, at least one receiving station is an injection station connected to a warehouse. Thus, items from different orders can be retrieved from the warehouse and presented, one after the other, to the injection station for picking by a shuttle. This connection can be manual, via one or more warehouse workers, semi-automatic, or fully automatic, for example, via a stacker crane.

[0024] In some embodiments, at least one entry station is a return station configured to present items returned by customers.

[0025] However, it should be understood that input and output stations can be of any conceivable type and can be modular and interchangeable depending on the intended applications.

[0026] In some embodiments, at least one input station, and preferably each input station, is configured to display a limited number of item SKUs at a time, for example, a maximum of four or preferably a single item SKU. It is also possible for only one item to be displayed at a time. This avoids potential errors in item picking. In practice, single-item bins are preferred, except for small items that can share a single bin, possibly divided into compartments. This applies primarily to injection stations; return stations, on the other hand, can display returned items in bulk.

[0027] In some embodiments, the retrieval of an item from an entry station to a shuttle is manual or automatic.

[0028] In some embodiments, the control unit is configured to assign an availability status to each output station. This availability status may include an open status (open / closed) as well as an allocation status (ready / assigned).

[0029] In some embodiments, the control unit is configured to form groups of output stations and to assign each output station to one or more groups. Such groups can, in particular, allow orders to be distributed according to their type, for example by volume or by brand or type of item.

[0030] In some embodiments, the control unit is configured to assign multiple output stations to a given order if the number of items in said given order exceeds the capacity of one output station.

[0031] In some embodiments, the unloading of an item from a shuttle to an exit station is manual or automatic.

[0032] In some embodiments, at least one output station is a packaging station configured to package together the different items of a given order. This type of output station is particularly well-suited for e-commerce.

[0033] In some embodiments, at least one output station is a wholesale station configured to store a large number of items. For example, these wholesale stations can store more than 50 items, preferably more than 100 items. This type of output station is particularly suitable for B2B sales or for replenishing stores, for example.

[0034] In some embodiments, at least one output station is a reintegration station connected to the warehouse. Such a reintegration station allows items returned by customers to be reintegrated into the warehouse. It can also allow the reintegration of items transported by shuttles, for example, when an order is canceled. This connection can be manual, via one or more warehouse workers, semi-automatic, or fully automatic, via a stacker crane, for example.

[0035] In some embodiments, the installation includes at least one error station intended to receive items that are the subject of an error.

[0036] In some embodiments, the control unit is configured to open or close certain input and / or output stations. This allows for real-time adjustment of resources based on the flow of items, thereby reducing operating costs.

[0037] In some embodiments, the control unit is configured to direct a shuttle to an error station and unload the item carried by that shuttle if the relevant order is erroneous, canceled, or has exceeded a predetermined time. Depending on the type of error, the item may also be unloaded at a reintegration station.

[0038] In some embodiments, each item bears an identifying element. This may be, in particular, a barcode or an RFID tag. The item can thus be tracked and monitored throughout the order preparation process; otherwise, an error signal can be generated.

[0039] In some embodiments, the shuttle fleet comprises at least 20 shuttles, preferably at least 100 shuttles, and even more preferably at least 300 shuttles. For example, such a fleet of 20 shuttles allows for a flow of approximately 400 items per hour, while a fleet of 300 shuttles allows for a flow of approximately 8,000 items per hour.

[0040] In some embodiments, the control unit is configured to activate or deactivate certain shuttles. This allows for real-time adjustment of resources based on the flow of items, thereby reducing operating costs. The deactivated shuttles can then be stored in a designated storage area, which can be located at the edge of the circulation area or within a specific zone within the circulation area. The shuttles are capable of autonomously entering and exiting the storage area.

[0041] In some embodiments, each shuttle is designed to transport only one item at a time.

[0042] In some embodiments, the shuttles move along a traffic surface. This traffic surface is preferably flat; the entry stations can, for example, be provided along one edge of this traffic surface while the exit stations can be provided along a second edge of this traffic surface, for example the opposite edge.

[0043] In some embodiments, the traffic surface is devoid of physical rails. However, traffic lines or other markers may be provided along the traffic surface to assist the autonomous navigation of the shuttles.

[0044] In some embodiments, the circulation area extends over at least two separate floors.

[0045] In some embodiments, at least one input station is a packing station and at least one output station is a shipping station. This is because, up to this point, the installation has been described in the context of order consolidation from the warehouse to packing; however, the same shuttle system can be used in a completely analogous way to sort and distribute packed orders among different shipping stations. Specifically, the installation can include a first fleet of shuttles responsible for order consolidation and a second fleet of shuttles responsible for dispatching shipments. Naturally, as required, the same individual shuttle can be assigned to one or both of these fleets.

[0046] This presentation also concerns an order preparation process implementing a plurality of entry stations, a plurality of exit stations, a first fleet of mobile shuttles configured to perform a first phase of order consolidation, each shuttle comprising a locomotion device, enabling the shuttle to move between the entry stations and the exit stations, and a receptacle intended to receive an item, and a control unit, in which, in order to prepare an order including at least two items, a first shuttle is directed to a first entry station to pick up a first item, a second shuttle is directed to a second entry station to pick up a second item, and the first and second shuttles are directed to a given exit station to unload the first and second items at said exit station. The process includes a second phase of distributing the shipments of the items, carried out by a second fleet of shuttles.

[0047] Naturally, all the configurations presented regarding the installation can be transposed to this order preparation process in order to obtain the same effects and advantages.

[0048] The aforementioned features and advantages, as well as others, will become apparent upon reading the detailed description that follows, along with examples of the proposed installation and process. This detailed description refers to the attached drawings. Brief description of the drawings

[0049] The attached drawings are schematic and are primarily intended to illustrate the principles of the presentation.

[0050] In these drawings, from one figure to another, identical elements (or parts of elements) are identified by the same reference symbols. [ Fig. 1 ] There figure 1 is a plan view of an installation according to the exposition. Fig. 2 ] There figure 2 illustrates a single-item order preparation. Fig. 3 ] There figure 3 illustrates a multi-item order preparation. Fig. 4 ] There figure 4 is a flowchart illustrating a command consolidation routine for a shuttle. Fig. 5 ] There figure 5 is a diagram illustrating the consolidation of several example commands. Fig. 6 ] There figure 6 illustrates the handling of an erroneous command. Fig. 7 ] There figure 7 illustrates a bulk order preparation. Fig. 8 ] There figure 8 illustrates a return of an article. Fig. 9 ] There figure 9 is a flowchart illustrating a shipping allocation routine for a shuttle. Description of the implementation methods

[0051] To make the explanation more concrete, examples of installation and order preparation processes are described in detail below, with reference to the attached drawings. It should be noted that the invention is not limited to these examples.

[0052] There figure 1 Figure 1 represents an example of an installation as described. This installation comprises a plurality of injection stations 10, connected to a storage unit 11, a plurality of conditioning stations 20, and a plurality of shipping stations 30. A first fleet 40a of shuttles 42 circulates between the injection stations 10 and the upstream face of the conditioning stations 20 along a first circulation surface 41a; a second fleet 40b of shuttles 42 circulates between the downstream face of the conditioning stations 20 and the shipping stations 30 along a second circulation surface 41b. A control unit 50 is provided to supervise and control the entire installation 1.

[0053] The first fleet of 40a shuttles handles the order consolidation work while the second fleet of 40b shuttles handles the dispatching of shipments.

[0054] Each injection station 10, which is a type of entry station for the first fleet of shuttles 40a, is connected to a store 11 containing all the referenced items 61 available to order. This connection can be made, in particular, using a stacker crane. As shown in the figure 2 Each injection station 10 includes a conveyor 12 designed to bring crates 14 from the warehouse 11 to an operator 13. Each crate contains a single item 61 (same brand, same model, and same size). Once an item 61 has been picked by the operator 13, the conveyor 12 returns the crate 14 to the warehouse 11.

[0055] Each shuttle 42 includes a locomotion device 43 and a receptacle 44. Each shuttle 42 also includes sensors, control electronics, and a communication device enabling it to communicate with the control unit 50.

[0056] Each conditioning station 20, which is an exit station type for the first fleet of shuttles 40a and an entry station type for the second fleet of shuttles 40b, includes an upstream face 21, a downstream face 22 and a conditioning device 23 configured to condition articles 61 into packages 70.

[0057] Each shipping station 30, which is a type of exit station for the second fleet of shuttles 40b, is designed to store packages 70 for shipment. These may include shipping docks in front of which trucks 31 can park.

[0058] Each exit station 20, 30 is equipped with an unloading sensor to confirm that the unloading of item 61 or package 70 has been completed.

[0059] Control unit 50 assigns each output station 20, 30 an open status, which can be either "open" or "closed," and an assigned status, which can be either "ready" or "assigned." Control unit 50 also links each output station 20, 30 to one or more groups of output stations, depending on the expected command types.

[0060] An order preparation process is broken down into a first phase of order consolidation, carried out by the first fleet of 40a shuttles, and a second phase of shipment distribution, carried out by the second fleet of 40b shuttles.

[0061] The first phase of order consolidation will now be explained with reference to figures 2 à 5 .

[0062] In particular, the figure 4 This details a shuttle control routine 100 implemented by the control unit 50. This routine begins when a command has been received and a first item 61 has been assigned to a first injection station 10. A shuttle 42 then moves to this injection station 10 (step 101). The item presented by this injection station 10 is then transferred to the shuttle 42 (step 102). In practice, in this example, this transfer is performed by the operator 13; however, it is possible to automate this transfer.

[0063] The control unit 50 then checks for an error in the order (step 103): if so, the shuttle 42 enters error mode, unloads the item 61 it is carrying, and is ready to process a new order (step 104). In particular, as shown in the figure 6 , installation 1 may include an error station 26, which is a type of exit station for the first fleet of shuttles 40a, intended to receive the parts thus unloaded by the shuttles 42 in error mode.

[0064] In the absence of an error, control unit 50 checks the order type (step 105). If it is a single-item order (case of the figure 2 ), the control unit 50 checks if there is already an open and assigned packaging station 20 for this order (step 106): if so, the shuttle 42 then moves to this packaging station 20 (step 107). The item 61 is then unloaded, manually or automatically, and taken over by the packaging station 20 (step 108).

[0065] If no conditioning station 20 is already assigned for this order, the control unit 50 checks if there is an open conditioning station 20 ready to be assigned within the group of output stations suitable for the current order (step 109). If such a station exists, the control unit 50 selects it and assigns it the current order (step 110): the shuttle 42 then moves to this station 20 (step 107). Otherwise, the shuttle 42 moves to a waiting area 49 (step 111) to wait for a suitable conditioning station 20 to become available (open and ready). During this wait, if a predetermined time is exceeded (step 112), the shuttle 42 enters error mode (step 104).

[0066] If it is now a multi-item order (as in the case of the figure 3 ), the control unit 50 checks if the current order is complete (step 113), in other words, if all items 61, 62, 63 of the order have been correctly picked up by shuttles 42. If this is not the case, shuttle 42 moves to a waiting area 49 (step 111) and waits there until the order is complete or until a predetermined time has elapsed (step 112), in which case shuttle 42 enters error mode (step 104). As can be seen on the figure 3 , the shuttles 42 carrying items 61-63 of the same order preferably wait next to each other within this waiting area 49.

[0067] Once the order is complete, the shuttles 42 carrying items 61-63 of the current order proceed to the packaging station 20 assigned to that order (step 107), assigning one if necessary as explained above. At this time, preferably, the shuttles 42 participating in the same order, or at least those waiting in the waiting area 49, can move together, forming, for example, a train of shuttles 42.

[0068] In any event, after unloading step 108, the control unit 50 verifies, using sensors on the shuttle 42 and / or the conditioning station 20, whether item 61 has been unloaded (step 114). If not, the shuttle 42 enters error mode (step 104). Conversely, if the verification is successful, the control unit 50 confirms that item 61 has been unloaded (step 115). The shuttle 42 is then released and can retrieve a new item 61 if a new order is received (step 116).

[0069] An example of allocating commands C1, C2, C3, C4, C5 between different input stations E1, E2, E3, different shuttles N1, N2, N3, N4 and different output stations S1, S2 will now be described with reference to the figure 5 .

[0070] In this example, a first order C1 arrives at t1: it includes a first item A and a second item B. The first item A is thus assigned to the first entry station E1 and the second item B is assigned to the second entry station E2. The light gray areas correspond to the time required to retrieve the item in question from the store and present it at the entry station for picking by a shuttle.

[0071] Since item A is the fastest to leave the store, the first shuttle N1 arrives at the first entry station E1 at time t2, picks up item A, and then waits for the second item B to be ready. This waiting time, spent in a holding area, is represented by a vertically hatched area. To simplify the explanation, we consider the travel time of the shuttles 42 to be negligible compared to the processing time of the entry and exit stations.

[0072] At time t3, the second item B is available at the second input station E2: a second shuttle N2 then arrives at the second input station E2 and picks up item B. The order being now complete, an output station S1 is assigned and the two shuttles N1, N2 head towards it to unload their items A and B. The dark gray areas correspond to the processing time by the output station: during this period the considered output station is unavailable; the shuttles are, however, freed up and can therefore be reused.

[0073] At t4, a second order C2 arrives: this one includes one item B, two items C and one item D. These four items are then distributed between the three input stations E1, E2 and E3.

[0074] At t5, the first item B is available at the first entry station E1. As shuttles N1 and N2 are available again, their unloading having been completed, the first shuttle N1 can go to the first entry station E1 to pick up the first item B; it then waits. Similarly, at t6, the second shuttle N2 goes to the entry station E2 to pick up the second item C and then waits; at t7, a third shuttle N3 goes to the entry station E3 to pick up the third item D and then waits.

[0075] At t8, a fourth shuttle N4 goes to the entry station E3 to pick up the fourth item C, the picking of the previous item at this same entry station E3 being complete. Since the unavailability period of the first exit station S1 has ended at t8, this second order C2, now complete, can be assigned to the same exit station S1: the four shuttles N1, N2, N3, and N4 then proceed to this exit station S1 to unload their items B, C, D, and C.

[0076] At t9, a third order C3 arrives: this one includes a single item A. This single item is then assigned to the input station E1.

[0077] At time t10, the single item A has been removed from the warehouse and is available at the first input station E1. Again, at this time t10, all shuttles have finished unloading and are therefore available. Consequently, the first shuttle N1 is sent to the first input station E1 to pick up item A. Since this order C3 is a single-item order, an output station can be immediately assigned, and shuttle N1 then heads straight there. As the unavailability period of the first output station S1 has ended at t10, this third order C3 can be assigned to the same output station S1.

[0078] At t11, a fourth order C4 arrives: this one includes an item B, an item E and an item F. These three items are then distributed between the three input stations E1, E2 and E3.

[0079] At time t12, the first item to leave the warehouse is item B, available at the first entry station E1. Again, at this time t12, all shuttles have finished unloading and are therefore available. Consequently, the first shuttle N1 is sent to the first entry station E1 to pick up item B; it then waits. At t13, the second shuttle N2 goes to the second entry station E2 to pick up the second item E and then waits.

[0080] At t14, a fifth order C5 arrives while the fourth order C4 is not yet complete. This fifth order C5 includes an item E, an item F, and an item G. These three items are then distributed among the three input stations E1, E2, and E3.

[0081] At time t15, the first item B of the fifth order C5 is available at the first entry station E1. However, at this time t15, shuttles N1 and N2 are immobilized because they are already carrying items from the fourth order C4. Consequently, the third shuttle N3 is sent to the first entry station E1 to pick up item E; it then waits.

[0082] At t16, the last item F of the fourth order C4 is available at the third input station E3. Since shuttles N1, N2, and N3 are already in use, the fourth shuttle N4 is sent to the third input station E3 to pick up this item F. As the unavailability period of the first output station S1 has ended at t16, this fourth order C4, now complete, can be assigned to this same output station S1: the three shuttles N1, N2, and N4 then head towards this output station S1 to unload their items B, E, and F.

[0083] At t17, the second item F of the fifth order is available at the second entry station E2. With shuttles N1, N2 and N4 available again, the first shuttle N1 is sent to the second entry station E2 to pick up this item F.

[0084] At t18, the second shuttle N2 travels to the entry station E3 to pick up the third and final item G of the fifth order C5. This time, the first exit station S1 has not yet finished processing the previous order. Consequently, the fifth order C5 is assigned to a second exit station S2. The three shuttles N3, N1, and N2 then proceed to this second exit station S2 to unload their items E, F, and G.

[0085] The consolidation of these five orders C1, C2, C3, C4 and C5 is thus complete.

[0086] So far, the order consolidation process has been described in a simplified situation implementing only one type of input station, the injection stations 10, and only one type of output station, the conditioning stations 20. However, this order consolidation process can be used with additional types of input and / or output stations.

[0087] For example, in addition to packaging stations 20, some exit stations of the first fleet of shuttles 40a may be wholesale stations 27, intended for B2B trade or for restocking stores, for example. This situation is represented on the figure 7 These bulk stations 27 are suitable for large-volume orders, whether single or multi-item: they therefore include one or more large containers capable of receiving bulk items 61. For such orders, it is preferable that each item 61 of the order be unloaded at the bulk station 27 directly after it is picked, without the shuttles 42 involved in this order having to wait for each other.

[0088] This process also allows for the management of returns of items to the store 11. Indeed, the installation 1 can include one or more reintegration stations 28, connected to the store 11, at which items 61 can be unloaded for reintegration into the store 11, in a symmetrical manner to the injection stations 10. Moreover, these reintegration stations 28 can be formed by injection stations 10 which the control unit 50 temporarily designates as reintegration station 28.

[0089] Thus, in case of error, rather than unloading the items 61 from the erroneous orders into an error station 26, it is possible to directly reintegrate these items 61 into the store 11 using such a reintegration station 28.

[0090] Installation 1 may also include one or more return stations, forming a type of entry station for the first fleet of shuttles 40a, at which items returned by customers can be injected into the system. Shuttles 42 are then responsible for collecting these items 61 and unloading them at one or more reintegration stations 28 for reintegration into the store 11.

[0091] The second phase of shipment allocation will now be explained with reference to the figure 9 The latter implements the second fleet of shuttles 40b. The operation of the latter is quite analogous to that of the first fleet of shuttles 40a except that these shuttles 42 transport parcels 70, instead of articles 61-63, and circulate between the conditioning stations 20 and the shipping stations 30.

[0092] There figure 9 This details a shuttle control routine 200 implemented by control unit 50 for this second fleet 40b. As can be seen, this routine is entirely analogous to routine 100 of the figure 4 .

[0093] This routine 200 begins when a shipping order has been received and a package 70 is available at a packing station 20. A shuttle 42 then moves to this packing station 20 (step 201). The package presented by this packing station 20 is then transferred to the shuttle 42 (step 202). This transfer can be performed manually or automatically.

[0094] The control unit 50 then checks if there is an error in the shipping order (step 203): if so, the shuttle 42 goes into error mode, unloads the package 70 it is carrying and is ready to process a new shipping order (step 204).

[0095] In the absence of an error, the control unit 50 checks if there is already an open and assigned shipping station 30 for this shipping order (step 206): if so, the shuttle 42 then moves to this shipping station 30 (step 207). The package 70 is then unloaded and taken over by the shipping station 30 (step 208).

[0096] If no dispatch station 30 is already assigned for this dispatch order, the control unit 50 checks if there is an open dispatch station 30 ready to be assigned within the group of dispatch stations suitable for the current order (step 209). If such a station 30 exists, the control unit 50 selects it and assigns it the current dispatch order (step 210): the shuttle 42 then moves to this station 30 (step 207). Otherwise, the shuttle 42 moves to a waiting area 49 (step 211) to wait for a suitable dispatch station 30 to become available (open and ready). During this wait, if a predetermined time is exceeded (step 212), the shuttle 42 enters error mode (step 204).

[0097] In any event, after unloading step 208, the control unit 50 verifies, using sensors on the shuttle 42 and / or the shipping station 30, whether package 70 has been unloaded (step 214). If not, the shuttle 42 enters error mode (step 204). Conversely, if the verification is successful, the control unit 50 confirms that package 70 has been unloaded (step 215). The shuttle 42 is then released and can retrieve a new package 70 if a new shipping order is received (step 216).

[0098] Although the present invention has been described with reference to specific embodiments, it is evident that modifications and changes can be made to these examples without departing from the general scope of the invention as defined by the claims. In particular, individual features of the various embodiments illustrated / mentioned can be combined in additional embodiments. Therefore, the description and drawings should be considered in an illustrative rather than restrictive sense.

[0099] It is also evident that all the characteristics described with reference to a process are transposable, alone or in combination, to a device, and conversely, all the characteristics described with reference to a device are transposable, alone or in combination, to a process.

Claims

1. An order preparation installation, comprising a plurality of input stations (10), a plurality of output stations (20), a first fleet of mobile shuttles (40a) configured to provide a first order consolidation phase, each shuttle (42) including a locomotion device (43), allowing the shuttle (42) to move between the input stations (10) and the output stations (20), and a receptacle (44) intended to receive an article (61), and a control unit (50), wherein, in order to prepare an order including at least two articles (61, 62), the control unit (50) is configured to assign a first article (61) of the order to a first input station (10) and direct a first shuttle (42) toward said first input station (10) to pick up said first article (61), assign a second article (62) of the order to a second input station (10) and direct a second shuttle (42) toward said second input station (10) to pick up said second article (62), and direct the first and second shuttles (42) toward a given output station (20) to unload the first and second articles (61, 62) at said output station (20), characterized in that it comprises: a second fleet of shuttles (40b) configured to ensure a second distribution phase of the shipments of the articles (61, 62).

2. The installation according to claim 1, wherein the control unit (50) is configured to mobilize, for a given order, as many shuttles (42) as there are articles (61-63) in said given order.

3. The installation according to claim 1 or 2, wherein, for a given order, the control unit (50) is configured to order the unloading of the articles (61-63) at the output station (20) only when all the articles (61-63) of said given order have been picked up by the shuttles (42).

4. The installation according to any one of claims 1 to 3, comprising a waiting area (49), the control unit (50) being configured to direct at least one shuttle (42) toward the waiting area (49) if at least one other article (63) of said given order has not yet arrived at an input station (20) or if no output station (20) is available to receive the articles (61-63) of said given order.

5. The installation according to any one of claims 1 to 4, wherein the control unit (50) is configured to order the unloading of the articles (61-63) of a given order in a predetermined order.

6. The installation according to any one of claims 1 to 5, wherein at least one input station is an injection station (10) connected to a warehouse (11).

7. The installation according to any one of claims 1 to 6, wherein at least one output station is a packaging station (20) configured to package together the different articles (61-63) of a given order.

8. The installation according to any one of claims 1 to 7, wherein at least one output station is a bulk station (27) configured to store a large number of articles (61).

9. The installation according to any one of claims 1 to 8, wherein at least one output station is a reintegration station (28), connected to the warehouse (11).

10. The installation according to any one of claims 1 to 9, wherein the shuttles (42) move along a travel surface (41a).

11. The installation according to any one of claims 1 to 10, wherein at least one input station is a packaging station (20) and at least one output station is a dispatch station (30).

12. An order preparation method implementing a plurality of input stations (10), a plurality of output stations (20), a first fleet of mobile shuttles (40a) configured to ensure a first order consolidation phase, each shuttle (42) including a locomotion device (43), allowing the shuttle (42) to move between the input stations (10) and the output stations (20), and a receptacle (44) provided to receive an article (61), and a control unit (50), wherein, in order to prepare an order including at least two articles (61, 62), a first article (61) of the order is assigned to a first input station (10) and a first shuttle (42) is directed toward said first input station (10) to pick up said first article (61), a second article (62) of the order is assigned to a second input station (20) and a second shuttle (42) is directed toward said second input station (10) to pick up said second article (62), and the first and second shuttles (42) are directed toward a given output station (20) to unload the first and second articles (61, 62) at said output station (20), characterized in that it comprises: a second distribution phase of the shipments of the articles (61, 62) ensured by a second fleet of shuttles (40b).

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