Automated store equipped with exchangeable automatic mobile robot

Abstract

To provide a system and method that manage multiple automatic mobile robots within an automatic robot storage and retrieval system.SOLUTION: One or two or more automatic mobile robots, which operate in an automatic inventory management system so as to perform a plurality of tasks across a plurality of different areas of an automated store, are reused. The same mobile robot operates in an order fulfillment mode where it moves in a horizontal and vertical direction in a multi-level storage structure (230), issues an order tote from an auto-fill section (204), and delivers the order tote to a delivery section (208). The same mobile robot operates in a delivery mode where it operates in a replenishment section (206) of the replenishment mode for receiving the item's eaches and depositing the item's eaches in the designated storage tote and receives the delivery bundle and transports the delivery bundle to the designated location of the transfer station.SELECTED DRAWING: Figure 2C

Description

[Technical Field]

[0001] The present invention relates to an automated mobile robot for use within an automated mobile robot storage and retrieval system of an automated inventory management system such as an automated store. In particular, the present invention relates to a mobile robot configured and enabled to perform in all areas of the automated store, including moving horizontally and vertically in a multi-level storage structure and operating in order fulfillment, replenishment, and delivery modes.

[0002] (Priority Claim) This application claims priority to U.S. Provisional Patent Application No. 62 / 444,693, filed January 10, 2017, entitled "Interchangeable Autonomous Mobile Robot with Multiple Operational Modes Constituting Multiple Different Robotic Task Capabilities," which is incorporated herein by reference in its entirety. [Background technology]

[0003] Typically, human-operated and automated inventory control systems include multiple vertical and / or horizontal storage racks for holding and transporting inventory. Typically, inventory is stored in boxes stacked on pallets and placed in racks. Inventory can be removed from the storage racks by a combination of human-operated transport devices, such as forklifts, and automated mobile robots configured to move inventory into and out of the storage racks. Traditional systems rely on human actions (e.g., forklifts, hand trucks, manual lifts) to receive, remove, replenish, etc. inventory. In addition, automated systems exist to assist humans with specific tasks within the inventory control system (e.g., picking and stocking inventory). Based on the specific tasks for which the automated system is designed, customized and dedicated robots or other automated devices are required to perform each of these tasks.

[0004] These systems and methods suffer from several drawbacks. In particular, most inventory control systems often rely on human operators, instructors, and / or supervisors to ensure tasks are performed properly. Human operators can unknowingly make errors and deviations from defined tasks within the inventory control system, which can result in lost, damaged, expired, or other inventory. Dedicated automated systems can be designed to assist human operators, but each machine requires customization specific to the inventory control system, adding complexity. Inventory in traditional stock systems can be difficult to manage, optimize, and track, and retrieval can be complicated when an item is in the wrong place. Additionally, it can be costly to acquire a customized automated system for each portion of the inventory control system that requires automation. Additional capabilities in the form of additional mobile robots must be acquired for each type of mobile robot (e.g., fulfillment robots, replenishment robots, delivery robots, and storage management robots). Managing the workload across the entire inventory control system becomes more difficult because each form of robot is limited in its ability to perform the specific tasks for which it was designed. For example, a bottleneck may occur in delivery, and without the ability to utilize other robotic resources, e.g., from fulfillment, replenishment, or storage, the bottleneck will reduce the overall inventory flow until demand drops or more delivery robots are procured. Such a system is capital intensive and inefficient in terms of robotic resources. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] U.S. Provisional Patent Application No. 62 / 444,693 Summary of the Invention [Problem to be solved by the invention]

[0006] There is a need for an improved system and method for managing inventory within all portions of an automated store that does not suffer from the above-mentioned drawbacks. Multiple interchangeable mobile robots are assigned to different operations (e.g., stock replenishment, marshalling, organizing, stock removal, etc.) based on demand within the automated store to improve the efficiency and effectiveness of inventory management. The present invention is directed to another solution that addresses this need, in addition to having other desirable features. Specifically, the present invention is directed to a system and method for operating an automated store with multiple interchangeable robots configured with different operational modes that are assigned based on real-time demand in a manner that optimizes inventory usage throughout the automated store system. In particular, the present invention provides a system and method that provides real-time task assignment for the operational modes of multiple interchangeable automated mobile robots. The operational modes include a replenishment mode in which inventory is restocked, a defragmentation mode in which each of the items is marshaled within a tote and the totes are marshaled, an order fulfillment mode in which customer orders for items are picked, and a delivery mode in which completed orders are delivered to customers. Each of the automated mobile robots is configured with the ability to operate in each of these modes and is assigned to operate in a single operational mode at any given time period to optimally manage inventory based on real-time demand within the automated store. [Means for solving the problem]

[0007] According to an exemplary embodiment of the present invention, an automated store is provided. The automated store includes a building structure divided into an automated fulfillment section, a shopping section, and a replenishment section. The shopping section includes one or more item drop-off transfer stations and a delivery section. The replenishment section includes a workstation configured to transfer each replenishment to a designated storage tote. The transfer station receives and stores the delivery bundle at a designated location until a customer arrives to pick up the delivery bundle. A mobile robot propels itself horizontally and vertically throughout the automated fulfillment section, the delivery section, and the transfer station in one or more different modes of operation based on task requirements. The one or more different modes of operation include an order fulfillment mode, a replenishment mode, and a delivery mode. The order fulfillment mode includes issuing order totes from the automated fulfillment section and delivering the order totes to the delivery section. The replenishment mode includes receiving each of the items and depositing each of the items in a designated storage tote. The delivery mode includes receiving the delivery bundle and transporting the delivery bundle to a designated location in the transfer station.

[0008] According to an aspect of the present invention, the automated fulfillment section includes a storage rack structure having multiple rack modules with multiple storage levels separated by aisles. The storage rack structure stores multiple interchangeable totes, each designated as an empty storage tote when empty, designated as a storage tote when containing each of the items, designated as an order tote when containing each of the items for an order, or a combination thereof. The automated store can include one or more sub-totes sized, dimensioned, and configured to fit within the empty storage tote and / or order tote, and the multiple empty totes and / or order totes are sized, dimensioned, and configured to fit within a standard pallet. The standard pallet can include one or more of a North American pallet, a European pallet, an Australian pallet, or an Asian pallet. The one or more sub-totes can include one or more of a 1 / 4 sub-tote, a 1 / 2 sub-tote, and / or a 3 / 4 sub-tote. The one or more different modes of operation of the mobile robot can include a defragmentation mode. When the mobile robot is in the defragmentation mode, the mobile robot can deliver an exchangeable tote to be defragmented to a decanter station to rearrange one or more sub-totes within an exchangeable tote positioned within the storage rack structure. The one or more sub-totes can be rearranged by removing one or more sub-totes from a storage tote of the partially filled plurality of exchangeable totes and placing one or more sub-totes into other storage totes of the partially filled plurality of exchangeable totes until the other storage totes are completely filled in such a manner that the other storage totes rearrange the one or more sub-totes to create empty totes from the previously partially filled storage totes. The defragmentation mode can include combining empty sub-totes to increase storage density and free up empty sub-totes for the replenishment mode.

[0009] According to an aspect of the invention, one or more item drop-off transfer stations are located in an automated store in the checkout section. According to an aspect of the invention, the delivery section includes an integrated module that combines each of the items picked from the automated fulfillment section with items picked from the shopping section and deposited at one or more item drop-off transfer stations, each of the combined items forming a delivery bundle. According to an aspect of the invention, when the mobile robot is designated and operating in an order fulfillment mode, the mobile robot propels itself through a storage rack structure in the automated fulfillment section, places totes in the storage rack structure, removes totes from the storage rack structure, and transports the totes.

[0010] According to aspects of the present invention, task requirements are determined based at least in part on the time of day in a manner that allows the time of day to act as a basis for assigning the mobile robot to an order fulfillment mode, a replenishment mode, or a delivery mode. Task requirements can be determined based at least in part on the relative amount of tasks to be completed in each of the automated fulfillment section and the shopping section. Task requirements can be determined at least in part on instructions from customers arriving to pick up their orders at the transfer station. Task requirements can be determined at least in part on the relative amount of tasks to be completed in each of the automated fulfillment section and the shopping section, as well as an applied weighting that gives higher priority to delivery of the delivery bundle relative to replenishment tasks.

[0011] According to aspects of the present invention, an automated store includes a plurality of interchangeable mobile robots that are assigned to and operate in either an automated fulfillment section or a shopping section. The plurality of interchangeable mobile robots can be managed by dedicating a greater proportion of the mobile robots to fulfillment and delivery tasks versus other tasks during peak operating hours. The plurality of interchangeable mobile robots can be managed by dedicating a greater proportion of the mobile robots to replenishment tasks versus other tasks during off-peak operating hours.

[0012] According to an aspect of the present invention, a checkout section located in an automated store includes a payment transaction facilitator that enables customers to pay for items. The checkout section may include one or more checkout kiosks.

[0013] According to an aspect of the present invention, the items included in the shipping bundle include perishable items, processed items, or both. Returned items are received at a transfer station, placed into one or more sub-totes or totes, and sent to an automated fulfillment section.

[0014] According to an exemplary embodiment of the present invention, an automated inventory management system is provided. The system of the present invention includes an automated robotic storage and retrieval system. The automated robotic storage and retrieval system includes a storage rack structure including multiple rack modules separated by aisles and having multiple storage levels. The storage rack structure stores multiple totes that are empty, each containing an order, or each containing an order. The automated robotic storage and retrieval system includes at least one mobile robot that propels itself horizontally and vertically through the storage rack structure to place totes in the storage rack structure, remove totes from the storage rack structure, and transport the totes. The at least one mobile robot has multiple operational modes, including an order fulfillment mode, a replenishment mode, and a delivery mode. When the automated inventory management system commands the at least one mobile robot to engage one of the multiple operational modes based on a task request, the operational mode is engaged and the at least one mobile robot performs a task assigned to perform in the commanded operational mode.

[0015] According to an exemplary embodiment of the present invention, a method related to the operation of an automated store is provided. The automated store includes a building structure divided into an automated fulfillment section, a shopping section, and a replenishment section. The shopping section includes an item drop-off transfer station, a delivery section, and a transfer station. The replenishment section includes a workstation configured to transfer each replenishment item to a designated storage tote. The transfer station is configured to receive and store the delivery bundle at a designated location until a customer arrives to pick up the delivery bundle. A mobile robot propels itself horizontally and vertically through the automated fulfillment section, the delivery section, and the transfer station in one or more different modes of operation based on task requirements, the one or more different modes of operation including an order fulfillment mode, a replenishment mode, and a delivery mode. When the mobile robot is in the order fulfillment mode, the mobile robot retrieves order totes from the automated fulfillment section and delivers the order totes to the delivery section. When the mobile robot is in the replenishment mode, the mobile robot receives each of the items for depositing each of the items in a designated storage tote. When the mobile robot is in delivery mode, the mobile robot receives a delivery bundle and transports the delivery bundle to a designated location on a transfer station.

[0016] In accordance with aspects of the present invention, when a mobile robot is designated and operating in an order fulfillment mode, the mobile robot propels itself through the storage rack structures of the automated fulfillment section, places totes into the storage rack structures, removes totes from the storage rack structures, and transports totes to any location on the storage rack structures.

[0017] According to an aspect of the present invention, the method includes determining task requirements based on time of day in a manner such that the time of day affects the assignment of the mobile robot to an order fulfillment mode, a replenishment mode, or a delivery mode. The method can include determining task requirements based on a relative amount of tasks to be completed in each of the automated fulfillment section and the shopping section. The method can include determining task requirements based on instructions from a customer arriving to pick up at least one of the delivery bundles at the transfer station. The method can include determining task requirements based on a relative amount of tasks to be completed in each of the automated fulfillment section and the shopping section and an applied weighting that gives higher priority to delivery of the delivery bundles over replenishment tasks.

[0018] According to an aspect of the present invention, a checkout section located in an automated store includes a payment transaction facilitator that enables customers to provide payment for items. The checkout section may include one or more checkout kiosks.

[0019] According to aspects of the present invention, the items included in the shipping bundle may include fresh items, processed items, or both.

[0020] These and other features of the present invention will be better understood by reference to the following detailed description taken in conjunction with the accompanying drawings. [Brief explanation of the drawings]

[0021] [Figure 1] 1 is a schematic diagram illustrating an automated mobile robot storage and retrieval system. [Figure 2A] 2 is a schematic diagram illustrating an automated store layout implementing the automated mobile robot storage and retrieval system of FIG. 1. [Figure 2B] 2 is a schematic diagram illustrating an automated store layout implementing the automated mobile robot storage and retrieval system of FIG. 1. [Figure 2C]2 is a schematic diagram illustrating an automated store layout implementing the automated mobile robot storage and retrieval system of FIG. 1. [Figure 2D] 2 is a schematic diagram illustrating an automated store layout implementing the automated mobile robot storage and retrieval system of FIG. 1. [Figure 2E] 2 is a schematic diagram illustrating an automated store layout implementing the automated mobile robot storage and retrieval system of FIG. 1. [Figure 2F] 2 is a schematic diagram illustrating an automated store layout implementing the automated mobile robot storage and retrieval system of FIG. 1. [Figure 3] 1 is an explanatory diagram showing a manual decanter station within an automated mobile robot storage and retrieval system. [Figure 4A] FIG. 1 is an illustration of a portable rack of totes for use in an automated mobile robotic storage and retrieval system. [Figure 4B] FIG. 1 is an illustration of a portable rack of totes for use in an automated mobile robotic storage and retrieval system. [Figure 5A] FIG. 1 is an illustration of a defragmentation station for use within an automated mobile robotic storage and retrieval system. [Figure 5B] FIG. 1 is an illustration of a defragmentation station for use within an automated mobile robotic storage and retrieval system. [Figure 6A] FIG. 1 is an illustration of a picking workstation for use within an automated mobile robotic storage and retrieval system. [Figure 6B] FIG. 1 is an illustration of a picking workstation for use within an automated mobile robotic storage and retrieval system. [Figure 6C] FIG. 1 is an illustration of a picking workstation for use within an automated mobile robotic storage and retrieval system. [Figure 7A] FIG. 1 is an illustration of a transfer station for use in an automated mobile robotic storage and retrieval system. [Figure 7B] FIG. 1 is an illustration of a transfer station for use in an automated mobile robotic storage and retrieval system. [Figure 8]1 is an example flow diagram showing modes of operation within an autonomous robotic storage and retrieval system. [Figure 9] FIG. 1 is a diagram illustrating a high-level architecture for implementing the processes described herein. DETAILED DESCRIPTION OF THE INVENTION

[0022] An exemplary embodiment of the present invention relates to a system and method for managing inventory in an automated mobile robot storage and retrieval system by utilizing different operational modes for each of a plurality of interchangeable automated mobile robots in the system. The operational modes are designed to provide task requests to each of a plurality of interchangeable automated mobile robots to perform different specific tasks throughout the automated mobile robot storage and retrieval system implemented in an automated store. The operational modes and associated task requests are uniquely implemented to perform tasks related to replenishment, defragmentation, order fulfillment, and delivery of items. Additionally, each of the plurality of automated mobile robots is functionally identical and interchangeable for the operational modes they are capable of performing. The system of the present invention allows each of the plurality of interchangeable mobile robots to be associated with a specific operational mode and to perform this operation with adjustments to the operational mode managed in real time based at least in part on the real-time demands or needs for the specific task to be completed. This enables improved overall inventory management efficiency and reduces bottlenecks throughout the system without requiring excess, underutilized robots waiting in standby or other non-operational modes until needed.

[0023] 1-9, in which like elements are designated by like reference numerals throughout, illustrate an exemplary embodiment or embodiments of an automated inventory control system implemented in an automated store utilizing multiple interchangeable mobile robots that can be assigned one of several different operational modes based on real-time demands across the automated store facility in accordance with the present invention. While the present invention will be described with reference to the exemplary embodiment or embodiments illustrated in the figures, it should be understood that many alternative forms can embody the present invention. Those skilled in the art will additionally recognize different ways to vary parameters of the disclosed embodiments, such as size, shape, or type of elements or materials, in a manner consistent with the spirit and scope of the present invention.

[0024] 1 illustrates an exemplary automated inventory control system 100 implemented by a plurality of automated mobile robots 122. In particular, FIG. 1 illustrates the inventory control system 100 configured to control various operational modes of each of the plurality of mobile robots 122 in the inventory control system 100. As used throughout this specification, each of the plurality of mobile robots 122 is interchangeable with one another in that each mobile robot can perform an entire set of operational modes and functions, such that if one mobile robot is insufficient to complete a task, an operational mode can be imposed on any of the additional plurality of mobile robots to perform a desired task.

[0025] According to an exemplary embodiment of the present invention, inventory management system 100 includes or is included within automated mobile robotic storage and retrieval system 102. Automated mobile robotic storage and retrieval system 102 is a combination of physical structures (e.g., storage facilities), hardware, and software configured to carry out aspects of the present invention. In particular, automated mobile robotic storage and retrieval system 102 includes a computer system with specialized software and a database designed to provide a method and system for managing inventory in an automated inventory management system. For example, automated mobile robotic storage and retrieval system 102 can be software installed on computing device 104, a web-based application provided by computing device 104 that is accessible by other computing devices (e.g., user device 124), a cloud-based application accessible by a computing device, etc. The combination of hardware and software that makes up automated mobile robotic storage and retrieval system 102 is specifically configured to provide a technical solution to a particular problem that utilizes a non-conventional combination of steps / acts to implement aspects of the present invention. In particular, the automated mobile robot storage and retrieval system 102 is designed to perform a unique combination of steps to provide a new approach that enables one or more automated mobile robots 122 and other devices to manage inventory and other tasks within the inventory management system 100.

[0026] According to an exemplary embodiment of the present invention, the automated mobile robotic storage and retrieval system 102 includes a computing device 104 having a processor 106, a memory 108, an input / output interface 110, input and output devices 112, and a storage system 114. Additionally, the computing device 104 may include an operating system configured to execute the operations of installed applications. As will be appreciated by those skilled in the art, the computing device 104 may include a single computing device, a collection of computing devices in a networked computing system, a cloud computing infrastructure, or a combination thereof. Similarly, as will be appreciated by those skilled in the art, the storage system 114 may include any combination of computing devices configured to store and organize a collection of data. For example, the storage system 114 may be a local storage device on the computing device 104, a remote database facility, or a cloud computing storage environment. The storage system 114 may store data related to the operation of the automated mobile robotic storage and retrieval system 102. For example, the storage system 114 may store databases for the automated mobile robots 122 and various zones throughout the automated inventory control system 100. The storage system 114 may also include a database management system that utilizes a given database model configured to interact with a user to analyze database data.

[0027] According to an exemplary embodiment of the present invention, input and output devices 112 may include or otherwise communicate with a combination of wireless transceivers configured to provide a means of communication between automated mobile robotic storage and retrieval system 102 and the plurality of automated mobile robots 122. As will be appreciated by one skilled in the art, input and output devices 112 may include any combination of communication means known in the art for transmitting signals and data between automated mobile robotic storage and retrieval system 102 and the plurality of automated mobile robots 122. For example, wireless transceivers utilized within automated mobile robotic storage and retrieval system 102 may include, but are not limited to, optical, short-range or radio frequency identification, Wi-Fi, or Bluetooth® wireless communication means for transmitting signals and data to the plurality of automated mobile robots 122.

[0028] Continuing with FIG. 1 , the automated mobile robotic storage and retrieval system 102 may include a combination of core components for performing various functions of the present invention. According to an exemplary embodiment of the present invention, the automated mobile robotic storage and retrieval system 102 may include central controllers 116 configured to manage operational modes of the automated mobile robots 122. In particular, each of the central controllers 116 is configured to provide the mechanisms required to select and assign various modes of operation of the automated mobile robots 122 operating within the automated inventory control system 100. As will be appreciated by those skilled in the art, the central controllers 116 may include any combination of hardware and software configured to perform various aspects of the present invention.

[0029] According to an exemplary embodiment of the present invention, the central controller 116 provides a user operating the automated mobile robot storage and retrieval system 102 with the ability to access and control multiple automated mobile robots 122 throughout the automated inventory control system 100. In particular, the central controller 116 is configured to manage the locations and operational modes of the automated mobile robots 122 based on user preferences. Primary operational modes of the automated mobile robots 122 include, but are not limited to, replenishment, decanting, defragmentation, order fulfillment, storage, and delivery. As will be appreciated by those skilled in the art, the automated mobile robots 122 may also include operational modes unrelated to managing inventory. For example, multiple automated mobile robots 122 may be assigned as block robots to establish safety zones within the automated inventory control system 100. Other examples of operational modes include an initialization mode, a standby mode, an idle mode, an active mode, an alarm mode, a disabled mode, a power-off mode, a charging mode, and a maintenance recall mode. The central controller 116 is configured to receive user input (e.g., from a user interface of the automated mobile robot storage and retrieval system 102) that dictates how and where the automated mobile robot 112 should operate (e.g., operational mode), and provides instructions to the automated mobile robot 122 for implementation of the user input. For example, the central controller 116 can receive user input with instructions to assign the automated mobile robot 122 to perform specific tasks within the automated inventory control system 100. Additionally, the central controller 116 can receive instructions to assign the automated mobile robot 122 in response to specific events (e.g., receiving a customer order for auto-fulfillment, receiving new inventory in the replenishment section 206, etc.). In response to the instructions and / or event, the central controller 116 provides instructions to the automated mobile robot 122 to act according to a specific combination of operational mode and task request, as described in more detail herein.

[0030] Based on the operational mode and task request received by the autonomous mobile robots 122, the respective electromechanical systems within each of the autonomous mobile robots 122 are initialized to perform the appropriate operation. For example, when the autonomous mobile robot 122 receives a task request to move to a specified location and performs the operation (e.g., remove / store a tote 232), a power mechanism is activated to control the supply of power to the propulsion system of each of the autonomous mobile robots 122 in the direction of the specified location. The primary operations performed by the autonomous mobile robots 122 within the store 200 based on priority include customer delivery, customer order picking, replenishment, and defragmentation. In customer delivery, the autonomous mobile robot 122 retrieves and organizes customer totes for store associates to transport to the customer or directly to customer retrieval. In order picking, the autonomous mobile robot 122 retrieves order totes and product totes and delivers them to the workstation 236 for order picking. The system 100 can request store associates from the picking workstation 236 based on system scheduling and order requests. In replenishment, the autonomous mobile robot 122 transports empty totes to a decanter station 254 where employees fill items into sub-totes, which are subsequently filled into totes being retrieved and stored by the autonomous mobile robot 122. Finally, upon completion of other activities and based on the percentage of empty sub-totes in the system, the autonomous mobile robot 122 is instructed to take the tote containing the empty sub-tote to a defragmentation station 238, as discussed with respect to Figures 5A and 5B.

[0031] According to an exemplary embodiment of the present invention, the automated inventory control system 100 may include a plurality of user devices 124 configured to communicate with the automated mobile robotic storage and retrieval system 102 over a telecommunications network 126. The automated mobile robotic storage and retrieval system 102 may act as a centralized host for the user devices 124, providing the functionality of the central controller 116 that shares a secure network connection. As will be appreciated by those skilled in the art, the plurality of user devices 124 may include any combination of computing devices, as described with respect to the automated mobile robotic storage and retrieval system 102 and the computing device 104. For example, the computing device 104 and the plurality of user devices 124 may include any combination of servers, personal computers, laptops, tablets, smartphones, etc. According to an exemplary embodiment of the present invention, the computing devices 104, 124 are configured to establish connections and communicate over the telecommunications network 126 to implement aspects of the present invention. As will be appreciated by those skilled in the art, the telecommunications network 126 may include any combination of known networks. For example, the telecommunications network 126 may be a combination of a mobile network, a WAN, a LAN, or other types of networks. The telecommunications network 126 may be used to exchange data between the computing devices 104, 124, to exchange data with the storage system 114, and / or to collect data from additional sources.

[0032] FIG. 2A illustrates an exemplary conceptual interior layout of an automated store 200 implementing the automated inventory control system 100 in accordance with the present invention. In particular, FIG. 2A illustrates the automated store 200, including the shopping section 202, the automated fulfillment section 204, the replenishment section 206, the delivery fulfillment section 208, and how each of the areas of the automated store 200 conceptually relate to one another. As will be appreciated by those skilled in the art, the automated store 200 is not limited to the areas defined in FIG. 2A , and multiple areas can be combined into a single area. For example, the automated fulfillment section 204 can include multiple areas or zones, including the storage section, the replenishment section 204, and the delivery fulfillment section 208 all within a single area. Additionally, although the different areas depicted in FIG. 2A are shown within a single plane, the areas can be separated across multiple floors of the automated store 200. During operation of the automated store 200, all transactions occur through one or more of these areas 202, 204, 206, and 208 and / or subareas within these areas.

[0033] FIG. 2B shows a schematic diagram of the internal structure of automated store 200 as discussed with respect to FIG. 2A. In particular, FIG. 2B shows an exemplary diagram of a shopping section 202 and its conceptual relationship to an automated fulfillment section 204, a replenishment section 206, and a delivery fulfillment section 208. Shopping section 202 includes an entrance and exit point 210, a mock market 212, and a wall opening 214 to automated fulfillment section 204, as shown in FIG. 2B. Mock market 212 includes a wall 216 of order screens, multiple physical shelving units 218 and display stand cases 220, and multiple shopping terminals and checkout kiosks 222. Checkout kiosks 222 include payment transaction facilitators that allow customers to provide payment for items. Shopping section 202 includes "non-fungible" items such as produce, meat, seafood, cheese (primarily random weights), deli items, flowers, bakery items, and prepared foods. Typically, non-fungible items are sold from display fixtures or cases 218 using three different pricing methods, including, but not limited to, "random dollar" (sterilizable items with price bar codes), random weight (loose items, particularly produce, priced based on item weight), and random count (loose items priced based on the number of each). These non-fungible items may also be sold at a service counter that offers customers the opportunity to customize their ordered products according to their individual tastes and preferences. According to exemplary operation, a customer utilizes entrance 210 to enter and exit shopping section 202 of automated store 200. Once inside shopping section 202 of automated store 200, the customer can place an order for sterilizable items on order screen 216, which will be fulfilled in automated order fulfillment section 204, and can purchase non-fungible items in shopping section 202, which will be combined with the sterilizable items and delivered to the customer in delivery fulfillment section 208.

[0034] 2C shows an exemplary diagram of the automated fulfillment section 204 and the conceptual relationship between the automated fulfillment section 204, the shopping section 202, the replenishment section 206, and the delivery fulfillment section 208. The automated fulfillment section 204 includes a storage rack 230 system configured to hold inventory totes 232 accessible by the automated mobile robot 122 and to enable the automated mobile robot 122 to retrieve the inventory totes 232 and deliver the totes 232 to a picker 234 at a picking workstation 236 for automated order fulfillment. In particular, the storage rack 230 includes multiple rack modules separated by aisles and having multiple storage levels, and the storage rack 230 structure stores multiple totes 232 that are empty, contain each, or contain an order. The storage rack 230 is configured to enable the automated mobile robot 122 to self-propel itself through the storage rack 230 structure horizontally and vertically. The automated mobile robot 122 is configured to place totes 232 in the storage rack 230 structure, remove totes 232 from the storage rack 230 structure, and transport totes 232. Additionally, the automated mobile robot 122 is configured to deliver totes 232 to and from picking workstations 236 and other areas 202, 206, 208 of the automated store 200. Examples of such systems are described in detail in U.S. Pat. No. 9,139,363, U.S. Patent Application Publication No. 2014 / 0288696, and U.S. Patent Application No. 15 / 171,802, all of which are incorporated herein by reference. During operation within the automated inventory control system 100, the automated mobile robot 122 traverses different aisles and storage levels of the storage rack 230 structure to remove and replace inventory totes 232 as directed by the system 100.

[0035] According to an exemplary embodiment of the present invention, customer orders for sterilizable items are fulfilled by an automated system in automated fulfillment section 204. When an automated fulfillment order is completed, totes 232 containing the sterilizable items picked by automated mobile robot 122 and picker 234 are provided to delivery fulfillment section 208 (e.g., via path 408). Similarly, when a customer completes picking non-fungible items in shopping section 202, the customer provides the items to delivery fulfillment section 208 (e.g., via path 410 and wall opening 214). According to an exemplary embodiment of the present invention, delivery fulfillment section 208 includes a marshalling section 240 in which items from automated fulfillment section 204 and items from shopping section 202 are combined and consolidated into order totes 232 for delivery to customers at one or more transfer stations 242, as shown in FIG. 2D .

[0036] In the sorting section 240 of the delivery fulfillment section 208, the sterilizable items provided from the automated fulfillment section 204 and the non-fungible "perishable items" provided from the shopping section 202 are combined into a single order for delivery to the customer at a transfer station 242. In particular, the sorting section 240 includes an integration module that combines each of the items picked from the automated fulfillment section 204 with each of the items picked from the shopping section 202 that have been deposited at one or more item drop-off transfer stations 242. Each of the combined items from both sections 202, 204 form a delivery bundle (e.g., one or more totes 232 of items), and the automated mobile robot 122 transfers the completed delivery bundle to the transfer station 242, which receives and stores the delivery bundle at a designated location until a customer arrives to retrieve the delivery bundle.

[0037] According to an exemplary embodiment of the present invention, during sorting, the plurality of automated mobile robots 122 retrieve totes 232 of items from the various sections 202, 204 and transfer these totes 232 to an integrated module in the sorting section 240, as shown in FIG. 2D . Based on the quantity of items, one or more of the plurality of automated mobile robots 122, or one or more new automated mobile robots 122, can retrieve a delivery bundle and transfer the bundle to the appropriate transfer station 242. Each of the tasks associated with FIG. 2D is performed within a delivery mode of operation, with different task requirements provided to each of the automated mobile robots 122 performing each specific task (e.g., delivering items from the shopping section 202, delivering items from the automated fulfillment section 204, delivering the completed delivery bundle to the transfer station 242, etc.). As will be appreciated by those skilled in the art, sorting can occur within the same physical space as the automated fulfillment section 204, the delivery section 208, or in separate physical spaces.

[0038] 2E shows an exemplary diagram of delivery fulfillment section 208 and its conceptual relationship to automated fulfillment section 204 and shopping section 202. According to an exemplary embodiment of the invention, delivery fulfillment section 208 includes a plurality of transfer stations 242 configured for customers to pick up their orders. Transfer stations 242 are configured to deliver items directly to customers or customer vehicles in a variety of ways, as shown in FIGS. 7A and 7B.

[0039] According to an exemplary embodiment of the present invention, the replenishment section 206 of the automated store 200 is configured to receive shipments of items from various suppliers and / or manufacturers. The replenishment section 206 is contained within the "back end" of the store, which is generally not seen by customers. FIG. 2F shows an exemplary diagram of the replenishment section 206 and its relationship to other sections of the automated store 200. In particular, FIG. 2F shows the replenishment section 206, including a docking area for receiving cases of items (e.g., via trucks). According to an exemplary embodiment of the present invention, the cases of items can be received either as pallets 250 of cases or as portable racks of totes 232 in which the items are stored. The portable racks 252 of totes 232 can be received from a distribution center designed for implementation with the automated store 200. An exemplary implementation of such a distribution center is discussed with reference to U.S. Patent Application No. 62 / 427,652, filed November 29, 2016, which is incorporated herein by reference. Initially, regardless of shipping method, when items are delivered to replenishment section 206, they are identified as either non-fungible items for storage in shopping section 202 or sterilizable items for storage in automated fulfillment section 204. Based on the determination of sterilizable or non-fungible items, the received items are assigned to designated areas accordingly. In particular, non-fungible items are transported to shopping section 202 (e.g., via path 406), and sterilizable items are transported (e.g., via path 404) and stored in a manner suitable for automated order fulfillment (e.g., stored in totes 232 and placed on storage racks 230).

[0040] As will be appreciated by those skilled in the art, depending on whether the goods are received by pallets of cases 250 or totes on portable racks 252, the items are received into inventory in the automated fulfillment section 204 via different methods. For example, based on the type of delivery method, the goods are received in the manner discussed with respect to FIGS. 3-4B. According to an exemplary embodiment of the present invention, the replenishment section 206 includes a decanter station 254 configured to replenish goods in the automated fulfillment section 204, as shown in FIG. 3. The decanter station 254 may be utilized to replenish goods received from manufacturers, suppliers, and customer returns. The decanter process involves transferring products from the pallets of cases 250 and / or customer returns to totes 232 stored within the storage racks 230 of the automated fulfillment section 204.

[0041] 2A , multiple paths are shown that multiple automated mobile robots 122 are configured to traverse during different modes of operation. The paths include receiving new inventory at replenishment section 206 via path 402, transferring inventory to automated fulfillment section 204 for storage via path 404, transferring inventory to shopping section 202 for storage via path 406, providing inventory (e.g., sterilizable items) from automated fulfillment section 204 to delivery fulfillment section 208 for order fulfillment via path 408, receiving inventory (e.g., non-fungible items) from shopping section 202 at delivery fulfillment section 208 for order fulfillment via path 410, and transporting fulfillment orders to delivery destinations (e.g., customer vehicles, delivery vehicles, etc.) via path 412. On each of paths 402, 404, 406, 408, 410, 412, at least one automated mobile robot 122 handles at least a portion, but not all, of the transit. For example, along route 402, the automated mobile robot 122 may handle inventory of items as they are unloaded from trucks manually or via automated processing (e.g., at decanter station 254). In another example, the automated mobile robot 122 may handle inventory throughout the automated fulfillment section 204 as well as transfers along route 408 from the automated fulfillment section 204 to the delivery fulfillment section 208. The responsibilities of each of the automated mobile robots 122 vary based on the areas of the automated store 200 to which the automated robot 122 is assigned and the tasks it is assigned to perform within or between those areas. According to an exemplary embodiment of the present invention, the automated store 200 is laid out so that locations within the store 200 are accessible from at least two routes to avoid single points of failure within the system 100.

[0042] During operation, the automated mobile robot 122 is configured to assist in and / or perform various operations throughout the automated store 200. Each of the various operations is performed by assigning the automated mobile robot 122 (e.g., via the central controller 116) to one or more modes of operation. The modes of operation include, but are not limited to, a replenishment mode, a defragmentation mode, an order fulfillment mode, and a delivery mode. The replenishment mode includes receiving each of the items and depositing each of the items in a designated storage tote and / or storage location within the storage rack 230; the defragmentation mode includes organizing the totes 232 and arranging the sub-totes stored within the totes 232; the order fulfillment mode includes shipping the order totes from the storage rack 230 and delivering the order totes to the delivery section 208; and the delivery mode includes receiving the delivery bundle and transporting the delivery bundle to a designated location on the pickup transfer station 242. According to an exemplary embodiment of the present invention, each of the different operational modes is performed by the same designed autonomous mobile robot 122. In other words, a single autonomous mobile robot 122 can perform the tasks required by each of the operational modes without modification.

[0043] According to an exemplary embodiment of the present invention, totes 232 are interchangeable and are designated by different identifiers to the automated mobile robot 122 and the system 100. That is, totes 232 are structurally identical so that they are interchangeable for available tasks based on instructions associated with them. Totes 232 are designated based on their capacity as well as the operational mode in which they are utilized. In particular, interchangeable totes 232 are designated as empty storage totes when empty (e.g., no items contained therein), as storage totes 232 or product totes 232 when they contain each of the items (e.g., inventory), and as order totes when they contain each of the items for a customer order, or a combination thereof. During operation, the system 100 provides instructions that assist the automated mobile robot 122 in identifying the totes 232 to utilize in the operational mode. For example, when the automated mobile robot 122 is instructed to retrieve and empty totes 232 as part of the operational mode, the automated mobile robot 122 knows or is informed of the location of the totes 232 designated as empty totes 232.

[0044] According to an exemplary embodiment of the present invention, central controller 116 can identify and track the location of all of the automated mobile robots 122, totes 232, and system 100 instructions (e.g., modes, operations, or tote instructions), as well as each of the locations within each sub-tote contained within each tote 232. Identification of the locations of all of the automated mobile robots 122 and totes 232 can be utilized by central controller 116 when assigning the automated mobile robots 122 to different modes of operation. In particular, central controller 116 can identify all of the automated mobile robots 122 located within a particular section and command the automated mobile robots 122 to perform a particular mode of operation within this section. Central controller 116 attempts to level load the automated mobile robots 122 so that all necessary store 200 operations are completed with the fewest number of automated mobile robots 122.

[0045] When the central controller 116 wishes to assign an operational mode to one or more autonomous mobile robots 122, the central controller 116 sends a task request to one or more autonomous mobile robots 122 to instruct them on the task to perform according to the operational mode. In particular, the task command includes instructions related to a destination and to pick or place a tote at the destination. In addition, the task request may include specifying one or more totes 232 to utilize during the operational mode and the source / destination locations of the one or more totes 232. As will be understood by those skilled in the art, although the present invention is discussed with respect to providing commands, requests, and the like via the central controller 116, some or all of the control elements, including logic stored within the autonomous mobile robots 122 themselves, may be distributed throughout the system 100.

[0046] According to an exemplary embodiment of the present invention, the replenishment mode involves the automated mobile robot 122 propelling itself through the storage rack 230, delivering partially filled or empty totes 232 to a decanter station, accepting totes 232 with items for replenishment (e.g., storage totes or product totes), and / or transporting refilled totes 232 with items to storage locations within the storage rack 230. As will be appreciated by those skilled in the art, the totes 232 are interchangeable and can be utilized interchangeably within the operational mode, such that product totes can be utilized for replenishment, storage, and delivering products to workstations for order fulfillment. Specific tote instructions relate to the function the tote is currently performing based at least in part on the contents of the tote. When operating in the replenishment mode, the automated mobile robot 122 receives multiple task requests regarding locations to hand over to the totes 232 for receiving items for replenishment and locations to hand over to the refilled totes 232 for deposit within the storage rack 230. As will be appreciated by those skilled in the art, the task requests repeat these steps for each new tote 232 for replenishment.

[0047] Additionally, depending on how items are provided in the replenishment section 206, the automated mobile robot 122 can perform the same mode of operation in various ways as affected by different task requirements. For example, the mobile robot 122 may be directed to traverse different sections within the replenishment section 206 / automated fulfillment section 204 when receiving items originating from a pallet of cases 250 than when receiving items originating from a portable rack 252 of totes 232. Figure 2F illustrates how the initial location for receiving totes 232 for replenishment varies based on the shipping method. In particular, when items are received via a pallet of cases 250, the pallet of cases 250 is unloaded and transported to a decanter station 254 either via automated processing or via a human operator.

[0048] As a pallet of cases 250 is delivered at decanter station 254, picker 234 removes each of the items from the case of goods on the pallet as directed by system 100 and inserts them into a combination of tote 232 and sub-totes stored within tote 232, as shown in FIG. 3. Picker 234 continues to fill each of the sub-totes stored within tote 232 with goods until the capacity of tote 232 is reached (e.g., filled with the maximum number of sub-totes). While FIG. 3 illustrates a manual decanter workstation with a human picker 234, as will be understood by those skilled in the art, picker 234 can be an automated robotic picker. As will be understood by those skilled in the art, each pallet of cases 250 can vary in size and quantity of cases (and each of the goods contained therein). For example, standard pallets can include, but are not limited to, North American pallets, European pallets, Australian pallets, or Asian pallets, each standard configured to hold a different quantity of cases. Additionally, according to an exemplary embodiment of the present invention, tote 232 is sized, dimensioned, and configured to fit onto a standard pallet to act as a case for the items. For example, a North American pallet measures approximately 1.2 m x 1.2 m, and tote 232 may measure 600 mm x 400 mm x 300 mm to fit onto the 1.2 m x 1.2 m pallet.

[0049] According to an exemplary embodiment of the present invention, the sub-totes are sized, dimensioned, and configured to fit in combination within tote 232 to fill the entire interior volume of tote 232. The sub-totes are sized and dimensioned as 1 / 4 sub-totes, 1 / 2 sub-totes, and / or 3 / 4 sub-totes to fill 1 / 4, 1 / 2, and / or 3 / 4 of the interior volume of tote 232, respectively. For example, tote 232 may hold two 1 / 4 sub-totes and one 1 / 2. As will be understood by those skilled in the art, sub-totes of any size configured to fill the interior volume of tote 232 may be used without departing from the scope of the present invention. When the tote 232 reaches capacity (e.g., is filled with sub-totes containing each of the items), the mobile automated robot 122 receives a task request to traverse to the decanter station 254, pick up the tote 232, and transport the tote 232 to a designated storage location within a storage rack for later retrieval (e.g., to fulfill an order).

[0050] According to an exemplary embodiment of the present invention, the replenishment process is less labor-intensive when items are received via the portable rack 252 of the tote 232. In particular, the portable rack 252 of the tote 232 is unloaded from a vehicle either via an automated process or via a human operator adjacent to the storage rack 230. When positioned adjacent to the storage rack 230, the autonomous mobile robot 122 receives a task request for delivery to the portable rack 252 of the tote 232, picks up the designated tote 232, and transports the tote 232 to a designated storage location within the storage rack 230, as shown in FIGS. 4A and 4B. In particular, FIGS. 4A and 4B illustrate an implementation that does not require the use of the decanter station 238 and picker 234. FIG. 4A illustrates the portable rack 252 of the tote 232 temporarily attached to the storage rack 230 structure, the portable storage rack 252 being transported to / from a truck, and the portable storage rack 252 positioned within the rack (left to right) bound for the retail store. Additionally, FIG. 4A shows the automated mobile robot 122 transferring loaded totes 232 to / from a portable rack 252 temporarily attached to the storage rack 230 .

[0051] According to an exemplary embodiment of the present invention, the portable storage rack 252 is transported using a mobile rack robot 122a configured to move the portable storage rack 252, as shown in FIGS. 4A and 4B . In particular, the mobile rack robot 122a positions itself directly underneath the portable storage rack 252, lifts the portable storage rack 252 slightly, and uses computer navigation (e.g., via a task request) to move the portable storage rack 252 to its destination (e.g., storage rack 230). The mobile rack robot 122a can enter the space directly underneath the portable storage rack 252, either between the support legs at the narrow end or between the support legs along its length. The mobile rack robot 122a can alternatively be controlled by a human operator. As will be appreciated by those skilled in the art, the portable storage rack 252 can alternatively be transported manually on attached wheels or using a human-assisted wheeled lift.

[0052] Once at the automated store 200, the portable storage rack 252 is removed from the track and secured to the storage rack 230 structure of the store 200. For example, the portable storage rack 252 can be secured using registration features such as registration pins, or a kinematic coupling can be located at the bottom of the rail structure to properly position the portable storage rack to the rail structure and storage rack 230 structure. The rail structure and storage rack 230 structure of the automated store 200 contain the same registration features, allowing the portable storage rack 252 to be quickly and accurately aligned therewith so that the tote 232 can be transferred to the storage rack 230 structure by the automated mobile robot 122.

[0053] According to an exemplary embodiment of the present invention, modes of operation include an automated decanter mode in which the automated mobile robot 122 is instructed (e.g., via a task request) to transfer a tote 232 with each containing sub-tote from a portable storage rack 252 to a static storage rack 230 structure of the store 200. The automated decanter mode involves the automated mobile robot 122 either extracting a full tote 232 from a portable storage rack 252 and delivering the tote 232 to a decanter station 254 or placing the tote 232 directly into a storage rack 230, as directed by the system 100. FIG. 4B illustrates the rail structure along which the automated mobile robot 122 travels when placing or picking a tote 232 from a portable storage rack 252. After the arriving full tote 232 has been transferred from the portable storage rack 252 to the storage rack 230 structure, the empty tote 232 (with or without empty sub-totes) can be transferred to the portable storage rack 252 for return to a distribution center (e.g., an automated distribution center).

[0054] According to an exemplary embodiment of the present invention, modes of operation include a defragmentation mode that occurs within the auto-fulfillment section 204 and / or the replenishment section 206. The defragmentation process is designed to optimize the use of stored totes 232 and sub-totes. In particular, the defragmentation process optimizes inventory by reconfiguring partially empty totes 232 (e.g., totes 232 with one or more empty sub-totes stored) to partially fill partially full totes 232 and create several empty totes 232, freeing them for other uses (e.g., as order totes 232). During defragmentation, the decanter station 254 and / or the picking workstation 236 may be utilized to defragment the inventory.

[0055] When the automated mobile robot 122 is in defragmentation mode, the automated mobile robot 122 receives a task request to deliver one or more exchangeable totes 232 to a decanter station 254 or picking workstation 236 and rearrange one or more sub-totes within the one or more exchangeable totes 232. The delivery step includes handing the storage rack 230 to a specific tote 232 positioned in the storage rack 230 structure, removing the specific tote 232 from the storage rack 230, and handing the storage rack 230 to a specific decanter station 254 or picking workstation 236 for defragmentation. While at the decanter station 254 or picking workstation 236, one or more sub-totes are rearranged by removing one or more sub-totes from one tote 232 (e.g., a tote 232 to be emptied) to another tote 232 (e.g., a tote 232 to be filled to capacity). The defragmentation process continues by removing one or more subtotes from a partially filled tote 232 in such a way as to rearrange one or more subtotes and create an empty tote from a previously partially filled storage tote, and by placing one or more subtotes into other partially filled storage totes until the other storage totes are completely filled.

[0056] Figure 5A illustrates an exemplary defragmentation process implemented at a decanter station 254 or a picking workstation 236. In particular, Figure 5A illustrates multiple automated mobile robots 122 delivering and retrieving partially filled and empty totes 232 from a decanter station 254 or a picking workstation 236, respectively, for defragmentation. The defragmentation process is implemented by a picker 234, which handles the removal and placement of sub-totes among the partially filled totes 232. As will be appreciated by those skilled in the art, the picker 234 can be a human operator, an automated robot (as shown in Figure 5A), or a combination thereof.

[0057] According to an exemplary embodiment of the present invention, the defragmentation mode of operation of the automated mobile robot 122 can include different progressions of operation or sets of task requests. In particular, the automated mobile robot 122 can receive task requests to shuffle partially filled totes 232, filled totes 232, and empty totes 232 among designated automated defragmentation stations 238 within a storage rack 230. FIG. 5B illustrates an exemplary implementation of the automated defragmentation station 238. In particular, FIG. 5B illustrates an automated defragmentation station 238 in an upper row of a storage rack 230, allowing the automated mobile robot 122 to move adjacent to the automated defragmentation station 238 to insert and remove totes 232 for defragmentation. Additionally, the automated defragmentation station 238 is configured with rails that allow lateral movement by the Cartesian robot 122b, which is configured to retrieve and place sub-totes stored within the totes 232 placed within the automated defragmentation station 238, as shown in FIG. 5B. The automated defragmentation station 238 and Cartesian robot 122b, combined with the automated mobile robot 122's retrieval of totes 232 from partially filled totes 232 and removal of full and empty totes 232, create a fully automated defragmentation process. As will be appreciated by those skilled in the art, the automated defragmentation station 238 can be utilized to decant items between totes 232 received via the portable storage rack 252.

[0058] According to an exemplary embodiment of the present invention, a defragmentation mode of operation of the automated mobile robot 122 may include directing the automated mobile robots 122 to distribute and reorganize the totes 232 within the storage rack 230 itself. For example, the totes 232 may be organized and distributed to reduce travel time for retrieving different items, such as empty totes. The distribution and reorganization of the totes 232 may be directed, for example, by the type of items stored within the tote 232. Based on the items within the tote 232, the totes 232 may be transported and stored by the automated mobile robot 122 within different areas of the storage rack 230. For example, ambient temperature items may be stored in a different area than items that require refrigeration or freezing. As will be appreciated by those skilled in the art, the defragmentation process may include allocating sub-totes within the tote 232 according to similar logic. For example, a sub-tote containing frozen items will not be stored in the same tote 232 as a sub-tote containing ambient temperature items. Additionally, other optimizations of the sub-totes may be performed. For example, the system 100 does not combine each from different cases into subtotes (eg, according to lot, expiration date, etc.).

[0059] According to an exemplary embodiment of the present invention, the operational mode includes an order fulfillment mode. When the automated mobile robot 122 is designated and operating in the order fulfillment mode, the automated mobile robot 122 propels itself through the storage rack 230 structure of the automated fulfillment 204 section, placing totes 232 into the storage rack 230 structure, removing totes 232 from the storage rack 230 structure, and transporting totes 232 throughout the storage rack 230 to various destinations coupled to the storage rack 230 structure (e.g., picking workstation 236, defragmentation station 238, decanter station 254, etc.). In particular, the automated mobile robot 122 delivers requested totes 232 (e.g., empty totes and product / storage totes, etc.) to the picking workstation 236 during automated order fulfillment, as shown in FIGS. 6A and 6B . During order fulfillment mode, one or more of the plurality of automated mobile robots 122 receives a task request to retrieve one or more totes 232 containing sub-totes containing each (e.g., product tote / storage tote) from a storage rack 230 and deliver the product totes 232 to a designated picking workstation 236. Prior to or concurrently with the retrieval of one or more product totes 232, another automated mobile robot 122 receives a task request to retrieve one or more empty totes 232 to be delivered to a picking workstation 236. The retrieved empty totes 232 can be designated as an order to be filled with each of the items from the product totes 232 specified in a customer order (e.g., at a picking workstation 236).

[0060] According to an exemplary embodiment of the present invention, a picker 234 is assigned to a designated picking workstation 236 and instructed to pick each of the items from a tote 232 (e.g., product tote 232) delivered by an automated mobile robot 122 operating in order fulfillment mode. As will be appreciated by those skilled in the art, the picker 234 can be any combination of manual human and automated operation. For example, the picker 234 can be a human who receives input from the system 100 indicating which and how many items to pull from each delivered product tote 232 and places each of these items into an order tote 232, as shown in FIG. 6A. In another example, the picker 234 can be an autonomous articulated arm robot 234 configured to transfer an ordered sub-tote containing each item into an empty order tote 232, as shown in FIG. 6B. Once the order tote 232 is filled with each, the autonomous mobile robot 122 receives a task request to either store the order tote 232 in a storage rack 230 structure in a temporary storage location in the delivery section 208 shown in FIG. 6C or transport it directly to a transfer station 242. The remaining steps in the product flow according to the disclosed embodiments involve the fulfillment of customer orders at the each picking workstation 236 and the transport of completed orders to customers, as described in U.S. Patent Application Serial No. 15 / 171,802, filed June 2, 2016, entitled "Storage and Retrieval System," which is incorporated herein by reference in its entirety.

[0061] According to an exemplary embodiment of the present invention, the operational mode includes a sorting and delivery mode. When the automated mobile robot 122 is designated and operating in the sorting and delivery mode, the automated mobile robot 122 propels itself through the storage rack 230 structure of the automated fulfillment 204 section to remove totes 232 (e.g., completed order totes 232) from the storage rack 230 structure or a temporary attached portable storage rack and transport these totes 232 to the delivery section 208 for storage at a transfer station 242. In particular, the automated mobile robot 122 receives task requests to retrieve specified completed order totes 232 from a specified storage location (e.g., within the storage rack 230) and to transport specified completed order totes 232 to the transfer station 242 for customer pickup and temporary storage in the sorting section 240 for sorting into a delivery bundle. If the task request requires delivery to the sorting section 240, multiple automated mobile robots 122 each receive task requests to retrieve multiple completed order totes 232 simultaneously or sequentially for delivery to the sorting section 240. In the organizing section 240, the integration module organizes each of the items from each of the issued order totes 232 into a distribution bundle (e.g., a group of order totes). According to an exemplary embodiment of the present invention, a distribution bundle includes one or more totes 232 designated as order totes 232 for distribution.

[0062] Upon completion of the organization of multiple order totes, one or more automated mobile robots 122 receive a task request to transport the totes 232 for the delivery bundle to a designated transfer station 242 within the delivery section 208 for storage and pickup by the customer. Figures 7A and 7B show two different transfer station configurations for delivery by automated mobile robots 122. Figure 7A shows an exemplary "in-store" or cart transfer station 242 configuration. The cart delivery configuration includes rails attached to a storage rack 230 that extend adjacent to one or more dedicated delivery carts. The delivery carts are designed to enable the automated mobile robot 122 to transfer delivery order totes 232 from the rails attached to the storage rack 230 to the cart, as shown in Figure 7A.

[0063] FIG. 7B shows an exemplary embodiment of a "curbside" or customer vehicle transfer station 242 configuration. Similar to the structure of FIG. 7A, the customer vehicle transfer station 242 configuration includes rails attached to a storage rack 230 that extend adjacent to one or more dedicated temporary customer storage racks. The temporary customer storage racks are designed so that an automated mobile robot 122 can transfer delivery order totes 232 from the rails attached to the storage rack 230 to the temporary customer storage racks, as shown in FIG. 7B. Additionally, the temporary customer storage racks are configured adjacent to customer parking spaces so that customers can arrive at their designated locations and pick up their respective orders from the temporary customer storage racks. As will be understood by those skilled in the art, if only one order tote 232 issued from the storage rack 230 is designated for delivery, the sorting step can be skipped and the issuing automated mobile robot 122 can transport the order tote 232 directly to the designated transfer station 242 in the delivery section 208.

[0064] According to an exemplary embodiment of the present invention, the operational mode for each of the autonomous mobile robots 122, and its associated task requests, is determined based at least in part on the time of day. In particular, the time of day influences which and how many autonomous mobile robots 122 are assigned within each mode of operation and the task requests sent to the autonomous mobile robots 122 during that mode of operation, such that the time of day acts as the basis for designating a mobile robot in an order fulfillment mode, a replenishment mode, a defragmentation mode, or a delivery mode. The operational mode and task requests determined by central controller 116 are based on a combination of factors. The factors may include, but are not limited to, the relative amount of tasks completed in each of the auto-fulfillment section 204, the replenishment section 206, the delivery section 208, and the shopping section 202, instructions from customers arriving to pick up their orders at the delivery fulfillment section 208 (e.g., transfer station 242), the relative amount of tasks completed in each of the auto-fulfillment section 204, the replenishment section 206, the delivery section 208, and the shopping section 202, and a weighting that applies a higher priority to the task of delivering a delivery bundle relative to the replenishment task.

[0065] Additionally, a majority of the automated mobile robots 122 may be assigned to particular modes of operation (e.g., picking each / order, delivering to a distribution / pickup location, etc.) during daytime "operating hours" versus nighttime "stocking hours" (receiving inventory, replenishing, defragmenting, etc.). For example, the system 100 may dedicate a greater percentage of the automated mobile robots 122 to order fulfillment and delivery tasks relative to other tasks during peak operating hours of the automated store 200. Similarly, the system 100 may dedicate a greater percentage of the automated mobile robots 122 to replenishment tasks relative to other tasks during off-peak operating hours. As will be appreciated by those skilled in the art, the assignment of operating modes for the automated mobile robots 122 may include any combination of modes based on the demands of the automated store 200, the number of available automated mobile robots 122, and other factors for optimization / efficiency.

[0066] FIG. 8 illustrates an exemplary flow diagram illustrating the implementation of the systems and methods of the present invention. In particular, FIG. 8 illustrates an exemplary flow diagram illustrating the implementation of different operational modes of the autonomous mobile robot 122 as discussed with respect to FIGS. 1-7B. In particular, FIG. 8 illustrates a process 800 illustrating how the functionality of the autonomous mobile robot 122 changes based on the operational mode assigned to the autonomous mobile robot 122. In step 802, one or more mobile robots receive an operational mode from the system 102. In step 804, the mode is identified and the autonomous mobile robot 122 implements the operational mode. In step 808, the autonomous mobile robot 122 receives a specific task request for a location where the autonomous mobile robot 122 should move to perform the next task. In step 808, the autonomous mobile robot 122 receives a specific task request associated with the operational mode. In particular, the task request includes a location for the tote 232 to be retrieved, a location for the tote 232 to be delivered, and what to do with the tote 232 at this location. Steps 806 and 808 are repeated until the mode of operation is completed or a new mode of operation is assigned in step 810 .

[0067] Any suitable computing device can be used to implement the computing devices 104, 124, 122 and the methods / functions described herein, and can be converted into a specific system for performing the operations and features described herein through hardware, software, and firmware modifications in a manner more efficient than simply executing software on a general-purpose computing device, as will be understood by those skilled in the art. One illustrative example of such a computing device 9000 is shown in FIG. 9. The computing device 9000 is merely an illustrative example of a suitable computing environment and does not limit the scope of the present invention. The "computing device" represented by FIG. 9 can include a "workstation," a "server," a "laptop," a "desktop," a "handheld device," a "mobile device," a "tablet computer," or other computing device, as will be understood by those skilled in the art. While the computing device 9000 is shown for illustrative purposes, embodiments of the present invention can use any number of computing devices 9000 in any number of different ways to implement a single embodiment of the present invention. Thus, embodiments of the present invention are not limited to a single computing device 9000 or to a single type of implementation or configuration of the exemplary computing device 9000, as will be understood by those skilled in the art.

[0068] The computing device 9000 may include a bus 9010 that may be directly or indirectly coupled to one or more of the following illustrative components: memory 9012, one or more processors 9014, one or more presentation components 9016, input / output ports 9018, input / output components 9020, and a power supply 9024. Those skilled in the art will appreciate that the bus 9010 may include one or more buses, such as an address bus, a data bus, or any combination thereof. Those skilled in the art will appreciate that multiple of these components may be implemented by a single device, depending on the intended application and use of a particular embodiment. Likewise, in some cases, a single component may be implemented by multiple devices. As such, FIG. 9 is merely illustrative of an exemplary computing device that may be used to implement one or more embodiments of the present invention, and is not intended to be limiting of the present invention.

[0069] Computing device 9000 may include or interact with a wide variety of computer-readable media. For example, computer-readable media may include random access memory (RAM), read-only memory (ROM), electronically erasable programmable read-only memory (EEPROM), flash memory or other memory technology, CD-ROM, digital multifunction disk (DVD) or other optical or holographic media, magnetic cassettes, magnetic tape, magnetic disk storage, or other magnetic storage devices that can be used to encode information and that can be accessed by computing device 9000.

[0070] The memory 9012 can include computer storage media in the form of volatile and / or nonvolatile memory. The memory 9012 can be removable, non-removable, or any combination thereof. Exemplary hardware devices are devices such as hard drives, solid-state memory, optical disk drives, etc. The computing device 9000 can include one or more processors that read data from components such as the memory 9012, various I / O components 9016, etc. The presentation component 9016 presents data indications to a user or other device. Exemplary presentation components include a display device, a speaker, a printer component, a vibrating component, etc.

[0071] The I / O ports 9018 may allow the computing device 9000 to logically couple to other devices, such as I / O components 9020, some of which may be incorporated into the computing device 9000. Examples of such I / O components 9020 include microphones, joysticks, recording devices, gamepads, satellite dishes, scanners, printers, wireless devices, networking devices, etc.

[0072] As used herein, the words "comprises" and "comprising" are intended to be inclusive rather than exclusive. As used herein, the words "exemplary," "example," and "illustrative" are intended to mean "serving as an example, instance, or illustration" and are not intended to be construed as indicating a preferred or advantageous configuration over other configurations, and do not indicate such a configuration. As used herein, "about" and "approximately" are intended to cover variations that may exist at the upper and lower limits of a range of subjective or objective values, such as variations in characteristics, parameters, sizes, and dimensions. In one non-limiting example, "about" and "approximately" mean plus or minus 10 percent or less. In one non-limiting example, "about" and "approximately" mean close enough to be considered included by one of ordinary skill in the art. As used herein, "substantially" refers to the complete or nearly complete extent or degree of an action, characteristic, property, state, structure, item, or result, as understood by one of ordinary skill in the art. For example, an object that is "substantially" circular means that the object is perfectly circular to the extent that it can be mathematically determined, or nearly circular as recognized or understood by one of ordinary skill in the art. The correct and acceptable degree of deviation from absolute perfection may depend on the specific context in some cases. In general, however, proximity to perfection will have the same overall result as absolute and total perfection would be achieved or obtained. The use of "substantially" is equally applicable when utilized in a negative sense to refer to the complete or nearly complete absence of an action, characteristic, property, state, structure, item, or result, as understood by one of ordinary skill in the art.

[0073] The terms "robot" and "bot" are used interchangeably herein in accordance with their conventional meaning, and specifically refer to a useful machine or device, i.e., a programmable multi-function device that can move materials, parts, tools, or specialized devices through a variety of programmed movements for the performance of a wide variety of tasks, assignments, designations, etc., and / or a machine or device that can perform a series of simple or complex actions, and / or a machine or device that can perform tasks that may or may not be human work, and / or a programmable mechanical device that can perform tasks and interact with its environment without the aid of human intervention, and a machine or device that can operate automatically or be controlled by a computer.

[0074] Unless otherwise noted or defined herein, to the extent directional terminology is used, this disclosure and the drawings are described in terms of a conventional X, Y, and Z three-dimensional coordinate axis system, where the X direction is generally left-right or east-west, the Y direction is generally in-out relative to the plane of the document page, and the Z direction is generally up-down or north-south on the page. As used herein, "horizontal" and "vertical" are used consistent with their conventional definitions as understood by those skilled in the art and as generally illustrated and extended downward. For example, in the fields of physics, engineering, and architecture, the direction designated as vertical is typically the direction along which a plumb line descends in response to the force of gravity. The horizontal direction is considered to be along a line or plane normal to or perpendicular to the vertical plane. Thus, moving horizontally (horizontally) is effectively equivalent to moving on the Earth's surface, e.g., moving forward, backward, left, right, etc., along the ground, and moving vertically (vertically) is effectively equivalent to moving up (away from the ground) or down (towards or into the ground). The unification of X, Y, and Z coordinate access into the terms vertical and horizontal indicates that the Z axis is vertical and the X and Y axes lie in a horizontal plane with the perpendicular vertical Z axis. To the extent that any ambiguity arises from the specific wording of the above description, it should be understood that such ambiguity can be interpreted and clarified consistent with conventional interpretations of the terms horizontal and vertical.

[0075] Numerous modifications and alternative embodiments of the present invention will be apparent to those skilled in the art in view of the foregoing description. Accordingly, this description is to be construed as illustrative only, and is for the purpose of teaching those skilled in the art the best mode of carrying out the invention. Details of construction may vary considerably without departing from the spirit of the invention, and the exclusive use of all modifications that come within the scope of the appended claims is reserved. While embodiments have been described herein in a manner that permits a clear and concise specification to be formatted, it will be understood that the embodiments can be variously combined or separated without separating from the invention. It is intended that the present invention be limited only to the extent required by the appended claims and the applicable rules of law.

[0076] It is to be understood that the following claims cover all general and specific features of the invention described herein, and all statements of the scope of the invention that are deemed to fall therein as a matter of language.

Claims

1. An automated store comprising a building structure, The building structure comprises: a replenishment section in which the automated store is replenished with product totes containing each new inventory; an automated fulfillment section where each product tote is transferred to an order tote at a workstation that fulfills customer orders; a delivery section where the order totes from the automated fulfillment section are utilized for delivery to the customers; Including, The automatic store further comprises: a mobile robot configured to move around the replenishment section; the auto-fulfillment section and the delivery section are in different modes of operation based on task priority, the different modes of operation including a replenishment mode, an order fulfillment mode, and a delivery mode; In the replenishment mode, the mobile robot is configured to transport the received product tote to a storage location; In the order fulfillment mode, the mobile robot is configured to transport the product tote to the workstation and transport the order tote to the workstation and the delivery section; The automated store, wherein in the delivery mode, the mobile robot is configured to transport an order tote to a location in the delivery section and make the order tote available for delivery to the customer.

2. 2. The automated store of claim 1, wherein the different operational modes include a defragmentation mode in which the mobile robot is configured to position product totes at a defragmentation station and organize each into several product totes for storage within the storage location.

3. 3. The automated store of claim 2, wherein the mobile robot is in the defragmentation mode, and the mobile robot delivers the product tote to the defragmentation station and rearranges one or more sub-totes within the product tote.

4. 4. The automated store of claim 3, wherein empty subtotes are organized into subsets of one or more product totes.

5. 5. The automated store of claim 4, wherein the defragmentation mode includes removing totes containing empty subtotes to increase storage density.

6. 2. The automated store of claim 1, wherein the automated fulfillment section includes a storage rack structure having a plurality of rack modules separated by aisles and having a plurality of storage levels, the storage rack structure storing a plurality of totes including product totes, order totes, and / or empty totes.

7. 7. The automated store of claim 6, wherein when the mobile robot is designated and operating in the order fulfillment mode, the mobile robot propels itself through a storage rack structure of the automated fulfillment section, places the tote in the storage rack structure, removes the tote from the storage rack structure, and transports the tote.

8. 2. The automated store of claim 1, wherein the task priority is determined based at least in part on time of day in a manner such that time of day serves as a basis for designating the mobile robot in the order fulfillment mode, the replenishment mode, or the delivery mode.

9. 2. The automated store of claim 1, wherein the task priority is determined based at least in part on a relative amount of tasks completed in each of the order fulfillment mode, the replenishment mode, or the delivery mode.

10. 10. The automated store of claim 1, wherein the task priority is determined based at least in part on instructions from the customer arriving to pick up an order.

11. 11. The automated store of claim 10, wherein upon receipt of a customer order, the task priority sets the mobile robot's operational mode to an order fulfillment mode in which each of the customer orders has not yet been placed in an order tote.

12. 11. The automated store of claim 10, wherein upon indication of customer arrival, the task priority sets the mobile robot's operational mode to a delivery mode in which each of the customers is placed in an order tote.

13. 2. The automated store of claim 1, wherein the task priority is determined based at least in part on a relative amount of tasks completed in the automated fulfillment section and an applied weighting that gives higher priority to delivery of completed order totes to locations in the delivery section.

14. 2. The automated store of claim 1, wherein the task priority is determined by a priority that prioritizes delivery of order totes in the delivery mode over operations in the order fulfillment mode and replenishment mode.

15. 15. The automated store of claim 14, wherein the task priority is determined by a priority that prioritizes operations in the order fulfillment mode over operations in the replenishment mode.

16. 16. The automated store of claim 15, wherein the task priority is determined by a priority that prioritizes operations in the replenishment mode over operations in a defragmentation mode, and in the defragmentation mode, the mobile robot is configured to position product totes at a defragmentation station to organize each into fewer product totes for storage in the storage location.

17. 2. The automated store of claim 1, wherein the product totes are stocked with each of the new inventory before the product totes arrive at the automated store.

18. 2. The automated store of claim 1, wherein said product totes are stocked with each of said new inventory in said replenishment section.

19. An automated store comprising a building structure, The building structure comprises: a replenishment section in which the automated store is replenished with product totes containing each new inventory; an automated fulfillment section where each product tote is transferred to an order tote at a workstation that fulfills customer orders; a delivery section in which the order totes from the automated fulfillment section are utilized for delivery to the customers; The automatic store further comprises: an automated store comprising a mobile robot configured to move throughout and perform functions within each of the replenishment section, the automated fulfillment section, and the delivery section;

20. 18. The automated store of claim 17, wherein the automated fulfillment section is further configured for defragmentation of the product totes by organizing each into fewer product totes for storage in the storage location, and the mobile robot is configured to perform functions that enable the defragmentation station of the product totes.

21. 18. The automated store of claim 17, wherein the building structure further includes a shopping section containing non-fungible items for selection by the customer, the non-fungible items selected by the customer being delivered to a transfer station.

22. 20. The automated store of claim 19, wherein the mobile robot is further configured to retrieve non-fungible items from the transfer station and deliver the non-fungible items to a delivery section for delivery to the customer.

23. 20. The automated store of claim 19, wherein the mobile robot is further configured to retrieve non-fungible items from the transfer station and transport the non-fungible items for a customer to a location where the non-fungible items can be added to an order tote with each for the customer.

24. 18. The automated store of claim 17, wherein the functionality of the mobile robot is determined by a priority that prioritizes delivery of the order tote to the delivery section over the functionality of the automated fulfillment section and replenishment section.

25. 23. The automated store of claim 22, wherein the functions of the mobile robot are determined by a priority that prioritizes functions in the automated fulfillment section over functions in the replenishment section.

26. 24. The automated store of claim 23, wherein the functions of the mobile robot are determined by a priority that prioritizes functions in the replenishment section over functions related to defragmenting the product totes, the defragmenting of the product totes including organizing each into fewer product totes for storage in the storage locations.

27. (a) receiving, at a replenishment section, a product tote containing each of the inventory items to be transported by a mobile robot; (b) retrieving the product totes from a storage location with the mobile robot and transporting the totes to an order fulfillment section for each transfer from the product totes to order totes based on customer orders; (c) transporting the order tote by the mobile robot to a delivery section for delivery of the order tote to the customer.

28. 28. The method of claim 27, further comprising transporting the order tote by the mobile robot to the storage location in the automated fulfillment section for storage.

29. 28. The method of claim 27, including transporting the product totes by the mobile robot to a defragmentation station, wherein each of the product totes is organized into fewer product totes for storage in the storage location.

30. 28. The method of claim 27, further comprising transferring non-fungible items from a transfer station to the delivery section by the mobile robot.

31. 28. The method of claim 27, further comprising the step of transferring the customer's non-fungible items by the mobile robot from a transfer station to a location for combination with each of the customer's order totes.

32. An automated store comprising a building structure, The building structure comprises: a replenishment section in which the automated store is replenished with product totes containing each new inventory; an automated fulfillment section where each product is transferred from the product tote to an order tote at a workstation for fulfilling customer orders; a shipping section in which order totes filled in the auto-fulfillment section are made available for delivery to the customer; The automatic store further comprises: a mobile robot configured to move through the replenishment section; The automatic fulfillment section and the delivery section are in different operation modes based on task priority, the different operation modes including a replenishment mode, an order fulfillment mode, and a delivery mode, and in the replenishment, order fulfillment, and delivery modes, the mobile robot: Transporting received product totes to storage; transporting the product tote to the workstation and transporting the order tote to the workstation and the delivery section; an automated store configured to transport an order tote to a location in the delivery section and make the order tote available for delivery to the customer;

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