Final process box processing mounted on an autonomous mobile robot

Abstract

A packaging system for end-of-line box processing includes two or more end-of-line box processing stations, each configured to perform one or more end-of-line processing operations, an autonomous vehicle, and a controller. The box processing stations include a supply of boxes, a product delivery station where items to be shipped are placed in the boxes, and sensors for detecting characteristics of the boxes and the items in the boxes. The autonomous vehicle is configured to autonomously transport boxes from the product delivery station to selected ones of the two or more box processing stations. The controller is configured to communicate with the sensors and the autonomous vehicle and to selectively guide the autonomous vehicle to transport boxes from the product delivery station to selected ones of the two or more box processing stations based at least in part on information from the sensors.

Description

[Technical Field]

[0001] The present disclosure relates generally to a packaging system for final stage box processing, and more particularly to a packaging system for final stage box processing using an autonomous mobile robot. [Background technology]

[0002] In the process of shipping one or more items from one location to another, the packages may undergo multiple final processing operations before they are ready for shipment. Some examples of final processing operations include forming or assembling a box, packing the box with both the items to be shipped and optionally protective packaging materials, and closing, capping, or sealing the box. Whether such final processing operations are performed manually or by an automated or semi-automated packaging system, the boxes are typically transported from the upstream end of a fixed, permanent transportation system, such as a continuous conveyor system. The continuous conveyor system defines a fixed path for all packages as they move downstream through each of several stations where each final processing operation is performed. Summary of the Invention

[0003] This disclosure describes a packaging system for end-of-line box processing mounted on an autonomous transport vehicle, such as an autonomous mobile robot, instead of a fixed transport system such as a conveyor. Using an autonomous transport device in conjunction with a control system that delivers packaged containers only to selected packing stations provides several advantages, including increased flexibility in worker movement around and within the packaging system, increased flexibility in the placement of packing stations within the packaging area, easier reconfiguration, and reduced need for human decision-making between stations. Eliminating the need for fixed paths also speeds the packing process by delivering containers only to required packing stations and bypassing packing stations with unnecessary packing operations, freeing up space at those stations for containers requiring those operations, and avoiding delays caused by containers not requiring those operations having to wait for previous containers to pass through the packing station.

[0004] An exemplary packaging system for final-stage box processing includes two or more final-stage box processing stations, each configured to perform one or more final-stage box processing operations, an autonomous vehicle, and a controller. The final-stage box processing stations include a supply of boxes, a product delivery station where items to be shipped are placed in the boxes, and sensors for detecting characteristics of the boxes and the items within the boxes. The autonomous vehicle is configured to autonomously transport the boxes from the product delivery station to a selected one of the two or more final-stage box processing stations. The controller is also in operative communication with the sensors and the autonomous vehicle. The controller is configured to selectively direct the autonomous vehicle to autonomously transport the boxes from the product delivery station to a selected one of the two or more final-stage box processing stations based, at least in part, on information from the sensors.

[0005] According to one or more embodiments of the packaging system, the autonomous vehicle is an autonomous mobile robot, and when at least one of the one or more final process box handling operations is performed on the box, the box is mounted on the autonomous mobile robot.

[0006] In one or more embodiments, the sensor is configured to detect at least one feature of the box, including at least one of a height dimension, a width dimension, a depth dimension, and a void volume. The at least one detected feature may include an incompatibility indicator of the box.

[0007] In one or more embodiments, the controller is configured to guide the autonomous vehicle to autonomously transport the box along a path that bypasses at least one of the two or more final process box handling stations.

[0008] In one or more embodiments, at least one of the two or more final process box handling stations is automated.

[0009] In one or more embodiments, at least one of the two or more final process box handling stations includes a first final process box handling station and a second final process box handling station disposed away from the first final process box handling station. As a result, the autonomous vehicle is guided to a selected one of the first final process box handling station and the second final process box handling station, but not to the other of the first final process box handling station and the second final process box handling station. The first final process box handling station and the second final process box handling station may perform the same final process box handling operation, or the first final process box handling station and the second final process box handling station may perform different final process box handling operations.

[0010] An exemplary final-stage box processing method includes the steps of: (a) providing a packaging system having two or more final-stage box processing stations and one or more autonomous vehicles configured to move boxes between selected ones of the two or more final-stage box processing stations, the final-stage box processing stations including a product delivery station where items to be shipped are placed into the boxes for shipping; (b) loading the boxes onto the autonomous vehicle and transporting the boxes to the selected ones of the two or more final-stage box processing stations; (c) scanning the boxes after the items to be shipped are placed into the boxes to detect characteristics of the boxes and the items within the boxes; and (d) guiding the autonomous vehicle to transport the boxes on a route from the product delivery station to the selected ones of the two or more final-stage box processing stations based at least in part on the detected characteristic information.

[0011] According to one or more embodiments of the final-stage box processing method, the method further includes causing at least one of the one or more final-stage box processing stations to selectively perform at least one of one or more final-stage box processing operations on the box. The box may be onboard an autonomous vehicle when the at least one of the one or more final-stage box processing operations is performed on the box.

[0012] In one or more embodiments, the method further includes detecting at least one feature of the box and updating the path based at least in part on the detected feature. The detecting step may include identifying at least one detected feature that indicates the box is non-conforming.

[0013] In one or more embodiments, the directing step includes directing the bypass of at least one final bin processing station.

[0014] In one or more embodiments, the loading step includes assembling a box and placing the box on the autonomous vehicle.

[0015] In one or more embodiments, the scanning step includes detecting one or more of a height dimension of the box, a width dimension of the box, a depth dimension of the box, a height dimension of one or more items in the box, non-conforming features of the box, and a void volume of the box. The scanning step may be repeated after the box is transported to at least one final box processing station.

[0016] In one or more embodiments, the method may further include transporting the boxes to a plurality of final box processing stations. [Brief explanation of the drawings]

[0017] [Figure 1] 1 is a schematic layout of an exemplary packaging system for final box processing. [Figure 2] 10 is a schematic operational diagram of an exemplary final process box processing operation showing an autonomous mobile robot moving autonomously toward a final process box processing station. FIG. [Figure 3] 3 is a schematic operational diagram of the exemplary end-of-line box processing operation of FIG. 2 showing the autonomous mobile robot interacting with the end-of-line box processing station to receive a box lid loaded onto the autonomous mobile robot. [Figure 4] 1 is a schematic flow chart of an exemplary final bin processing method. DETAILED DESCRIPTION OF THE INVENTION

[0018] Referring now to the drawings, and initially to FIG. 1 , a schematic diagram of an exemplary automated packaging system 10 for back-end box processing is shown. The packaging system 10 includes a plurality of back-end box processing stations and one or more autonomous vehicles 12 for moving packaging containers 14 to selected ones of the back-end box processing stations. The back-end box processing stations are positioned such that the autonomous vehicles 12 have space to maneuver around any of the back-end box processing stations. By using autonomous vehicles 12, the packaging system 10 minimizes or eliminates the need for permanent, fixed-location, continuous conveyor systems, such as those used in conventional packaging systems for back-end processing. The use of autonomous transport vehicles 12 in conjunction with a control system that delivers packaging containers only to select back-end box processing stations provides several advantages, including increased flexibility in worker movement through and within the packaging system 10 and increased flexibility in the placement of back-end box processing stations within the packaging area, facilitating easier reconfiguration.

[0019] The elimination of fixed routing also speeds the packaging process by delivering containers only to required final-stage box processing stations, bypassing final-stage box processing stations with unnecessary packaging operations, freeing up space at final-stage box processing stations for containers requiring final-stage processing operations, and avoiding delays caused by containers that do not require final-stage processing having to wait for previous containers to pass through a final-stage box processing station. For example, instead of arranging multiple final-stage box processing stations at fixed locations along a permanent conveyor system and transporting packaged containers downstream from one end of the permanent conveyor system through each and every final-stage box processing station, the packaging system 10 described herein provides stand-alone modular final-stage box processing stations that can be arranged in any desired configuration, and a system controller 40 that guides the autonomous vehicle 12 to move the packaged container 14 through selected ones of the multiple final-stage box processing stations while the packaged container 14 is onboard the autonomous vehicle 12. The modular nature of the final-stage box processing stations also facilitates maintenance and improves scalability, implementation, and process changes.

[0020] Throughout this description, the terms "container" and "box" are used interchangeably and refer to any enclosure having adequate strength to withstand shipping, storage, and handling, with the required characteristics generally varying depending on the nature of the items being shipped within the enclosure. The most common shipping containers are corrugated cardboard boxes, such as regular slotted containers (RSCs) that have a foldable flap to close the open side of the container, and half slotted containers (HSCs, also known as shoebox containers) that have a separate lid, usually adhesively secured to close the open side of the container. There are further different types and construction styles of corrugated cardboard boxes. However, the term "box" is not limited to corrugated cardboard and other materials.

[0021] The final-end box processing stations include a plurality of box delivery stations 20, also referred to as box forming stations or case assembly stations, for providing boxes 14 to the autonomous vehicle 12, product delivery stations 22, also referred to as product filling stations or case packing stations, for providing items 52 to be shipped to the boxes 14, a scanning station 24 for detecting characteristics of the boxes 14 and the items therein, a box sizing station 26 for reducing a height dimension of the boxes 14 based on detected characteristics of the items 25 therein, a dunnage dispensing station 30 for providing dunnage material to the boxes 14, a lid application station 34 for folding flaps of the boxes 14 inwardly to the open side of the boxes 14 and attaching lids to the open side of the boxes 14, and a label application station 36 for applying shipping labels to the boxes 14. Each final-end box processing station may be designed as a standalone modular final-end box processing station that can be positioned or moved to any suitable location within the final-end box processing area. Each final bin processing station is spaced apart from other final bin processing stations to facilitate movement between the final bin processing stations.

[0022] Additionally, while some of these final-stage box processing stations can be combined to provide all functions in one final-stage box processing station rather than two or more, or some of these final-stage box processing stations can be split into multiple final-stage box processing stations, an advantage of packaging system 10 over traditional fixed conveyor systems is the ability to direct boxes around final-stage box processing stations without waiting for the previous box to exit the final-stage box processing station. As an example, label application station 36 can be combined with lid application station 34 if a shipping label is always added to a box 14 after lid application station 34 closes the open side of the box 14. However, combining box sizing station 26 with dunnage dispensing station 30 slows down final-stage processing if not all boxes 14 require processing at box sizing station 26 because boxes 14 cannot bypass box sizing station 26 to reach dunnage dispensing station 30.

[0023] As another example, if the packaging system 10 processes both flaps and flaps-less boxes 14, the lid attachment stations 34 can be divided into two different types: lid attachment stations 34 with both flap folding and lid attachment functions for flaps-less boxes 14, and lid attachment stations 34 without flap folding functions (or with the flap folding function disabled) but with lid attachment functions for flaps-less boxes 14. In effect, flaps-less boxes 14 can bypass the flap folding stations.

[0024] Although specific end-of-line box processing stations are described in connection with the embodiment of Figure 1, the end-of-line box processing stations may be any suitable end-of-line box processing stations, and may include, by way of example only, dunnage transfer stations, scanning systems, printing stations, labeling stations, height reduction stations, non-conformance detection stations, non-conformance correction stations, other quality assurance stations, and protective packaging systems and their associated consumables. This list is not exhaustive.

[0025] The packaging system 10 further includes a system controller 40 for controlling the coordination and interaction of the various components of the packaging system 10 and the final box processing stations 20, 22, 24, 26, 30, 34, and 36. However, one or more components of the packaging system 10 and the final box processing stations may be controlled manually, semi-automatically, or automatically, independently of one another. The system controller 40 is a programmable controller that is suitably programmed to operate the packaging system 10 in a desired manner for a given application. The operation of the system controller 40 may be performed by a single processor or by separate processors for the various components of the packaging system 10, appropriately intermediated to coordinate the operation of the entire packaging system 10.

[0026] For example, system controller 40 may perform operations in response to execution of software instructions stored on a non-transitory computer-readable medium, such as non-transitory memory, which may include storage space within a single physical storage device or across multiple physical storage devices. The software instructions may be stored locally within system controller 40 or may be received remotely from another non-transitory computer-readable medium via a communications interface, such as a non-transitory computer-readable medium of a computing device located remotely from system controller 40 and in operative communication with system controller 40 via a wireless protocol.

[0027] Execution of software instructions stored in memory or other storage elements associated with system controller 40 enables system controller 40 to perform one or more of the operations described herein. Additionally, or alternatively, hardware circuitry may be used in place of or in combination with software instructions to perform one or more of the processes described herein. Thus, the implementations described herein are not limited to any specific combination of hardware circuitry and software.

[0028] Thus, system controller 40 may include a processor in the form of a central processing unit (CPU), graphics processing unit (GPU), accelerated processing unit (APU), microprocessor, microcontroller, digital signal processor (DSP), field programmable gate array (FPGA), application specific integrated circuit (ASIC), or another suitable type of processor, or a combination thereof. The processor may be implemented in hardware, software, or a combination of hardware and software. In some embodiments, system controller 40 may include memory for storing information or instructions used by system controller 40, such as random access memory (RAM), read-only memory (ROM), another type of dynamic or static storage device (e.g., flash memory, magnetic memory, optical memory, etc.), or a combination thereof.

[0029] The components of packaging system 10 can communicate with each other directly or via system controller 40 over a communications network 42, such as, for example, a wireless communications network. However, the components of packaging system 10 may also operatively communicate via any suitable combination of one or more wired, wireless, or hybrid networks. For example, communications network 42 may include any one or more of the Internet, an intranet, a cloud network, a wide area network (WAN), a local area network (LAN), a wireless network, a digital subscriber line (DSL) network, a frame relay network, an asynchronous transfer mode (ATM) network, a virtual private network (VPN), or any other suitable communications network or combination of communications networks.

[0030] At least one of the autonomous vehicles 12 of FIG. 1 may comprise an autonomous mobile robot (AMR) 12 for autonomously transporting boxes 14 through the packaging system 10. Each AMR 12 comprises an on-board navigation system for guiding the packaging system 10 without a predetermined, fixed physical path. The on-board navigation system may comprise an inertial navigation system (INS) 44 ( FIG. 2 ) and a navigation system 46 ( FIG. 2 ) in communication with the system controller 40. The INS 44 and navigation system 46 may comprise a computing device, a motion sensor, a rotation sensor, a global positioning system (GPS), or other suitable components, or a combination thereof. The INS 44 enables the system controller 40 to determine the position, orientation, and velocity of the AMR 12 without relying on external references, and the navigation system 46 enables the system controller 40 to independently and selectively control each AMR 12 as the AMR 12 moves along a desired route, as described further below. For example, the INS 44 may calculate position, direction, and velocity by dead reckoning and communicate the position, direction, and velocity data to the system controller 40. However, the AMR 12 may use other suitable localization or positioning systems, such as external positioning markers or signals at final processing stations.

[0031] Generally, each AMR 12 moves between final-stage processing stations along a selected route independently of the system controller 40. In other words, the system controller 40 may instruct the AMR 12 which final-stage processing stations to visit without predefining the route the AMR 12 should take between two final-stage processing stations. In other words, the system controller 40 does not need to instruct the AMR 12 in real time, for example, when to turn. This also means that the system controller 40 can instruct the AMR 12 to visit a final-stage processing station multiple times if necessary, or to navigate between a set of final-stage processing stations that are used only in very rare circumstances. Therefore, this is not economically feasible in a fixed-route transportation system. Therefore, the route of the AMR 12 shown in FIG. 1 is only a small portion of the possible paths the AMR 12 may take, and the AMR 12 is not limited to the illustrated path.

[0032] Packaging system 10 preferably includes multiple AMRs 12 for automatically and substantially independently moving multiple boxes 14 through the final processing stations without continuous control by system controller 40. AMRs 12 may be provided as part of a supply of AMRs 12 at the upstream end of the final processing stations, or AMRs 12 may wait at the final processing stations until needed.

[0033] In the illustrated embodiment, the first final processing station is a box delivery station 20 that includes a supply of one or more boxes 14. The boxes 14 are either formed from flat corrugated cardboard that is cut, folded, and glued to form open-top boxes 14, or are provided from a supply of pre-formed boxes 14 that are folded flat and opened at the box delivery station 20, with the bottom side of the boxes 14 closed. Machines that open flat-folded boxes are commonly referred to as case assemblers.

[0034] The illustrated box delivery station 20 includes multiple case assemblers 50 to speed delivery of boxes 14 or to provide boxes 14 of different cross-sectional sizes (width and depth) and heights. For example, the box delivery station 20 includes two case assemblers 50 that assemble boxes 14 of smaller cross-sectional sizes, one of which assembles boxes 14 of shorter heights and the other of which assembles boxes 14 of taller heights. The box delivery station 20 also includes two case assemblers 50 that assemble boxes 14 of larger cross-sectional sizes, one of which assembles boxes 14 of shorter heights and the other of which assembles boxes 14 of taller heights. Thus, this embodiment provides four different sizes of boxes 14 with four different combinations of height, width, or depth dimensions.

[0035] A packer or other operator, such as at product delivery station 22, can communicate over communication network 42 to notify box delivery station 22 that a box 14 is needed. If multiple different box sizes or types are available at box delivery station 22, the signal includes the size or type of box 14 needed, and AMR 12 is directed to the appropriate location to receive the needed box. Alternatively, AMR 12 may be positioned at each of multiple locations within box delivery station 22, each ready to receive a particular size or type of box 14.

[0036] The box delivery station 22 places the box 14 on the AMR 12 such that the AMR 12 supports the box 14 for movement with the AMR 12. The AMR 12 then moves from the box delivery station 22 to the product delivery station 24, where one or more items 52 are placed into the box for shipping. The product delivery station 24 can automatically perform a product filling operation, such as using a robot to pick up the items 52 to be shipped from a supply and place the items 52 into the box 14 on the AMR 12. Alternatively, a packer can manually place the items 52 to be shipped into the box 14. The items 52 to be shipped may include multiple items. The box 14 can remain on the AMR 12 while the items 52 are placed into the box 14, or the box 14 can be moved to the product delivery station 22 for filling and then returned to the AMR 12 after the items 52 have been placed into the box 14.

[0037] The box 14 is tracked through the remaining selected final stage box processing stations either from the identity of the AMR 12 transporting the box 14 or from the identity of the box 14 itself through sensors at or around the final stage processing stations. The sensors may include, for example, sensors capable of detecting a bar code or radio frequency identification device (RFID) on the box 14 or AMR 12.

[0038] From product delivery station 22, AMR 12 moves bin 14 through quality scanning station 24 where sensors in communication with system controller 40 determine the bin dimensions, void volume, and height of the tallest item in bin 14 and communicate that information to system controller 40. In other words, the sensors may be configured to identify characteristics of bin 14, the contents of bin 14, or a combination thereof, compatibility indicators of bin 14, the contents of bin 14, or a combination thereof, and the void dimensions of bin 14 relative to the contents of bin 14.

[0039] System controller 40 determines, based at least in part on information from sensors at quality scanning station 24, the final processing operations required for box 14 and its contents and instructs AMR 12 to move box 14 to selected ones of the remaining final processing stations in a particular order, or simply instructs AMR 12 to move box 14 to the next selected one of the final processing stations.

[0040] In the illustrated embodiment, the next final processing station may be a box sizing station 26 where the box size, specifically the height dimension, is reduced depending on the tallest item in the box 14. The exemplary box sizing station 26 trims the corners of the box 14 to a height that approximates the height of the tallest item in the box 14 and forms a crease in the box 14 adjacent the height of the tallest item in the box 14. If no resizing is required, the AMR 12 may bypass the box sizing station 26 and any AMRs within the box sizing station 26 and reorder the sequence of boxes 14 being processed at the final processing station.

[0041] Another final processing station is the dunnage dispensing station 30. The dunnage dispensing station 30 includes one or more protective packing machines with dunnage dispensing devices configured to dispense dunnage products into the boxes 14. The AMRs 12 are directed along a path to a particular dunnage dispensing device, or if dunnage is not needed, the AMRs 12 may bypass the dunnage dispensing station 30 and all AMRs 12 within the dunnage dispensing station 30. Each dunnage dispensing device dispenses protective packing material, also referred to as dunnage, dunnage pads, or dunnage products, into the boxes 14 to protect the items 52 within the boxes 14 during transport. Examples of protective packing machines include void-fill systems, cushioning systems, and wrapping systems.

[0042] A void-filling system can quickly and efficiently convert stock material, such as paper, to fill empty spaces within the box 14, protecting the items 52 within the box 14 by reducing movement and potential damage to the items 52 during transport. A cushioning system typically converts stock material, such as paper, into a cushioning pad by folding or crumpling it to form a crush-resistant material, protecting the items 52 from external shock and vibration during transport and preventing movement of the items 52 during transport. A packaging system can, for example, create a relatively flat pad or mesh to securely encase the items 52, protecting them from impact and surface damage during the shipping and handling process, lining the box 14, and providing separation when transporting multiple products. An insulation system can provide insulation for items 52 that require temperature control during transport.

[0043] The packaging system 10 may include multiple dunnage dispensers 54 within the dunnage dispensing station 30, each configured to dispense the same or different types or qualities of dunnage, such as void filler, cushioning, packing, or insulation, converted from different stock materials, or configured to provide redundancy for larger volumes, for example, by dispensing dunnage to multiple boxes with different dunnage dispensers 54 or by using different basis weight paper with different dunnage dispensers 54. If multiple types of dunnage are required, the AMR 12 may be routed through the dunnage dispensing station 30 multiple times. For example, a flat wrapping or insulating pad may be placed on the box 14 before the item 52 to be shipped is placed therein, and then the item 52 to be shipped may be placed on top of the pre-inserted dunnage pad. Thus, in appropriate circumstances, the AMR 12 may be routed through the dunnage dispensing station 30 both before and after the product delivery station 22.

[0044] When the box 14 is ready to be closed, the AMR 12 autonomously moves the box 14 to the lid application station 34. As part of applying a lid to the box, the lid application station 34 may include folding arms that fold upstanding flaps inward onto the open top side of the box 14 to partially or completely close the open top side of the box 14. If the flaps do not completely close the open side of the box 14, the lid application station 34 can place a lid on the box 14 to close the open side of the box 14, as shown in FIG. 3. In FIG. 3, the lid application station 34 is shown placing a lid 56 on the box 14 while the box 14 is mounted on the AMR 12. If the box 14 does not have flaps that need to be folded down before the lid is applied, an alternative lid application station 34 can be provided for boxes 14 without flaps.

[0045] After the lid 56 is placed on the box 14, the AMR 12 moves the box 14 to the labeling station 36, where a shipping label 60 can be applied to the box 14. In addition to, or instead of, simply applying the shipping label 60 to the box 14, the labeling station 36 can provide the shipping label 60 by printing it directly on the box 14 or by applying an adhesive label to the box 14 and then printing the shipping label on the adhesive label. Once the back-end processing is complete, the box 14 is removed from the AMR 12. The AMR 12 is then either returned to the AMR supply source or directed to the box supply station 20 to receive another box 14 until needed.

[0046] The packaging system 10 may include additional sensors adjacent to one or more final processing stations to check for non-conforming boxes. For example, as the AMR 12 leaves the dunnage dispensing station 30, the sensors may check for non-conforming conditions, such as improperly bent flaps, bulging sidewalls, or a box 14 that has become misaligned relative to the AMR 12, i.e., the sidewalls of the box 14 are no longer parallel to the sidewalls of the AMR 12. After determining that the box 14 is non-conforming, the system controller 40 sends an updated path signal (not shown) to the AMR 12 to change the previously determined path of the AMR 12 so that the AMR 12 can move the box to a final processing station to correct the non-conforming condition. The non-conforming box 14 can be made conforming by any suitable method, such as, for example, by an automated conforming station (not shown) or manually by an operator.

[0047] An exemplary final-stage box processing method 300 using the packaging system 10 described above is described below with reference to FIG. 5 . The method includes step 302 of providing the packaging system 10 having two or more final-stage box processing stations and one or more autonomous vehicles 12 configured to move boxes 14 between selected ones of the two or more final-stage box processing stations. The final-stage box processing stations include product delivery stations 22 where items 52 to be shipped are placed in the boxes 14 for shipping. The method also includes step 304 of loading the boxes 14 onto the autonomous vehicle 12 and transporting the boxes 14 to the selected ones of the two or more final-stage box processing stations. After the items 52 to be shipped are placed in the boxes 14, the method includes step 306 of scanning the boxes 14 to detect characteristics of the boxes 14 and the items 52 within the boxes 14. Finally, the method includes step 310 of directing the autonomous vehicle 12 to transport the boxes 14 from the product delivery stations 22 to the selected ones of the two or more final-stage box processing stations based at least in part on the detected characteristic information.

[0048] The loading step 304 includes assembling the box 14, such as at the box delivery station 20, and placing the box 14 on the autonomous vehicle 12. The scanning step 306 may include detecting one or more of a height dimension of the box, a width dimension of the box, a depth dimension of the box, a height dimension of one or more items in the box, non-conforming characteristics of the box, and a void volume of the box. The scanning step 306 may be repeated after the box 14 has been transported to at least one final box processing station. The guiding step 310 may include instructions to bypass the at least one final box processing station.

[0049] The method may further include selectively causing at least one of the one or more final-stage box processing stations, e.g., via system controller 40, to perform at least one of the one or more final-stage box processing operations on box 14. Box 14 may be onboard autonomous vehicle 12 when at least one of the one or more final-stage box processing operations is performed on box 14.

[0050] The method may further include detecting at least one characteristic of the box 14 and updating a path of the autonomous vehicle 12 based at least in part on the detected characteristic. The detecting step may include identifying the at least one detected characteristic that indicates the box 14 is unsuitable.

[0051] The method may also include transporting the boxes 14 to multiple final box processing stations where one or more processing steps are performed. Example processing steps include providing dunnage to the boxes 14, forming flaps on the boxes 14, folding the flaps inward on the open sides of the boxes 14, attaching and securing a lid to the open sides of the boxes 14, applying a shipping label to the boxes 14, and / or printing information directly on the boxes 14 or on labels pre-applied to the boxes 14.

[0052] In summary, packaging system 10 for back-end box processing includes two or more back-end box processing stations 20, 22, 24, 26, 30, 34, 36, each configured to perform one or more back-end processing operations, autonomous vehicle 12, and controller 40. Box processing stations 20, 22, 24, 26, 30, 34, 36 include a source of boxes 14, a product delivery station 22 where items 52 to be shipped are placed into the boxes 14, and sensors for detecting characteristics of the boxes 14 and the items within the boxes 14. Autonomous vehicle 12 is configured to autonomously transport boxes 14 from product delivery station 22 to a selected one of the two or more box processing stations 24, 26, 30, 34, 36. The controller 40 is in communication with the sensors at the box scanning station 24 and the autonomous vehicle 12 and is configured to selectively direct the autonomous vehicle 12 to transport the box 14 from the product delivery station 22 to a selected one of the two or more box processing stations 24, 26, 30, 34, 36 based at least in part on information from the sensors at the scanning station 24.

[0053] While the invention defined by the following claims has been shown and described with respect to particular embodiments, equivalent substitutes and modifications will occur to those skilled in the art upon reading and understanding this specification and the accompanying drawings. In particular, with respect to the various functions performed by the above-described components (parts, assemblies, devices, compositions, etc.), the terms used to describe such components (including references to "means") are intended, unless otherwise indicated, to correspond to (i.e., be functionally equivalent to) any component that performs the specified function of the described component, even if it is not structurally equivalent to the disclosed structure that performs that function in the exemplary embodiments of the invention described herein.

Claims

1. two or more end-of-line box processing stations each configured to perform one or more end-of-line box processing operations, the end-of-line box processing stations including a supply of boxes, a product delivery station where items to be shipped are placed into the boxes, and sensors for detecting characteristics of the boxes and the items within the boxes; an autonomous vehicle configured to autonomously transport the boxes from the product delivery station to a selected one of the two or more final processing box processing stations; a controller in operative communication with the sensor and the autonomous vehicle, the controller configured to selectively direct the autonomous vehicle to autonomously transport the box from the product delivery station to another selected one of the two or more final stage box processing stations based at least in part on information from the sensor.

2. The system of claim 1 , wherein the autonomous vehicle is an autonomous mobile robot.

3. 3. The system of claim 1 or claim 2, wherein the box is mounted on the autonomous mobile robot when at least one of the one or more end-of-line box processing operations is performed on the box.

4. The system of claim 1 , wherein the sensor is configured to detect at least one characteristic of the box, including at least one of a height dimension, a width dimension, and a depth dimension.

5. The system of claim 1 , wherein the at least one detected feature comprises a mismatch indicator for the box.

6. 6. The system of claim 1, wherein the controller is configured to guide the autonomous vehicle to autonomously transport the box along a path that bypasses at least one of the two or more final-stage box processing stations.

7. 7. The system of claim 1, wherein at least one of the two or more final bin processing stations is automated.

8. 8. The system of claim 1, wherein at least one of the two or more final step box processing stations comprises a first final step box processing station and a second final step box processing station located away from the first final step box processing station, whereby the autonomous vehicle is directed to selected ones of the first final step box processing station and the second final step box processing station, but is not directed to other ones of the first final step box processing station and the second final step box processing station.

9. The system of claim 8 , wherein the first final bin processing station and the second final bin processing station perform the same final bin processing operation.

10. 10. The system of claim 8 or claim 9, wherein the first final bin processing station and the second final bin processing station perform different final bin processing operations.

11. providing a packaging system having two or more final bin processing stations and one or more autonomous vehicles configured to move containers between selected ones of the two or more final bin processing stations, the final bin processing stations comprising a product delivery station where items to be shipped are placed into the containers for shipping; loading the container onto the autonomous vehicle to transport the container to a selected one of the two or more final stage bin processing stations; scanning the container after the items to be shipped are placed in the container to detect characteristics of the container and the items within the container; and guiding the autonomous vehicle to transport the container on a path from the product delivery station to a selected one of the two or more final destination box processing stations based at least in part on the detected characteristic information.

12. 12. The method of claim 11, further comprising causing at least one of the one or more final stage bin processing stations to selectively perform at least one of one or more final stage bin processing operations on the bin.

13. 13. The method of claim 11 or claim 12, wherein the box is onboard the autonomous vehicle when at least one of one or more end-of-line box processing operations is performed on the box.

14. The method of any one of claims 11 to 13, further comprising detecting at least one feature of the box and updating a path based at least in part on the detected feature.

15. 15. The method of any one of claims 11 to 14, wherein the detecting step comprises identifying at least one detected feature that indicates that the box is non-conforming.

16. 16. The method of any one of claims 11 to 15, wherein the directing step includes instructions to bypass at least one final bin processing station.

17. 17. The method of any one of claims 11 to 16, wherein the loading step includes assembling a box and placing the box on the autonomous vehicle.

18. 18. The method of any one of claims 11 to 17, wherein the scanning step includes detecting one or more of a height dimension of the box, a width dimension of the box, a depth dimension of the box, a height dimension of one or more items in the box, non-conforming characteristics of the box, and a void volume of the box.

19. 19. A method according to any one of claims 11 to 18, wherein the scanning step is repeated after the box has been transported to at least one final box processing station.

20. 20. The method of any one of claims 11 to 19, further comprising transporting the boxes to a plurality of final box processing stations.

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