End-to-end automated fulfillment center system and method

Abstract

A warehouse with a system for automated order fulfillment includes an inbound and outbound system and a sealing machine. The inbound and outbound system includes a storage structure designed to store storage bins in stacks and one or more robots. The storage structure has pillars supporting a first set of rails and a second set of rails extending perpendicular to the first set of rails, the first and second sets of rails collectively forming a grid defining a plurality of grid spaces such that each stack is stored within the footprint of a respective grid space. The one or more robots are operable on the grid and include a body coupled to a wheel assembly, the wheel assembly including a plurality of wheels and a drive mechanism configured to move the body along the first and / or second sets of rails, and a picking arm for placing inventory items directly into containers for shipment to end users.

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of the filing date of U.S. Provisional Application No. 63 / 401,873, filed August 29, 2022, the disclosure of which is hereby incorporated by reference herein.

[0002] The present disclosure relates to distribution fulfillment centers, and more particularly, to automated robotic order fulfillment systems within distribution fulfillment centers. [Background technology]

[0003] Distribution fulfillment centers, such as warehouses, require systems to unload incoming inventory, store the inventory in storage structures, pick and pack items into individual orders, and ship the orders to customers. Each of these order fulfillment processes typically requires the assistance of warehouse personnel, which can result in inefficiencies, costs, burdens, and increased potential for error.

[0004] Incoming inventory packages are typically unloaded from delivery trucks, and outgoing packages are typically loaded onto delivery trucks, by baggage dock personnel either manually or using one or more machines or robotic systems. When inventory packages are manually unloaded from delivery trucks, baggage dock personnel remove consecutively stacked rows of packages from the trailer (e.g., cargo space) starting with the row adjacent to the rear of the trailer and extending along the width of the trailer. This process is labor-intensive. Moreover, once the first row of packages is removed, the second row positioned after the first row is no longer supported and is prone to tipping over, which can result in damage to inventory items, inefficient unloading speeds, or injury to baggage dock personnel. It will be appreciated that packages cannot be manually unloaded height-by-height (top-down through the trailer), which stabilizes the packages during unloading without requiring baggage dock personnel to climb on top of the packages that have not yet been unloaded. The same problem exists during loading of outgoing packages.

[0005] Warehouse personnel often also assist in performing other order fulfillment processes and / or transferring inventory between various stations within the warehouse. For example, inventory items are traditionally stored in warehouses on rows of shelves on either side of aisles. Aisles are needed to provide access between shelves so that operators can navigate the aisles to retrieve items. However, it is well understood that aisles reduce the storage density of a warehouse. In other words, the amount of space (e.g., shelving) used to store products is relatively small compared to the amount of space required for the entire storage system.

[0006] In one alternative approach, which provides a significant improvement in storage density, storage packages are stacked on top of each other and arranged in adjacent rows, i.e., no aisles are provided between adjacent rows of stacked packages.

[0007] Various methods for removing inventory from stacked packaging containers are contemplated. For example, U.S. Patent Publication No. 2021 / 0032034, incorporated herein by reference in its entirety, discloses a system in which packaging containers are stacked and arranged in multiple rows under a grid, and the packaging containers are retrieved by robots, which then pick and place the inventory items into order bins. While the robots disclosed in U.S. Patent Publication No. 2021 / 0032034 automate the inventory picking and packing process, further automation of warehouses is desirable to reduce or eliminate human presence, thereby reducing costs and improving efficiency. Summary of the Invention [Means for solving the problem]

[0008] The automated order fulfillment system disclosed herein reduces, if not eliminates, the personnel required to operate a warehouse and improves warehouse space utilization. In one aspect of the present disclosure, the order fulfillment system includes an inbound and outbound system including a grid-based storage structure and one or more robots operable on the grid, and a sealer for sealing containers to form packets. The storage structure includes vertical pillars supporting a first set of rails and a second set of rails extending perpendicular to the first set of rails, configured to store the storage bins in stacks. The first and second sets of rails collectively form a grid defining a plurality of grid spaces such that each stack is stored within the footprint of a respective grid space. The one or more robots have a body coupled to a wheel assembly including a plurality of wheels and a drive mechanism configured to move the body along the first and / or second sets of rails; and a picking arm for placing inventory items directly into containers for shipment to end users.

[0009] In some examples, the sealing machine may be an automatic bagging machine and the container may be a plastic bag.

[0010] The automated bagger may be positioned on the grid, or alternatively adjacent to the grid, at a height that may be substantially equal to the height of the grid.

[0011] The order fulfillment system may further include a plurality of ramps extending from the grid to each gaylord.

[0012] The containers may alternatively be cartons, and the order fulfillment system may further include a carton assembler located upstream of the storage structure.

[0013] The sealer may be a carton sealer positioned downstream of the storage structure and configured to seal cartons to form packets.

[0014] The one or more robots may further include a grapple suspended from the support arm by a cable connected to a take-up mechanism for adjusting the vertical height of the grapple, and the grapple may be arranged to secure a tray on which the storage bins and cartons may be placed.

[0015] The order fulfillment system may further include loading / unloading equipment for unloading packages from the cargo space of the vehicle and / or loading parcels into the cargo space of the vehicle.

[0016] The loading / unloading device may be an autonomous gantry, which may include a pair of beams extending in a first direction, a rail extending between the pair of beams and movable in the first direction along the pair of beams, and a hoist coupled to the rail and movable along the rail in a second direction transverse to the first direction. The hoist may include a plate having a fixture movable between a retracted position and an extended position in a direction perpendicular to the rail.

[0017] In another aspect of the present disclosure, an order fulfillment system includes an input / output system including a grid-based storage structure arranged to store storage bins in stacks, one or more robots operable on the grid, an automated packing machine arranged downstream of the storage structure, and a manipulator robot. The storage structure defines a plurality of I / O modules and includes vertical pillars supporting a first set of rails and a second set of rails extending perpendicular to the first set of rails. The first and second sets of rails collectively form a grid defining a plurality of grid spaces such that each stack is stored within the footprint of a respective grid space. The one or more robots have a body coupled to a wheel assembly including a plurality of wheels and a drive mechanism configured to move the body along the first and / or second sets of rails; and a grapple movable vertically and configured to selectively secure and lift at least one of the storage bins from one of the stacks to a position above the grid. The manipulator robot includes a picking arm for picking one or more items from the order bins and placing the one or more picked items into the automated packing machine.

[0018] The automated packing machine may be a carton packing machine configured to form custom-sized packets around one or more items.

[0019] A manipulator robot may be positioned downstream of the storage structure, and the manipulator robot may place one or more items picked from the order bin into a carton packer.

[0020] The manipulator robot may be positioned on a grid to indirectly place one or more picked items into a carton wrapper via a ramp and / or conveyor.

[0021] The fulfillment system may further include a sorting system. In one example, the sorting system may be a sorting grid disposed adjacent to and at a height less than the height of the grid. The sorting system may include: a frame having vertical pillars supporting a first set of rails and a second set of rails extending perpendicular to the first set of rails, the first and second sets of rails collectively forming the sorting grid and defining a plurality of sorting grid spaces.

[0022] The sorting system may further include sorting bins, each of which may be transitionable between a closed position in which items are retained within the sorting bin and an open position in which items are dispensed from the sorting bin.

[0023] The sorting bin may further include a hammer and trigger for transitioning the sorting bin from the closed position to the open position.

[0024] The sorting system may further include one or more sorting robots operable on the sorting grid. The sorting robot may further include: a body coupled to a wheel assembly including a plurality of wheels and a drive mechanism configured to move the body along the first and second sets of rails of the sorting grid, and a grapple suspended from the support arm by a cable coupled to a take-up mechanism for adjusting the vertical height of the grapple. The grapple may be configured to secure and lift one of the sorting bins, which may be transitioned from a closed position to an open position when a hammer of the sorting bin contacts the support arm of the sorting robot.

[0025] The sorting system may further include a plurality of gaylords positioned around the perimeter of the sorting grid.

[0026] The automatic packaging machine may be an automatic bagging machine.

[0027] In yet another aspect, a method of order fulfillment includes the following steps: moving one or more robots around a storage structure including a grid formed from a first set of parallel rails and a second set of parallel rails extending perpendicular to the first set of parallel rails; picking items from storage bins using the picking arms of the one or more robots; placing the picked items into one or more partitioned compartments in one or more order bins secured to the one or more robots so that each partitioned compartment holds either one or more units of a single SKU or items for a single order; and transferring the picked items from the one or more order bins to either (1) an automated packer located on or adjacent to the storage structure to form a parcel, or (2) an open carton configured to be shipped to an end consumer.

[0028] The transfer step may include transferring the picked items using one or more robots directly from one or more order bins to an automated packing machine located on or adjacent to the grid to form a parcel, and a subsequent transfer step of transferring the parcel to a gaylord or pallet located outside the storage structure.

[0029] The subsequent transfer step may be performed at least in part by a ramp.

[0030] Parcels can be placed on the ramp by a robotic picking arm.

[0031] Parcels may be placed on the ramps when one or more robots transition the retractable bottom of the sorting bin from a closed position to an open position.

[0032] The retractable bottom may be mechanically actuated by one or more robotic grapples.

[0033] The transferring step may originate on the grid and may be performed, at least in part, by one or more robots, and may include transferring the picked items into a container configured for shipping to a customer.

[0034] The containers may be cartons placed in an inbound and outbound system.

[0035] The method may further include a subsequent transfer step that may include lowering the carton within the I / O module using one or more robotic grapples and passing the carton through a carton sealing machine.

[0036] The containers may be open cartons located outside the input / output system, and the transferring step may be performed, at least in part, by a ramp or conveyor located between the storage structure and the cartons.

[0037] The transfer step may originate on the grid and may be performed, at least in part, by one or more robots, and includes transferring the picked items to a carton packer.

[0038] The transferring step may be performed at least in part by a ramp.

[0039] The transferring step may begin on or near a sorting grid positioned adjacent to the grid, and the transferring step may be performed, at least in part, by one or more other robots.

[0040] An item, or a package containing the item, may not be scanned between the time the item is stored in a storage structure and the time the package is staged for shipment.

[0041] In yet another aspect of the present disclosure, a method of delivering a parcel includes securing a parcel to an autonomous drone; and placing the parcel in a receiving locker secured in a window of a building.

[0042] The receiving locker may include a bottom and at least three sides.

[0043] The receiving lockers may be open or have a retractable top. [Brief explanation of the drawings]

[0044] [Figure 1] 1 is a high-level schematic flow diagram illustrating an automated order fulfillment system within a warehouse according to one embodiment of the present disclosure. [Figure 2] 1 is a schematic perspective view illustrating the process of unloading packaging containers from a vehicle using a loading / unloading device; [Figure 3] 1 is a schematic perspective view illustrating the process of unloading packaging containers from a vehicle using a loading / unloading device; [Figure 4] 1 is a schematic perspective view illustrating the process of unloading packaging containers from a vehicle using a loading / unloading device; [Figure 5] FIG. 5 is a perspective view of the loading / unloading device of FIGS. 2 to 4. [Figure 6] FIG. 1 is a perspective view of a CubiScan machine according to one embodiment of the present disclosure. [Figure 7] 7A-7C are perspective views of an example inventory removal station illustrating a robotic manipulator decanting a package, transferring the contents of the package to a storage bin, and discarding the package. [Figure 8] 8A-8B are perspective views of another example of an inventory removal station illustrating a robotic manipulator with a cutting tool. [Figure 9] 1 is a schematic perspective view of a storage structure for storing a plurality of stacked packaging containers. FIG. [Figure 10] FIG. 10 is a top elevation view of a portion of the storage structure of FIG. [Figure 11A] FIG. 10 is a perspective view of a mobile robot including a picking arm and grapple configured to operate on top of the storage structure of FIG. [Figure 11B] FIG. 11B is a perspective view of an order bin tray securable to the grapple of the robot of FIG. 11A. [Figure 11C] FIG. 11C is a perspective view of an order bin in the form of a carton being transferred to the order bin tray of FIG. 11B. [Figure 12] 12A-12E are perspective views of a carton assembly machine designed to assemble cartons of predetermined sizes according to one embodiment of the present disclosure. [Figure 13] FIG. 1 is a perspective view of a carton assembly machine designed to assemble custom-sized cartons according to one embodiment of the present disclosure. [Figure 14] FIG. 1 is a perspective view of a carton packing machine folding packaging units around inventory items to form packets. [Figure 15] FIG. 1 is a perspective view of a carton packing machine folding packaging units around inventory items to form packets. [Figure 16] FIG. 1 is a perspective view of a carton packing machine folding packaging units around inventory items to form packets. [Figure 17] FIG. 1 is a perspective view of an automatic bagging machine. [Figure 18] FIG. 1 is a perspective view of a carton sealing machine. [Figure 19] 6 is a schematic perspective view of a process for loading parcels into a vehicle using the loading / unloading device of FIG. 5; [Figure 20] A schematic perspective view of the process of loading parcels into a vehicle using the loading / unloading device of FIG. [Figure 21] 1 is a schematic diagram of a portion of a warehouse illustrating an automated order fulfillment system according to one embodiment of the present disclosure. [Figure 22A] 1 is a schematic diagram showing portions of a grid-based storage structure and a sorting grid according to one embodiment of the present disclosure. [Figure 22B] FIG. 22B is a partial side view of FIG. 22A. [Figure 22C] FIG. 22B is a partial side view of an automated bagging machine positioned adjacent to the grid of the grid-based storage structure of FIG. 22A. [Figure 22D] FIG. 22B is a partial side view of an automated bagging machine positioned on the grid of the grid-based storage structure of FIG. 22A. [Figure 22E] FIG. 22B is a partial side view of an automated bagging machine positioned on the grid of the grid-based storage structure of FIG. 22A. [Figure 22F] FIG. 2 is a partial perspective view of the warehouse of FIG. 1. [Figure 23] FIG. 1 is a perspective view of a sorting bin including a hatch door according to one embodiment of the present disclosure. [Figure 24] 24A-24C are side views of the grapple of the robot of FIG. 11A actuating the hatch door of the sorting bin of FIG. 23. [Figure 25] FIG. 1 is a perspective view of a delivery robot according to one embodiment of the present disclosure. [Figure 26] FIG. 1 is a perspective view of a parcel being placed in a receiving locker by a drone, according to one embodiment of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0045] The technology disclosed herein relates to a warehouse with an autonomous system for order fulfillment and delivery. The autonomous system is configured to unload packaging containers of incoming inventory from vehicles, transport the packaging containers to an inventory retrieval station, and transfer the inventory to storage bins. The storage bins can then be organized, inserted, and stored within an automated inventory system, such as a grid-based storage structure. When an order is received, a robot traverses the grid-based storage structure to pick the inventory and transfers the picked inventory to an order bin or an automated packing machine, which can seal and label the package for shipment. The packaged inventory can then be transported to a loading / unloading device and loaded onto a vehicle for outgoing shipment.

[0046] As used herein, the terms “automated” or “autonomous” refer to devices or systems capable of operating autonomously, at least sometimes. In other words, the terms “automated” or “autonomous” include devices and systems that are sometimes operated with human assistance, so long as the devices and systems can be operated autonomously, at least sometimes. It should also be noted that the terms “container,” “storage bin,” “order bin,” and “package” refer to any container capable of holding one or more items. Because inventory is transferred between different containers during various stages of order fulfillment, these terms are used solely for ease of reading. To avoid doubt, unless otherwise specified, the terms “package,” “storage bin,” “order bin,” and “package” encompass any container, including a bin, tote, carton, bag, or any other structure capable of storing inventory items. Also, as used herein, the terms “substantially,” “generally,” “about,” and the like are intended to mean that slight deviations from the absolute are included within the scope of the term so modified.

[0047] FIG. 1 is a high-level schematic flow diagram illustrating a fulfillment process performed by a series of fulfillment systems. The process begins by unloading packaging containers of incoming inventory from a vehicle 100 and transporting the packaging containers into a warehouse 1000 using a loading / unloading device 200. The packaging containers may then be transported to an inventory removal station 300, where the inventory is transferred to storage bins. The storage bins may then be transported to a storage structure within an input / output system 400 for storage until an order is received. Once an order is received, the item(s) for the received order are removed from the storage structure, packed into order bins, and transported to an automated packing and / or sealing machine to form a package. The formed package is then transported to the loading / unloading device 200 and loaded onto a vehicle 100 for outbound dispatch. Each of the fulfillment systems illustrated schematically in FIG. 1 is described in further detail below.

[0048] 2-4 illustrate the process of delivering inventory to warehouse 1000 using vehicle 100. Vehicle 100, carrying packaging containers 10 of incoming inventory, may be maneuvered to position the vehicle's cargo space 110 adjacent to the dock door of warehouse 1000. Loading / unloading equipment 200 may then be deployed to unload the packaging containers 10 from vehicle 100's cargo space 110. The packaging containers 10 may be unloaded one packaging container at a time or multiple packaging containers at a time. After the packaging containers 10 are unloaded, loading / unloading equipment 200 may place the packaging containers on a conveyor for transport to a destination within warehouse 1000, such as inventory retrieval station 300 (FIG. 1). Alternatively, the loading / unloading device 200 may place the packaging container 10 on another surface, such as the ground or a queuing buffer, before the packaging container is transported to the inventory removal station 300 by an autonomous mobile robot (AMR) or another transport mechanism.

[0049] 5, loading / unloading apparatus 200 includes first and second beams 214 and 216, rails 218 extending between first and second carriages attached to the first and second beams, respectively, and a hoist 220 suspended below a trolley movable along the rails. Hoist 220 includes a telescoping plate 242 arranged to unload packaging containers from cargo space 110 of vehicle 100 and / or load packaging containers into the cargo space of a delivery vehicle. While the term “cargo space” is described herein primarily as the trailer of a semi-trailer truck, the term also includes the cargo space of other vehicles, such as box trucks, U-Hauls, step vans, buses, or any other vehicle capable of transporting cargo. Additionally, “cargo space” can refer to a staging area within a warehouse where packaging containers are stacked onto pallets or crates before the staging media and all packaging containers staged thereon are loaded onto a delivery vehicle. In some embodiments, the operation of the loading / unloading equipment 200 is automated by one or more processors. That is, the loading / unloading equipment 200 operates without a human manually manipulating its components. In other embodiments, the operation of the loading / unloading equipment 200 may be controlled by dock personnel or remote personnel remotely using a graphical user interface (GUI), electronic signals, manually, or a combination of the above.

[0050] In some examples, the first beam 214 and the second beam 216 are secured to a structure within the warehouse 1000 and are arranged to extend and retract through a dock door to position the hoist 220 within the trailer of the vehicle 100. In other examples, the loading / unloading apparatus 200 may include a base 212 made up of feet 222 and legs 224. The feet 222 may include rollers, such as wheels, carriages, or bearings, for moving the loading / unloading apparatus 200 across the ground, and a locking mechanism to prevent the rollers from unintentionally rolling. When the feet 222 include rollers, the loading / unloading apparatus 200 can be moved between docks, thereby allowing a single loading / unloading apparatus 200 to load and / or unload cargo from semi-trailers parked at different loading entrances. As a result, capital investment costs may be reduced.

[0051] First beam 214 and second beam 216 include tracks 232 on which respective carriages are mounted. A rail 218 is coupled between the first and second carriages such that the rail is movable in the x-direction along track 232 (e.g., along the length of the first and second beams). Rail 218 may include a position sensor, such as an encoder, and one or more actuators for driving movement of the rail. Example actuators include linear actuators, belts, chains, lead or ball screws, and the like. In this regard, a processor can determine the position of rail 218 relative to track 232 and generate and transmit processor-executable control signals for automating movement of the rail along the length of the beam.

[0052] Hoist 220 is coupled beneath a trolley that is movably mounted on rail 218, such that the hoist is movable in the y-direction along the rail. Hoist 220 includes a plate 242 suspended by a cable connected to a winding mechanism, such as a spool, reel, or winch. The cable can then be wound and unwound to move plate 242 in the z-direction relative to the trolley. Hoist 220 may include a position sensor and one or more actuators to automate the y-direction movement of the hoist along the rail and the z-direction extension and retraction of plate 242. The combination of x-direction movement along the beam of rail 218, y-direction movement of hoist 220 along the rail, and z-direction extension and retraction of plate 242 allows the hoist to load and unload packaging containers 10 from any area of ​​the semi-trailer.

[0053] Plate 242 may optionally include one or more suction cups designed to secure packaging container 10 by suction. If plate 242 includes suction cups, a pneumatic source (not shown), such as a vacuum source or compressor, is provided to generate the pneumatic force necessary to operate the suction cups. If the pneumatic source is a compressor, a venturi pump or another device capable of using compressed air to create the vacuum or suction force is positioned downstream of the fluid source and upstream of the suction cups, for example, in the fluid line within hoist 220 or trolley. The pneumatic fluid line used to deliver air pressure to the suction cups may be an air hose reel or coil hose. However, plate 242 need not include suction cup(s). Plate 242 may instead include a pivoting flap, a slidable or pivotable hook, a latch, a grapple, or another gripping device capable of securing packaging container 10 to hoist 220 (hereinafter, together with the suction cups, a "retainer").

[0054] A camera, or another imaging device, may be provided somewhere on loading / unloading apparatus 200, for example, on plate 242, to capture images of the cargo space that may then be transmitted to one or more processors to assist in controlling automation of the loading / unloading apparatus, including movement of rail 218 along the beam in the x direction, movement of hoist 220 along the rail in the y direction, extension and retraction of plate 242 relative to the rail in the z direction, and actuation of fasteners to grasp and / or release packaging container 10. Loading / unloading apparatus 200 may be further designed in any manner contemplated in U.S. patent application Ser. No. 63 / 238,431, the disclosure of which is incorporated herein by reference in its entirety.

[0055] 2-5, an example process for unloading incoming inventory using the loading / unloading apparatus 200 will now be described. First, the base 212 of the loading / unloading apparatus 200 may be positioned adjacent the rear of the trailer at the end of the loading entrance to position the first beam 214 and the second beam 216 within the cargo space 110 of the vehicle 100. Once the loading / unloading apparatus 200 is in place, a locking mechanism may be activated to prevent the rollers from unintentionally rolling, thereby securing the loading / unloading apparatus to the ground.

[0056] Rail 218 may then be moved in the x-direction along track 232, and hoist 220 may be moved in the x-direction along the rail to position plate 242 above the desired packaging container 10. Once hoist 220 is in position, plate 242 may then be extended, as described above, to engage and secure one or more packaging container(s) 10 located below the plate. Plate 242 may then be retracted and the hoist moved to a position above conveyor 50, after which the plate may be extended again to release one or more packaging container(s) onto the conveyor, either individually or simultaneously.

[0057] The process of unloading packaging containers 10 may continue until all packaging containers have been unloaded from the trailer. It will be appreciated that the loading / unloading device 200 allows packaging containers 10 to be unloaded "in level," starting with the packaging containers closest to the ceiling of the semi-trailer and ending with the packaging containers resting on the trailer floor. Unloading packaging containers 10 in this manner maintains a platform of packaging containers throughout the cargo space 110 that supports adjacent stacks of packaging containers, thereby preventing the stacks from tipping over. Unloading packaging containers "in level" is only possible because the hoist 220 can pass over one or more stacks of packaging containers that have not yet been unloaded. In other words, a loading dock attendant cannot unload packaging containers "in level" from the semi-trailer without stepping on or jumping over the packaging containers that have not yet been unloaded. Similarly, known robotic systems have components that are prohibitively large and prevent the components from passing over stacks of a certain height, thus requiring packages to be unloaded from semi-trailers in a continuous vertical stack from the rear of the trailer to the front end of the trailer. As previously mentioned, when packages are unloaded in this manner, the unsupported stack of packages is prone to tipping over, which can result in damage to inventory and injury to loading dock personnel.

[0058] Although the loading / unloading device 200 is primarily described herein as a gantry, the loading / unloading device may alternatively be an autonomously operated mobile robot with a gripping arm, or a similarly autonomously operated robotic device.

[0059] After the packaging container 10 is unloaded from the vehicle 100, the packaging container may be transported to the inventory removal station 300, for example, by a conveyor 50 or an autonomous mobile robot (AMR). The warehouse management system (WMS) of the warehouse 1000 may record information obtained from each incoming packaging container as it is transported to the inventory removal station 300. For example, as shown in FIG. 6 , each packaging container 10 may pass through a CubiScan machine, which includes an array of cameras, scanners, and / or other sensors, on its way to the inventory removal station 300. As the packaging container passes through the tunnel, the scanner scans an identifier, such as a barcode, QR code, or RFID, provided on the packaging container to determine the stock keeping unit (SKU) contained within the packaging container, while the camera and / or sensors measure the dimensions and weight of the packaging container. The information determined by the array of cameras, scanners, and / or other sensors may be recorded in the WMS and used to facilitate subsequent storage and fulfillment processes.

[0060] 7A-7B illustrate an example inventory removal station 300 in the form of a packaging container decanting station. The packaging container decanting station may include a robotic manipulator 310 and a cutting table 320 arranged to "decant" a packaging container 10 and then transfer the inventory from the decanted packaging container to a storage bin 20. The robotic manipulator 310 may include an arm 314 and a gripping head 316 coupled to the arm. The gripping head 316 may be a pneumatically actuated tool, such as a suction cup. In some examples, the gripping head 316 may be removably attached to the arm 314, thereby enabling the robotic manipulator 310 to autonomously replace one gripping head with a different gripping head better suited to manipulating the packaging container 10 and / or particular inventory items based on the size, weight, or other physical characteristics of the items the robotic manipulator is tasked with manipulating.

[0061] The cutting table 320 may include a cutting device 322, such as a blade, protruding from the top surface of the cutting table. In this regard, the robotic manipulator 310 may manipulate the packaging container 10 relative to the cutting device 322 to cut one or more sides of the packaging container. For example, the robotic manipulator 310 may slide the packaging container 10 over the top surface of the cutting table 320 in a manner that cuts three of the four sides of the bottom surface of the packaging container. As shown in FIG. 7B , the robotic manipulator 310 may then slide the packaging container 10 laterally off the cutting table 320 and onto the storage bin 20, dumping the inventory into the storage bin. Specifically, the storage bin 20 may be delivered to a packaging container decanting station and placed adjacent to the cutting table 320 with the top of the storage bin positioned slightly below the surface of the cutting table. Thus, when the robotic manipulator 310 slides the packaging container 10 off the cutting table 320, the weight of the inventory will pry open the bottom surface of the packaging container, allowing the inventory to fall into the storage bin 20. Cutting three of the four sides of the bottom surface of the packaging container leaves the bottom surface of the packaging container 10 attached to the body of the packaging container, so that the packaging container can be discarded as a single unit, as shown in FIG. 7C. In some examples, the robotic manipulator 310, or another robotic device, may then rearrange the inventory to pack the items tightly within the storage bin 20 and ensure that nothing protrudes above the top surface of the storage bin.

[0062] 8A and 8B illustrate another inventory removal station 300 in the form of a package lid removal station. The package lid removal station may include a robotic manipulator 310 having an arm 314 equipped with a cutting tool 318, such as a razor blade, laser, or another cutting implement, designed to “de-lid” the package 10 or otherwise create an access opening through which the inventory items can be accessed. The access opening may be one face (e.g., the top or side) of a box or any other opening defined through at least one face of a box package. The robotic manipulator 310, or another robot located at or downstream from the lid removal station, may then pick the inventory items through the access opening in the package 10 and then pack the picked inventory items into a storage bin 20. Alternatively, inventory may be transferred to a storage bin 20 by nesting the package 10, from which the lid has been removed or otherwise cut, into the storage bin 20. After the inventory is transferred to the storage bin 20, the storage bin may be transferred to the inventory system 400 and then inserted into a storage structure for storage. When the storage bin 20 is inserted into the storage structure of the inventory system 400, the WMS may record and log the location of the storage bin, and consequently the SKU stored therein, for later retrieval.

[0063] 9 and 10 illustrate an example storage and retrieval system 400 including a grid-based storage structure designed for efficient storage of multiple stackable storage bins 20, according to one embodiment of the present disclosure. The storage bins 20 are designed to nest within the top surface (i.e., rim) of another storage bin to form a stack 412 that can be placed within a frame 414.

[0064] The frame 414 includes pillars 416 and a series of rails 422 arranged in a grid-like pattern at the top level of the frame. Thus, the rails 422 are collectively referred to as a grid 426, which defines a plurality of grid spaces 427. The pillars 416 form shafts within which the stacks 412 are housed. As a result, each stack 412 is positioned within the footprint of its respective grid space 427 (e.g., longitudinally below its respective grid space). FIG. 10 is a top elevation view of a single grid space 427. As shown in FIG. 10, the cross-sectional area of ​​each shaft is slightly larger than the exterior dimensions of the storage bins 20, resulting in a small gap 418 extending all the way around the outer surface of the storage bin and between the outer surface of the storage bin and the pillars 416.

[0065] Each rail 422 may be extruded from a metal or metal alloy and formed with a W-shaped track. The track provides a drive surface for a robot 500 (shown in FIG. 11A ) to move about the grid 426 while picking and packing orders. A first set of rails 422 a guides the robot 500's movement in a first direction (e.g., the x-direction), and a second set of rails 422 b, positioned perpendicular to the first set of rails, guides the robot's movement in a second direction (e.g., the y-direction). In this manner, the rails 422 enable the robot 500 to move laterally in two directions (x-direction and y-direction) across the top of the frame 414, allowing the robot to move to a position above any one of the stacks 412 of storage bins 20.

[0066] 11A , the robot 500 includes a communications interface for transmitting and receiving data between the robot and a remote computer, such as a WMS, allowing the remote computer to control the movement and operation of each of the robots around the grid 426. The robot 500 includes a body 502 and a wheel assembly 504 configured to guide the body's movement around the rails 422. In one embodiment, the wheel assembly 504 may include a plurality of wheels, a motor, and one or more transmissions (belts or linkages) operably coupling each one of the wheels to the motor. The orientation of the wheels is controlled by the motor and the one or more transmissions. More specifically, the motor is coupled to each one of the wheels via the one or more transmissions, such that rotation of the motor simultaneously pivots the orientation of each one of the wheels. In this regard, the wheels may be simultaneously pivoted (e.g., 90 degrees) between a first orientation in which each of the wheels is aligned with the first set of rails 422 a and a second orientation in which each of the wheels is aligned with the second set of rails 422 b. A drive mechanism is associated with the wheel assemblies 504 for rotating the wheels and moving the body 402 along the rails on which the wheels are positioned.

[0067] In an alternative embodiment, the wheel assembly 504 of the robot 500 may be constructed with first and second sets of non-pivoting wheels, one or more displacement mechanisms for raising and lowering the first and second sets of wheels, and a drive mechanism, as known from U.S. Patent No. 9,682,822. Specifically, the wheel assembly 504 may include a first set of non-pivoting wheels (comprising a pair of wheels at the front of the robot and a pair of wheels at the rear of the robot), a second set of non-pivoting wheels (comprising a pair of wheels on each side of the robot), one or more displacement mechanisms for lifting the first set of wheels off the first set of rails 422a and lowering the first set of wheels into engagement with the first set of rails, and lifting the second set of wheels off the second set of rails 422b and lowering the second set of wheels into engagement with the second set of rails, and a drive mechanism for rotating the wheels along the rails to which they are engaged.

[0068] The body 502 of the robot 500 also includes a picking arm 506 with an end effector 508 for picking and packing inventory items and / or one or more storage bin retrievers 510. The picking arm 506 is movable in at least three dimensions to enable the end effector 508 to pick inventory items from the storage bins 20 and pack the picked inventory items into order bins. The end effector 508 may be a pneumatically actuated end effector, such as a suction cup.

[0069] 11A, the robot 500 includes two storage bin acquirers 510: a first storage bin acquirer mounted to the front of the body 502 and a storage bin acquirer mounted to the rear of the body. However, it is contemplated that the robot 500 may include zero, one, two, three, or four storage bin acquirers 510, and that the storage bin acquirers may be mounted on the sides of the body 502 in any arrangement.

[0070] Each storage bin retriever 510 includes a pair of support arms 512 and a grapple 514 designed to extract a storage bin 20 from a frame 414 and / or secure an order bin to the body 502 of the robot 500. The grapple 514 is suspended from the support arm 512 by a cable (not shown) connected to a winding mechanism 516, such as a spool, hoist, or winch. The cable can thus be wound and unwound to adjust the height of the grapple 514 relative to the support arm in the z-direction.

[0071] The grapple 514 includes a three-sided grapple frame 518 and a pivotable flap 520. The three sides of the grapple frame 518 are formed by opposing grapple arms 522 and connectors 524. The grapple arms 522 and connectors 524 collectively define an opening. Each flap 520 is pivotable relative to its respective grapple arm 522 between a deployed state, in which the flap extends into the opening away from the grapple arm to which it is coupled, and an undeployed state, in which the flap lies substantially flush against or otherwise within the footprint of the grapple arm. Movement of the flap 520 between the undeployed and deployed states can be controlled by an actuator disposed within the grapple 514 and configured to convert electrical signals carried through a cable into flap movement. When the flap 520 is in an undeployed state, the opening is larger than the storage bin 20, allowing the grapple 514 to be lowered into the gap 418 and around the stack of storage bins 412, after which the flap is deployed to engage with an engagement feature, such as a rib (not shown), on the side of the storage bin. In this manner, the storage bin retriever 510 is arranged to extract one or more storage bins 20 in a single lift (e.g., the storage bin secured to the grapple 514 and any storage bins stacked above it).

[0072] When an order is received by warehouse 1000, the WMS will instruct robot 500 to pick an inventory item from a storage bin 20 and pack the item into an order bin. After receiving a pick-and-pack instruction from the WMS, robot 500 can secure the order bin to grapple 514 and navigate to a desired location on grid 426 using wheel assembly 504. For example, if the desired SKU is stored in a storage bin 20 located at the top of stack 412, wheel assembly 504 can drive grapple 514, which secures the order bin, along rail 422 to position it over a grid space located adjacent to the grid space in which the item is located. Once in place, end effector 508 (e.g., a suction cup) can be positioned within the storage bin to grasp the item. After the item is grasped, picking arm 506 can be moved toward the order in a packaging container to pack the item.

[0073] On the other hand, if the desired item is stored in a storage bin 20 that has storage bins stacked on top of it, the storage bin containing the desired item (e.g., the "target bin") must be retrieved first. To retrieve the target bin, the robot 500 moves along rails 422 to position the storage bin retriever 510 above the stack 412 containing the target bin. The grapple 514 may then be lowered into the gap 418 and around the stack 412 until the grapple is positioned around the storage bin nested within the target bin. Once the grapple 514 is in place, the flap 520 may be deployed to engage a rib or another engagement feature on the side of the storage bin to secure the storage bin to the grapple. Once the storage bin 20 is secured to the grapple 514, the winding mechanism may be wound to retract the grapple, lifting the storage bin and any storage bins placed above it. The body 502 of the robot 500 may then be moved to another location so that each of the storage bins secured by the grapple 514 is temporarily placed on top of another stack 412. The storage bin acquirer 510 may then be used to retrieve the target bin. With the retrieved target bin secured to the grapple 514, the picking arm 506 may pick items from the target bin and pack the picked items into an order bin. The target bin and the temporarily moved storage bin may then be returned to the stack 412 in their original order. It will be understood that other robots 500 operating on the grid 426 may assist in retrieving "non-target bins" (e.g., bins stacked on top of the "target bin"), retrieving the "target bin," or picking and packing inventory items. In other words, a single robot 500 need not perform each task required to pick and pack items. That is, robots 500 operating on the grid 426 may be assigned tasks from the WMS and work cooperatively with one another to fulfill one or more orders and increase overall fulfillment efficiency.

[0074] This process may be repeated until the robot 500 has filled the order bin with all items associated with a particular order. The robot 500 may then transport the completed order bin out of the inventory system 400. For example, the order bin may be transported to an automatic packing machine, an automatic sealing machine, or another staging area, as described in more detail below.

[0075] In some embodiments, the order bin may be structurally similar to the storage bin 20, such that the order bin may be secured directly to the grapple 514 of the robot 500. An order bin of this configuration may be undivided or divided into two or more compartments, each of which may correspond to a single order. In this regard, a single robot 500 may pick and pack several different orders. In other embodiments, the order bin may be a container designed to be delivered to a purchasing consumer, such as a polybag or carton, thus avoiding the need to transfer items from the order bin to another container downstream of the order and retrieval system 400. In other words, the robot 500 may pack items directly into a container that is later sealed and labeled to form a package and delivered to the purchaser.

[0076] A conventional grid-based storage structure (not shown) utilizes I / O modules to transport storage bins 20 into and out of the storage structure. More specifically, the grid includes one or more I / O modules, consisting of hollow shafts that are not utilized to store storage bins 20, but instead are used only to move storage bins into and out of the storage structure. Conventional I / O modules may include drawers, carousels, or bin queuing mechanisms (collectively "protection mechanisms") to protect warehouse workers when loading refilled storage bins into the I / O module and unloading empty storage bins from the I / O module. In other words, the storage bins 20 are held within the protection mechanisms so that subsequent storage bins lowered from above are not dropped into the hands of warehouse workers working below. The I / O modules often contain expensive electronics and motors to control and operate the protection mechanisms.

[0077] On the other hand, the grid-based storage structure of the inbound / outbound system 400 may include a series of I / O modules arranged around the perimeter of the grid 426. As shown in FIGS. 21 and 22A , each I / O module may be associated with a processing station equipped with a pick-and-pack robot 580, a manual processing station such as a packing table, and / or a conveyor or other queuing device for directing storage bins 20 and / or other bins into or away from the storage structure. Specifically, an in-module may be associated with an inbound conveyor for transporting refilled storage bins 20 (e.g., storage bins containing unordered inventory) into the storage structure and / or empty order bins into the storage structure. On the other hand, an out-module may be associated with an outbound conveyor for transporting empty storage bins 20 away from the storage structure for replenishment or completed order bins (e.g., containing purchased items) out of the storage structure for further processing. In some examples, a majority of the grid spaces 427, or all of the grid spaces disposed along one or more sides of the grid, may be I / O modules. In this regard, order bins and storage bins 20 may be rapidly transported to and from the storage structure and immediately presented to a pick-and-pack robot 580 disposed at a processing station, thereby reducing the time it takes to present to the pick-and-pack robot 580 storage bins 20 containing items that the robot is tasked with picking. As a result, the amount of time the pick-and-pack robot 580 is idle is reduced.

[0078] As shown in FIG. 22A , a sortation grid 426′ may be positioned adjacent to a storage structure of the inbound and outbound system 400. The sortation grid 426′ may be formed substantially similar to the grid 426, but with a reduced height. In other words, the sortation grid 426′ includes vertically oriented rails defining a grid space that houses stackable sortation bins 60 (shown in FIG. 23 ). The robot 500, with or without a picking arm 506, may operate on the sortation grid 426′ to sort items into individual order bins, sort multiple parcels 40 into gaylords for shipping vehicles 100 (e.g., based on carrier), and / or assist in moving storage bins 20 and order bins into and out of the storage structure.

[0079] FIG. 22B is a partial side view of a grid 426 illustrating an I / O module. When a storage bin 20 is placed within the in-module, the grapple 514 of the robot 500 is extended to secure the storage bin, and then subsequently retracted to lift the storage bin onto the grid 426, after which the robot can insert the refilled bin into the storage structure as directed by the WMS. The robot 500 may alternatively lower an empty storage bin 20 from the out-module for replenishment. It will be appreciated that if the order bins have the same structure as the storage bins 20, the robot 500 lifts the empty order bin from the in-module and lowers a completed or partially completed order bin from the out-module in the same manner. As shown in FIG. 22B, the pillars 416 defining the outer perimeter of the I / O module may not extend all the way to the warehouse floor or to the top of the sortation grid 426′. Instead, such pillars 416 may be connected to pillars defining the interior of the I / O module via inwardly extending support bridges. In this regard, a robot 500 operating on the sortation grid 426′ may position the grapple 514 within the I / O module by carrying under the pillars 416 and inserting the support arm 512 of the storage bin retriever 510 into the I / O module. Because the robot 500 is tasked with transporting storage bins 20 and order bins into and out of the storage structure of the inventory system 400, the I / O module need not include protective features, such as drawers or the expensive electronic and mechanical components associated therewith. Instead, in some examples, a robot 500 operating on the grid 426′ utilizes sensors, such as a camera on the grapple 514, to determine when the robot operating on the sortation grid 426′ is within the I / O module so that it does not lower a storage bin 20 onto the robot below. In other cases, a central control system, such as a WMS, may send a "pause command" to the robot 500 if another robot is in the I / O module, and then send a "release command" after it is safe for the robot to leave the I / O module and lower the storage bin 20 or order bin.

[0080] It will be appreciated that if the order bin is an unsealed carton, the grapple 514 of the robot 500 cannot directly grasp the carton. Instead, the carton must be indirectly secured to the grapple 514 of the robot 500 by nesting the carton within a storage bin 20 or via an intermediary device, such as a tray 550 as shown in FIG. 11B . The tray 550 may include prongs 552 defining a bottom surface upon which the carton can be placed, a back retaining surface 554, such as a lip or wall, and sidewalls 556 having outer surfaces with ribs 558. The robot 500 may utilize the grapple 514 to engage the ribs 558, thereby securing the tray 550 in the same manner as a grapple secures a storage bin 20. The tips of the prongs 552 may include lips that retain the carton within the tray 550 when the carton is placed on the prongs. As a result, the carton can be indirectly secured to the grapple 514 via the tray 550 .

[0081] The process of securing order bins in the form of cartons to the grapple 514 will now be described with reference to FIGS. 11C and 21. With the tray 550 secured to the grapple 514, the robot 500 can navigate around the grid 426 to a carton exchange position located on the periphery of the grid. The cartons can be delivered to the carton exchange position by a conveyor extending around at least a section of the periphery of the grid 426. The carton exchange position can include a right angle transfer (RAT) and carton exchange prongs 450 extending over a grid space or an area adjacent to the edge of the grid. The RAT is thus arranged to transfer incoming cartons to the carton exchange prongs 450. Each one of the carton exchange prongs 450 includes a belt. The prongs 552 of the tray 550 are sized and arranged to be inserted between the carton exchange prongs 450.

[0082] When the robot 500 is tasked with picking up a carton, the grapple 514 extends, which then lowers the prongs 552 of the tray 550 below the carton replacement prongs 450. The carton then travels along the conveyor to the RAT, which transfers the carton to the carton replacement prongs 450. A belt on each of the carton replacement prongs 450 guides the carton into engagement with the rear retention surface 554 of the tray 550. With the carton in place, the grapple 514 retracts to lift the tray 550 onto the carton replacement prongs 450, which lifts the carton from the carton replacement prongs 450 and places the carton in the tray, thereby indirectly securing the carton to the grapple of the robot 500.

[0083] One or more carton change positions may also be provided on the shipping side of grid 426 to release completed or partially completed cartons. When the robot is tasked with releasing a packed order bin in the form of a carton for shipping processing, grapple 514 is extended to lower prongs 552 of tray 550 through the space between carton change prongs 450, which transfer the carton from the tray to the carton change prongs. A belt provided on carton change prongs 450 may then be driven to move the filled carton to the RAT, which in turn transfers the carton to a shipping conveyor away from inbound and outbound system 400 for further shipping processing.

[0084] It will be appreciated that if the order bins are cartons or other final containers that will be shipped to the purchaser, the cartons will need to be assembled and transported to the inventory system 400 before the robot 500 begins the picking process, thereby allowing the robot to pack the items for that order directly into the final containers. In these embodiments, the carton assembler CE will need to be located upstream of the inventory system 400.

[0085] 12A-12D show an example carton assembler CE designed to assemble at least one carton of a predetermined size. That is, the carton assembler CE may include a set of uniformly sized packaging units 30 in a flattened or folded configuration, and the carton assembler may pull one packaging unit from the set of packaging units at a time to substantially assemble each carton. For example, the packaging units 30 may be substantially assembled into a box, except for one open side, preferably the top side.

[0086] The carton assembler CE may include a track 610a, a gripping device 620, a directing arm 622, and a sealing device 624. A stack 32 of packaging units 30 may be provided to the carton assembler CE, and the gripping device 620 may grasp a face of the top packaging unit (e.g., with a suction cup) and remove the top packaging unit from the stack while unfolding it from the flattened configuration. In the unfolded configuration, the packaging unit 30 may be passed along the track 610 by the gripping device 620, the directing arm 622, or a combination thereof. After transitioning the packaging unit 30 to the unfolded configuration, the interior flaps of the packaging unit may be positioned generally flat or parallel to the portion of the track 610 below the packaging unit, and the packaging unit may then be passed to the sealing device 624 to seal the bottom of the packaging unit. The sealing device 624 may include an adhesive strip projecting upward from the track 610 so as to contact the packaging unit 30 as the packaging unit passes over the sealing device, thereby applying adhesive along the bottom surface of the packaging unit to secure the flaps together. The assembled cartons may then be sent to the input / output system 400 for use as order bins as described above.

[0087] Alternatively, a customizable carton assembly machine (CCE), such as that shown in FIG. 13, can be used to create cartons in customized sizes for specific orders. In other words, instead of assembling boxes of predetermined sizes, the CCE unfolds and cuts continuous sheets of corrugated cardboard, which are then folded and sealed to assemble cartons with open tops. Similarly, the customized cartons can then be sent to the inventory system 400 for use as order bins.

[0088] After the orders are packed into order bins in the form of cartons, the cartons can be sealed and labeled by a carton sealer 900 provided downstream of the input / output system 400. As shown in FIG. 18 , the example carton sealer 900 includes a track 910, a folding device 920, and a sealing device 924. The carton passes along the track 910 until the open flaps engage the folding device 920, which folds the flaps downward to close the top of the carton. As the carton continues along the track 910, it passes under the sealing device 924, which applies adhesive strips along the top of the carton to secure the flaps together and affix one or more shipping labels to the outside of the carton to form a parcel 40 for shipment. In some examples, the sealing device 900 may optionally apply branded tape, stickers, or custom graphics to the surface of the parcel 40. The above-described sealer 900 is merely an example, and any other known sealer may be used.

[0089] In other embodiments, items may be picked and placed into an automated packer within the input / output system 400, or alternatively, downstream of the input / output system 400. For example, a pick-and-pack robot 580 located at a processing station may be tasked with transferring items from order bins to a final container, such as a carton assembler CE, a customizable carton assembler CCE, or a carton previously assembled by an automated packer for shipment delivery.

[0090] An example of an automated packaging machine in the form of a carton packing machine 700 is shown in FIGS. 14-16. The carton packing machine 700 includes a track 710 for transporting loaded items and various folding devices, such as a folding arm 712, folding forks 714, and folding bar 716. The folding devices, which may be operated independently, work together to fold a packaging unit 30, such as a carton, around loaded item(s) as they are transported along the track 710 to form a customized package 40. In other words, the size and shape of the package 40 are customized to the size and shape of the items to minimize empty space within the package. As a result, more shipping orders can be transported by a single vehicle 100. For example, as shown in FIG. 14, an item, such as a frying pan 35, may be loaded into the carton packing machine 700, transported along the track 710, and placed on the packaging unit 30. The folding devices may then work in concert to fold the packaging unit 30 around the frying pan 35, as shown in FIG. 15, to form a customized sized packet 40, as shown in FIG. 16.

[0091] The automatic packing machine may alternatively be an automatic bagging machine 800, as shown in Figure 17. The automatic bagging machine 800 is designed to open bags formed from polyethylene (plastic bags) and seal the plastic bags after items such as clothing have been placed therein. As a result, the automatic bagging machine 800 may be referred to herein as an automatic packing and / or sealing machine.

[0092] 22C-22F show an example in which an automated packing machine is provided within the inbound and outbound system 400. For example, the automated packing machine may be positioned on the grid 426 (as shown in FIGS. 22D-22F) or on a track or a platform adjacent thereto (as shown in FIG. 22C), so that the automated packing machine is disposed substantially at the same height as the grid. Accordingly, the robot 500 may transfer the picked items directly into containers, such as polybags or assembled boxes, designed for shipment to the end consumer. Advantageously, the storage, retrieval, picking, unit consolidation, packing, and parcel sorting processes may all occur within the inbound and outbound system 400. As a result, the order fulfillment stations described above may be reduced in size or eliminated entirely, and the size of the grid 426 may be increased relative to the size of the warehouse 1000, thereby improving warehouse storage capacity and storage density. Moreover, stuffing the orders directly into containers that are shipped to the end consumer may eliminate subsequent picking and packing steps downstream of the inventory system 400, which may also eliminate downstream scanning and sorting steps, as described in more detail below. In other words, the system shown in Figures 22C-22F allows the robot 500 to pick items, consolidate and pack the picked items, and sort the orders into shipping gaylords or shipping parcels 40 without scanning the picked items, thus eliminating the need for expensive scanners.

[0093] An example pick-and-pack process in the form of an automated bagging process may include the following steps. In this example, robot(s) 500 may pick items into order bins, e.g., partitioned order bins, based on a customer order. In some examples, the partitions of the order bins may be movable, e.g., slidable or pivotable, as described in U.S. Patent Publication No. 2022 / 0388774, which is incorporated herein by reference in its entirety. In other words, the order bin may be partitioned into multiple partitions, and the first robot 500 may traverse the grid 426 to at least partially pick one or more orders into each partition of the order bin without intermingling items of different orders within each partition. For simplicity, if the order bin includes two partitions, the robot 500 may pick items related to a first order into the first partition and items related to a second order into the second partition.

[0094] Each bin may contain all of the items for an order or only a portion of the items for an order. If each bin contains all of the items for an order, the robot 500 simply transfers each of the items for that order to the automated bagger 800 to form a package 40 for shipment. On the other hand, if an order bin contains only a portion of the items for an order, one or more other robots 500 operating on the grid 426 may work in cooperation with the first robot to complete the order. This allows each of the robots 500 to pick the portion of the order that is close to its respective robot, reducing the total distance the robots must travel around the grid 426. For example, if a first order includes three items, the first robot 500 may pick two items for that order into a first compartment of a first order bin, while the second robot may pick the third item into a partitioned compartment of a second order bin, and the first and second robots may meet at the automatic bagger 800 or another location on the grid to pack the complete order for shipping, as described in more detail below.

[0095] It will be appreciated that the robots 500 do not need to be present at the assembly location; only the order bins need be present. That is, in the previous example, the second robot would drop the second bin at a location on the grid 426, such as an adjacent automated bagger 800, and the first robot would pick up the second order bin and consolidate the order items into the first order bin, or pack the complete order directly into a polybag in the automated bagger 800. Importantly, because items for one order do not mix with items for another order in a particular compartment, no scanning is required between the picking and packing process. Instead, one or more robots 500 and / or the WMS may track the items from the time they are stored in the storage bins 20 to the time they are placed in the polybags to ensure that only items for the order (and all items for that order) are packed into the polybags in the automated bagger 800.

[0096] In an alternative example, robot(s) 500 may pick items based on SKU into order bins, such as partitioned order bins. In this example, robot 500 may traverse grid 426 to pick one or more items of a first SKU into a first compartment of the first order bin and one or more items of a second SKU into a second compartment of the first order bin. A second robot 500 may operate in a similar manner to pick one or more items of third through sixth SKUs into separate compartments of a four-compartment order bin. In this example, the first and second robots may converge at automatic bagger 800 to pack the items into plastic bags in the automatic bagger 800 as a complete order. Continuing with this example, a first order may include two items of a first SKU and one item of a third SKU, a second order may include one item of a fourth SKU, and a third order may include one item of a second SKU, one item of a fifth SKU, and one item of a sixth SKU. The first and second robots may converge at the automatic bagging machine 800 to pack the items into plastic bags as needed to complete the order and form three packages 40. That is, the robot 500 may pick two items of the first SKU into a plastic bag and one item of the second SKU into that plastic bag, after which the automatic bagging machine 800 seals the first order. The second and third orders may then be fulfilled in a similar manner.

[0097] It will be appreciated that either the first or second robot, a combination of the first and second robots, or an entirely separate robot 500 may pack items into the automated bagging machine 800. Importantly, because different SKUs do not commingle within the compartment, no scanning is required between the picking and packing process. Instead, one or more robots 500 and / or the WMS may track each SKU from the time they are stored in the storage bin 20 to the time they are placed in a polybag to ensure that only SKUs related to an order (and all SKUs related to that order) are packed into polybags in the automated bagging machine 800.

[0098] In yet another example, the robot 500 may employ a combination of order picking and SKU picking, as described above. For example, if an order includes a first SKU, a second SKU, and a third SKU, the robot 500 may utilize order picking to select the first and second SKUs into a first compartment of a first order bin and assemble with a second robot carrying a second order bin having a compartment containing only items of the third SKU. Either the first robot, the second robot, or another robot 500 may consolidate the third SKU into a partitioned compartment of the first order bin or directly pack the first, second, and third SKUs into plastic bags in the automated bagging machine 800 to form a parcel 40. Again, because items from different orders (other identifiable single SKUs) do not commingle within a single compartment of the order bin, downstream scanning to determine product or order identification is not required, as described in further detail below. This reduces takt time and increases accuracy.

[0099] Having placed all items for the completed order into one or more order bins, robot(s) 500 may go to a position on grid 426 adjacent to automated bagging machine 800 and optionally place one or more order bins into picking arms 506 of robot(s) 500 and the workspace of automated bagging machine 800. Robot(s) 500, or the WMS, may then send order information (e.g., an order ID) to automated bagging machine 800, which may use the order information to print a shipping label or barcode to be affixed to the outside of the plastic bags. Based on the order ID and in cooperation with the vision system of robot(s) 500, automated bagging machine 800 may optionally vary the opening of the plastic bag to assist robot(s) 500 in accurately placing each of the ordered items. One or more robots 500 may then use picking arms 506 to pick each of the items for the first order and place those items into the open plastic bags of automated bagging machine 800. After the robot(s) 500 place the items into the plastic bags, the automated bagging machine 800 may seal the plastic bags to form the parcels 40. In other scenarios, after the robot 500 places the items into the plastic bags to form the parcels 40, a label may be applied to the outside of the plastic bags.

[0100] The polybag parcel 40 may then be dropped directly into an order bin secured to grapple 514 of robot 500 (FIG. 22D). Alternatively, parcel 40 may be dropped into another container located below automated bagger 800 (FIG. 22E) before it is grasped by robot 500. In either scenario, picking arm 506 of robot 500 may relocate parcel 40 into the appropriate container based on the requested shipping carrier. This process may continue until several orders have been packed, sealed, labeled, and sorted into containers, such as order bins or sorting bins 60 (described in more detail below), so that the orders can be transported directly or indirectly to another area of ​​the warehouse, such as Gaylord, for shipment.

[0101] Again, this process may exclude all scanning within the inbound and outbound system 400 and downstream. Nevertheless, in some cases, the parcel may be weighed by a load cell of the robot 500, such as a load cell associated with the robot's picking arm 506 or grapple 514, or a scale located downstream of the inbound and outbound system, to compare the actual weight of the parcel with the expected weight of the parcel to confirm that the parcel contains the correct items and / or that the shipping label indicates the correct weight.

[0102] After the parcels 40 are sorted into bins based on shipping carrier, the bins can then be lowered below the I / O module and transported to a gaylord for outbound dispatch, as shown in FIG. 22C. Alternatively, if the parcels 40 are to be transported to a different dock, for example for shipment by a different carrier, one or more robots 500 can move to a position on a grid containing shipping ramps 482 as shown in FIG. 22F. Each ramp can extend from the grid 426 to a different gaylord, staging area, or transportation means (conveyor, AMR, etc.), and the one or more robots can place the sealed parcels on the appropriate ramp 482 using a picking arm 506 or sortation bins 60 (described below) to sort the parcels to the appropriate gaylord, staging area, or transportation means (conveyor, AMR, etc.) for outbound dispatch. For example, one robot 500 may be tasked with picking items into the automated bagging machine 800, while a second robot holding an order bin, or sorting bin 60, may be positioned below the automated bagging machine to receive one or more sealed parcels 40. Upon receiving one or more parcels 40, the second robot may be dispatched to place the parcel(s) on the appropriate ramp, while a third robot may place the order bin, or sorting bin 60, below the automated bagging machine 800 to receive subsequent parcels. In this regard, the robot 500 may continue to pick orders into the automated bagging machine 800, while one or more robots sort the parcels to increase throughput.

[0103] While the foregoing example describes the packaging of items into poly bags in the automatic bagging machine 800, it will be understood that the items may alternatively be packed directly into cartons previously assembled in the input / output system 400 in a similar manner, without scanning the items. After the order is packed into the assembled carton, the container may be sent from the input / output system 400, for example, via an I / O module, to the sealing machine 900, which then seals and labels the carton to form a package 40. Alternatively, a consolidated order contained within an uncompartmentalized or compartmentalized order bin may be transferred from the input / output system 400 to the carton packing machine 700, which may subsequently wrap a customized carton around the ordered item(s), seal it, and label the carton to form a package 40. The consolidated order may be transferred from the input / output system 400 while still in the order bin, or without the order bin. For example, a consolidated order may be picked from an order bin compartment and placed on a ramp, which may transport the consolidated order from the input / output system 400 to a carton packing machine. Furthermore, items for a previously picked order may be transferred from the input / output system 400, e.g., via a ramp or conveyor, to a sortation system or placed outside the input / output system and into a container designed for shipping to an end consumer. In one example, the container may be a carton or box. After all items for the order have been transferred into the container, the container may be transferred to a sealer for outbound shipping.

[0104] 22A , the automated bagging machine 800 may alternatively be located on the floor of the warehouse 1000 or on the sortation grid 426′. In this manner, a pick-and-pack robot 580 operating at a processing station, or a robot 500 operating on the sortation grid 426′, may pick at least a portion of the items for an order into the automated bagging machine 800. The pick-and-pack robot 580, or robot 500, may then place the poly bag parcels 40 into the sortation bins 60.

[0105] Similarly, carton packer 700 may be located on the floor of warehouse 1000 or on sortation grid 426′ adjacent to the storage structure of input / output system 400. After the items for a particular order are picked into the partitioned order bins, robot 500 may slide or otherwise move one of the order bin's partitions to securely pack the items. Robot 500 then lowers the order bin below the I / O module into carton packer 700, after which the bottom of the order bin is opened and the carton packer may wrap a carton around the ordered items to form parcel 40. Alternatively, after the order bin is lowered below the I / O module, a robot such as robot 500 or pick-and-pack robot 580 may pick the items from the order bin into the carton packer or into another tote configured to interface with the carton packer, after which the carton packer wraps a carton around the ordered items to form parcel 40.

[0106] FIG. 23 is a perspective view of a sorting bin 60 that can be actuated by a grapple 514 of a robot 500 between a closed state, in which a package 40 is retained within the sorting bin, and an open state, in which a package can be placed from the sorting bin into a Gaylord. The exterior of the sorting bin 60 is formed from four side walls, an open top, and an opening / closing bottom 62. In one example, the opening / closing bottom can be in the shape of a bomb bay and can include a hatch door that is biased closed by a spring or other biasing member. As shown in FIG. 23, the sorting bin 60 can further include a trigger 64 and a hammer 66. The trigger 64 can include a latching mechanism that deploys the hammer 66 when the grapple 514 of the robot 500 engages and lifts the sorting bin 60. The hammer 66 may include a track roller 68 designed to mate with the bottom surface of the support arm 512 of the storage bin retriever 510, and opposing cam ends 70 that interact with and deploy the hatch door when the track roller 68 contacts the bottom support of the support arm.

[0107] An example process for sorting polybag packages 40 into individual gaylords will now be described with reference to FIGS. 24A-24C. First, the robot 500 may move around the sorting grid 426' to position its grapple 514 over the sorting bin 60 it is tasked with grasping. The grapple 514 of the robot 500 may then be lowered around the sorting bin 60, after which the flap 520 is deployed and engaged with the trigger 64. As the sorting bin 60 is lifted from the stack of sorting bins, the trigger 64 deploys the hammer 66, as shown in FIG. 24A. Then, as shown in FIG. 24B, the grapple 514 of the robot 500 may pull the sorting bin 60 to a height where the hatch door is located above the sorting grid 426' without fully bending the grapple back to its home position. Having lifted the sorting bin 60 onto the sorting grid 426', the robot 500 can move around the sorting grid to the appropriate location (e.g., above another sorting bin, a gaylord, or a ramp 482 extending to a gaylord). Once in the appropriate position, the sorting bin 60 can be further lifted so that the track rollers 68 of the hammer 66 engage the bottom surface of the support arm 512, causing the opposing cam ends 70 to open the hatch door and deposit the contents of the sorting bin 60 directly into another sorting bin, the ramp 482, or the appropriate gaylord. The gaylord can be positioned adjacent to a warehouse dock door or moved to a position adjacent to the dock door by a conveyor, forklift, pallet jack, AMR (autonomous mobile robot), or another manual or automated system before the packages are loaded onto a vehicle by the loading / unloading equipment 200. It will be appreciated that sorting grid 426' may not only function as a sorting location, but may also be used to temporarily store partially completed or completed orders, thus acting as a buffer zone to prevent congestion at the baggage entrance. While sorting bins 60 are described above in connection with sorting grid 426', it will be appreciated that sorting bins 60 may also be utilized by robots 500 on grid 426 to deposit orders onto ramp 482 toward a particular gaylord or another area of ​​the warehouse.

[0108] 19-20 , an example process for loading parcels 40 onto a semi-trailer using loading / unloading apparatus 200 will now be described. With parcels 40 placed under loading / unloading apparatus 200, plate 242 may be extended to engage and secure one or more parcel(s), as previously described. Hoist 220 may then be moved to a desired location within the semi-trailer by sliding the rail along the beam in the x-direction and the hoist along the rail in the y-direction. After hoist 220 is positioned in the xy plane as desired, plate 242 may be extended in the z-direction, followed by release of the parcel(s).

[0109] The process of loading one or more packages may continue as the packages are loaded height-by-height. In other words, the packages may be loaded in one or more rows along the length of the vehicle and one or more rows along the width of the vehicle, with little or no space between adjacent rows, and then the packages are stacked on top of each other. Again, loading packages into the semi-trailer in this manner, as shown in the arrangement of FIG. 20, creates a stronger foundation for subsequently loaded packages and increases the packing density of the semi-trailer, facilitating the stacking process.

[0110] After each package is loaded into the semi-trailer, the loading / unloading device 200 is either relocated to another dock for immediate use, stored inside the dock for future use, or slid within the cargo space 110 of the semi-trailer and transported, along with the load, to a destination location where the loading / unloading device is available to load the packages therein.

[0111] 21 and 22A are detailed schematic diagrams illustrating various automated order fulfillment systems described herein. With specific reference to FIG. 21, an example order fulfillment process will now be described. When incoming inventory arrives at warehouse 1000, loading / unloading equipment 200 unloads packaging containers 10 from vehicles 100. The packaging containers 10 are then transported by conveyor 50, or AMR, through CubiScan 250 to an inventory removal station 300, such as a packaging container decanting station or a packaging container lid removal station, where an access opening will be cut through the packaging container. In one example, the access opening can be the removal of a packaging container lid. Inventory removal station 300 may be located along a buffer line corresponding to an I / O module of input / output system 400, where robotic manipulator 310 (or another robot) transfers items into storage bins 20 by dumping the inventory into the storage bin, picking the inventory and stuffing it into the storage bin, or nesting cut-open packaging containers into the storage bin. When inventory is dumped or picked and stuffed from packaging container 10 into storage bin 20, robotic manipulator 310 (or another robot) may discard packaging container 10 onto a waste line, which may be lifted up or down a buffer line or conveyor to transport the empty packaging container to a waste dump. After inventory items are transferred to storage bin 20 and the storage bin is placed in the I / O module, the storage bin is secured to grapple 514 of robot 500 and lifted into a position above grid 426. The robot 500 may then immediately insert the storage bin 20 into the grid-based storage structure, or pick one or more items from the storage bin 20 and place the picked items into other storage bins to replenish those bins, as directed by the WMS.

[0112] Carton assemblers CE and / or customizable carton assemblers CCE may also be provided upstream of the inbound / outbound system 400. Assembled cartons from the carton assemblers CE and / or customizable carton assemblers CCE may be used in two ways: (1) they may be transferred to the grid 416 and used as order bins by the robot 500; or (2) they may be transferred to a processing station. In a first example, when an order is received, the robot 500 may indirectly secure the desired carton to the grapple 514 using the tray 550 and then traverse the grid to pick and pack items for the order directly into the carton. The robot 500 may then send the fully or partially filled order to a carton exchange location located on the shipping side of the grid 426. The cartons are then transferred from the tray 550 to the carton exchange prongs 450, then to the right angle transfer (RAT), and finally to the shipping conveyor, which transfers the cartons to the shipping buffer line. If the order is complete, it may be transferred immediately to the sealer. On the other hand, if the order is only partially complete, the carton may be sent to a designated processing station where the pick-and-pack robot 580 finishes packing the items into the order before the cartons proceed to the sealer.

[0113] Alternatively, in a second example, the assembled carton may be transferred to a buffer line corresponding to one of the processing stations adjacent to the I / O module. After one or more items for a particular order have been picked by the robot 500 and placed in an order bin, the robot may transfer the order bin to the I / O module and out of the input / output system 400 to a processing station. The pick-and-pack robot 580 may then pick one or more items from the order bin and pack the picked items into a carton. After all of the items for a particular order have been packed into the carton, the carton may be pushed onto a conveyor for further shipping processing.

[0114] The shipping conveyor may, for example, transport the cartons to a sealer 900, which seals and labels the cartons to form completed packages 40. On the other hand, if the automatic packing machine is an automatic bagging machine 800 located along a buffer line, the poly bags may be transported by a bypass conveyor to avoid the sealer 900. In either scenario, the completed packages 40 may be transported by a conveyor, or AMR, to a designated dock door corresponding to the appropriate delivery vehicle 100, whereupon the packages are loaded into the vehicle 100 using loading / unloading equipment 200.

[0115] 22A , the conveyor loop within the dashed line in FIG. 21 may be replaced with a sorting grid 426′, and / or one or more of the automated processing stations may be replaced with manual processing stations, such as a packing table. The robot 500 may traverse the sorting grid 426′ to move storage bins 20 and / or order bins to and from the storage structures of the inbound and outbound system 400 and between various stations within the warehouse 1000 to sort the parcels 40 into the appropriate gaylords for outbound dispatch. While the warehouse 1000 is described herein as not requiring a warehouse operator, it will be understood that warehouse personnel may be utilized to supplement or replace the pick-and-pack robot 580 or to perform other fulfillment operations.

[0116] FIG. 25 illustrates an example delivery robot 1100 that can deliver a package 40 to a purchaser. The delivery robot 1100 can be deployed directly from the warehouse 1000 to deliver the package to a location proximate the warehouse 1000, or can be mounted in a vehicle 100 and subsequently deployed once the vehicle reaches the appropriate destination. The delivery robot 1100 can include a body 1102 having a locomotion assembly 1104 and at least one arm (not shown). The body 1102 of the delivery robot 1100 can be compact, such that it is approximately the width of a standard human. In this regard, the delivery robot 1100 can be designed to travel along crowded sidewalks and any suburban or urban corridor. As shown in FIG. 25, the locomotion assembly 1104 of the delivery robot 1100 can include two or more legs, each of which can optionally be equipped with a wheel. The wheels of the delivery robot 1100 can be used to drive the robot over generally flat terrain, such as bike paths, sidewalks, and other paths, at an appropriate speed based on environmental conditions. On the other hand, the legs may be used to straddle obstructions and / or climb stairs around the delivery route.

[0117] One or more arms may be used to secure an order parcel. More specifically, each arm may include a hand designed to secure the order between the arms using a compressive force. The hand may be a friction-enhancing nub formed from a silicone or rubber material with friction-enhancing properties. In some embodiments, the nub may include a protrusion or otherwise uneven surface to further enhance friction and secure the order, or other features designed to hold the parcel 40 in a passive manner. However, the hand is not limited to a nub and may alternatively include a gripping element such as a finger or one or more suction cups.

[0118] As shown in FIG. 25 , the arms may be replaced with a transport cavity 1150 designed to transport the parcels 40 within the body 1102 of the delivery robot 1100. In this regard, the transport cavity 1150 protects the parcels 40 from theft, environmental conditions, and minimizes the area occupied by the combination of the delivery robot 1100 and the parcel, allowing the delivery robot to quickly navigate busy streets. In some examples, the transport cavity 1150 may be temperature-controlled and therefore designed to safely transport parcels 40 containing perishable food items. A suction cup or other retaining device (not shown) may be positioned within the transport cavity 1150 to grasp the parcel 40. The transport cavity 1150 may be transitionable between a closed state in which the parcel is stored within the body 1102 of the delivery robot 1100 and an open state in which the parcel is dispensed from the body. As shown in FIG. 25, the transport cavity 1150 may include a bomb bay door, although any other mechanism used to open and close a cavity may be utilized.

[0119] It will be appreciated that the delivery robot 1100 is much less expensive to manufacture without arms and / or hands. However, arms and hands provide convenient functionality, such as pressing keypads, the ability to open doors or drawers, or any function commonly performed by human hands. For this reason, the body 1102 of the delivery robot 1100 may include a passive or underactuated device 1160. In one example, the passive or underactuated device 1160 may have a hook-like shape, as shown in FIG. 25 . When the hook is positioned in a vertical plane, the hook may define a recessed area designed to accept a horizontally positioned handle. In this manner, the delivery robot 1100 may engage a horizontal handle of a drawer and then move its body rearward to open the drawer. In some examples, the hook may be mounted to extend from the body in other orientations, such as a horizontal plane, so that the hook engages a vertical handle to open a door in a similar manner. In other examples, the hook may be rotatably mounted to the body 1102 of the delivery robot 1100 and configured to open various features with handles. As shown in further detail, the hook may additionally include an end 1170 defining a rubber or silicone tip, which may be used to input information onto a touch screen or keypad to gain access to an area such as a building lobby. In this regard, the passive or underactuated device 1160 is designed to perform many of the functions of a human or robotic arm and hand, but at a fraction of the cost.

[0120] FIG. 26 shows a receiving locker 1200 secured to the interior surface of a windowsill. The receiving locker 1200 includes a bottom surface and at least three side walls. In other words, the receiving locker has an open (or retractable) side facing the residence's window. The top of the receiving locker 1200 can be permanently open or designed with a retractable surface. As a result, a drone 1250 can secure a parcel 40, transport the parcel from the warehouse 1000 or vehicle 100, and place the parcel into the receiving locker 1200 through the open top or using a small ramp. The drone 1250 can include wings and / or propellers and a clamshell-shaped cavity 1260 in which a suction cup or other securing device (not shown) is disposed to grasp the parcel 40. The clamshell-shaped cavity 1260 can be connected to the body of the drone 1250 using an extendable rope and designed to transition between a closed position and an open position. In this regard, clamshell cavity 1260 may be lowered toward package 40 and then opened to expose its securing device, which may be used to secure the package. With package 40 secured, clamshell cavity 1260 may be closed around the package and raised toward the body of drone 1250 for transport to a delivery destination, such as receiving locker 1200.

[0121] In some examples, it may be desirable for the receiving locker 1200 to have a retractable top to protect the parcel 40 from theft or harsh environments. In such scenarios, part or all of the top may be manually or electronically movable between a closed and an open position. Alternatively, the receiving locker 1200 may include a sensor, such as a load sensor or a camera, designed to detect when a parcel is placed in the receiving locker and an actuator for autonomously closing the top when the parcel 40 is received. In other examples, the drone itself may send instructions to the receiving locker 1200 after placing the parcel 40, instructing the receiving locker to close the top.

[0122] Multi-family buildings, including apartment buildings in urban areas, may utilize shuttle sorters, such as those disclosed in U.S. Patent Publication No. 2021 / 0188554, to sort packages delivered by ground transportation. The packages 40 may then be delivered using drones to place them in receiving lockers 1200. Alternatively, the sorted packages 40 may be transported to another storage location within the residence where they can be placed in a locker or storage space for the resident. Alternatively, a shuttle sorter may be placed on the roof or in another area of ​​the building to sort packages delivered by drone, which are then placed in a locker or storage space for the resident. In any case, the building may notify the resident via text, email, or resident portal that a package 40 has arrived.

[0123] The autonomous order fulfillment and delivery system of warehouse 1000 described herein essentially automates the entire order fulfillment process, eliminating the need for any or substantially all human intervention. The compact flow between systems also maximizes the percentage of the warehouse that can be occupied by the inbound and outbound systems 400, thereby increasing warehouse storage density, which in turn reduces working capital.

[0124] Although the invention herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present invention. It is therefore to be understood that numerous modifications can be made to the exemplary embodiments and that other arrangements can be devised without departing from the spirit and scope of the invention as defined by the appended claims.

Claims

1. A storage and retrieval system, a storage structure storing storage bins in stacks, the storage structure including vertical pillars supporting a first set of rails and a second set of rails extending perpendicular to the first set of rails, the first and second sets of rails collectively forming a grid defining a plurality of grid spaces such that each of the stacks is stored within the footprint of a respective grid space; one or more robots operable on the grid, the one or more robots comprising: a body coupled to a wheel assembly, the wheel assembly including a plurality of wheels and a drive mechanism configured to move the body along the first and / or second sets of rails; and Picking arms to place inventory items directly into containers for shipment to end users one or more robots, and a warehouse entry and exit system, including a sealer for sealing the container to form a packet; An order fulfillment system comprising:

2. 10. The system of claim 1, wherein the sealing machine is an automatic bagging machine and the container is a plastic bag.

3. The system of claim 2 , wherein the automated bagger is positioned on the grid.

4. The system of claim 2 , wherein the automated bagger is positioned adjacent to the grid at a height substantially equal to the height of the grid.

5. The system of claim 1 further comprising a plurality of ramps extending from the grid to respective gaylords.

6. The system of claim 1 , wherein the container is a carton.

7. The system of claim 6 further comprising a carton assembler for assembling said cartons, said carton assembler being upstream of said storage structure.

8. 8. The system of claim 7, wherein the sealer is a carton sealer located downstream of the storage structure, the carton sealer configured to seal the cartons to form packets.

9. 10. The system of claim 1, wherein the one or more robots further include a grapple suspended from a support arm by a cable connected to a take-up mechanism for adjusting the vertical height of the grapple, the grapple configured to secure a tray on which the storage bins and cartons can be placed.

10. 10. The system of claim 1, further comprising a loading / unloading device for unloading packages from a cargo space of a vehicle and / or loading packages into the cargo space of the vehicle.

11. the loading / unloading device is an autonomous gantry; a pair of beams extending in a first direction; a rail extending between the pair of beams and movable in the first direction along the pair of beams; a hoist coupled to the rail and movable along the rail in a second direction transverse to the first direction, the hoist including a plate having a locking device, the plate movable perpendicular to the rail between a retracted position and an extended position; The system of claim 10, comprising:

12. A storage and retrieval system, a storage structure arranged to store storage bins in stacks defining a plurality of I / O modules, said storage structure including vertical pillars supporting a first set of rails and a second set of rails extending perpendicular to said first set of rails, said first and second sets of rails collectively forming a grid defining a plurality of grid spaces such that each of said stacks is stored within the footprint of a respective grid space; one or more robots, a body coupled to a wheel assembly, the wheel assembly including a plurality of wheels and a drive mechanism configured to move the body along the first and / or second sets of rails; and a grapple vertically movable and configured to selectively secure and lift at least one of the storage bins from one of the stacks to a position above the grid; one or more robots, a storage and retrieval system including: an automatic packaging machine located downstream of the storage structure; a manipulator robot including a picking arm for picking one or more items from an order bin and placing the one or more picked items into the automated packing machine; An order fulfillment system comprising:

13. 13. The system of claim 12, wherein the automated packing machine is a carton packing machine configured to form custom-sized packages around the one or more items.

14. 14. The system of claim 13, wherein the manipulator robot is positioned downstream of the storage structure, and the manipulator robot places the one or more picked items from the order bin into the carton packer.

15. 14. The system of claim 13, wherein the manipulator robot is positioned on the grid to indirectly place the one or more picked items into the carton packer using a ramp and / or conveyor.

16. The system of claim 12 further comprising a sorting system.

17. The sorting system is a sorting grid disposed adjacent to the grid and at a height lower than the height of the grid, the sorting grid comprising: a frame including vertical pillars supporting a first set of rails and a second set of rails extending perpendicular to the first set of rails, the first and second sets of rails collectively forming the sorting grid and defining a plurality of sorting grid spaces; 17. The system of claim 16, comprising:

18. 20. The system of claim 17, further comprising sorting bins, each of the sorting bins being movable between a closed position in which items are retained within the sorting bin and an open position in which items are dispensed from the sorting bin.

19. 20. The system of claim 18, wherein the sorting bin further includes a hammer and trigger for transitioning the sorting bin from the closed position to the open position.

20. further comprising one or more sorting robots operable on the sorting grid, the sorting robots comprising: a body coupled to a wheel assembly, the wheel assembly including a plurality of wheels and a drive mechanism configured to move the body along the first and second sets of rails of the sorting grid; a grapple suspended from a support arm by a cable connected to a take-up mechanism for adjusting the vertical height of the grapple, the grapple configured to securely lift one of the sorting bins that is transitioned from the closed position to the open position when the hammer of the sorting bin contacts the support arm of the sorting robot; and 20. The system of claim 19, comprising:

21. 20. The system of claim 17, further comprising a plurality of gaylords disposed around a perimeter of the sorting grid.

22. The system of claim 12 , wherein the automated packaging machine is an automated bagging machine.

23. moving one or more robots around a storage structure including a grid formed from a first set of parallel rails and a second set of parallel rails extending perpendicular to the first set of parallel rails; picking an item from a storage bin using the one or more robotic picking arms; placing the picked items into one or more compartments within one or more order bins secured to the one or more robots, so that each compartment holds either one or more units of a single SKU or items related to a single order; removing the picked items from the one or more order bins; (1) an automated packing machine located on or adjacent to the storage structure to form packages; or (2) An open carton configured for shipment to an end consumer and A method comprising the step of:

24. 24. The method of claim 23, wherein the transferring step includes using the one or more robots to transfer the picked items directly from the one or more order bins to an automated packing machine located on or adjacent to the grid to form a parcel, and a subsequent transferring step of transferring the parcel to a gaylord or pallet located outside the storage structure.

25. 25. The method of claim 24, wherein the subsequent transferring step is performed at least in part by a ramp.

26. 26. The method of claim 25, wherein the parcel is placed on the ramp by the picking arm of the robot.

27. 26. The method of claim 25, wherein the parcel is placed on the ramp when the one or more robots transition a retractable bottom of a sorting bin from a closed position to an open position.

28. 28. The method of claim 27, wherein the retractable bottom is mechanically actuated by grapples of the one or more robots.

29. 24. The method of claim 23, wherein the transferring step originates on the grid and is performed at least in part by the one or more robots to transfer the picked items into a container configured for shipping to a customer.

30. 30. The method of claim 29, wherein the container is the open carton, and the open carton is provided in the inventory system.

31. 31. The method of claim 30, further comprising a subsequent transfer step comprising lowering the carton in an I / O module using a grapple of the one or more robots and passing the carton through a carton sealer.

32. 30. The method of claim 29, wherein the containers are cartons located outside the inbound and outbound system, and the transferring step is performed at least in part by a ramp or conveyor positioned between the storage structure and the cartons.

33. 24. The method of claim 23, wherein the transferring step originates on the grid and is performed at least in part by the one or more robots to transfer the picked items to a carton packer.

34. 34. The method of claim 33, wherein the transferring step is performed at least in part by a ramp.

35. 24. The method of claim 23, wherein the transferring step begins on or near a sorting grid positioned adjacent to the grid, and the transferring step is performed, at least in part, by the one or more other robots.

36. 24. The method of claim 23, wherein the item, or the parcel containing the item, is not scanned between the time the item is stored in the storage structure and the time the parcel is staged for shipment.

37. 1. A method of delivering a parcel, comprising: Securing the parcel to an autonomous drone; placing said parcel in a receiving locker secured within a window of the building; A method comprising:

38. 38. The method of claim 37, wherein the receiving locker includes a bottom and at least three sides.

39. 39. The method of claim 38, wherein the receiving locker is open or has a retractable top.

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