Hybrid Order Fulfillment

Abstract

Aspects of the present invention relate to an order fulfillment system. The order fulfillment system may include an autonomous mobile robot (AMR). The AMR may travel to a shipping container guidance station to receive a shipping container from a shipping container forming machine for transport to various fulfillment stations. The AMR then transports the shipping container to one or more item loading stations and / or one or more product racks, where one or more products are manually or robotically placed within the shipping container. The AMR further travels to or through a closing station, where the shipping container is top-sealed and labeled. The AMR then moves the shipping container to a routing staging station, where the AMR releases the top-sealed and labeled shipping container for entry into a transport device. Conveniently, the AMR can maintain a grip on the shipping container during the entire fulfillment operation.

Description

[Technical Field]

[0001] FIELD OF THE DISCLOSURE The present disclosure relates generally to methods and systems for order fulfillment, and more particularly to order fulfillment based on collection items per order from multiple types of product storage areas. [Background technology]

[0002] Containers are used to package various types of products. One form of container used in the packaging industry is commonly known as a "box," which can be used to hold a variety of products and sometimes to hold other boxes that contain products. Some in the packaging industry refer to boxes used to package one or more products as "cartons." Other containers / boxes in the industry are referred to as "cases." In this patent document, including the claims, the terms "case," "box," "carton," "container," and "container" are used interchangeably to refer to boxes, cartons, trays, envelopes, and / or cases, etc., that can be used to package any type of item, including products and other cartons.

[0003] Cases come in a variety of shapes and are made from a variety of materials, but many cases are foldable and are formed from a flattened state (commonly called a carton blank). Cases may be made from an assortment of foldable materials, including, but not limited to, corrugated cardboard, chipboard, paperboard, corrugated fiberboard, other types of corrugated materials, plastic materials, composite materials, etc., and sometimes even combinations thereof.

[0004] The cases can be used to fulfill customer-initiated orders for one or more products by obtaining each product from one or more locations within a storage facility, such as a warehouse, loading the product into the case, sealing the loaded case, and shipping the loaded case to the customer. Summary of the Invention [Problem to be solved by the invention]

[0005] However, there are many obstacles to providing an efficient method and system for fulfilling customer orders. In particular, it is desirable to be able to fulfill orders for a large number of customers, each of whom may have orders for a wide variety and number of products. [Means for solving the problem]

[0006] According to one aspect of the present invention, an order fulfillment system is provided. The order fulfillment system includes a processor operable to generate carton formation instructions and generate autonomous mobile robot (AMR) instructions. The order fulfillment system further includes a carton formation system configured to receive the carton formation instructions from the processor, select carton blanks from a plurality of magazines in accordance with the carton formation instructions, and form the carton blanks into erected cartons. The order fulfillment system further includes an AMR configured to receive AMR instructions from the processor, move to the carton formation system in accordance with the AMR instructions, receive erected cartons from the carton formation system, move to a station in a product guidance area while holding the erected carton in accordance with the AMR instructions, receive product into the erected carton at the station, and move the erected carton with the product therein to a location for further processing in accordance with the AMR instructions.

[0007] According to another aspect of the present invention, an order fulfillment system is provided. The order fulfillment system includes a processor operable to generate shipping container selection instructions and generate autonomous mobile robot (AMR) instructions. The order fulfillment system further includes a shipping container distribution system configured to receive the shipping container selection instructions from the processor and select a selected shipping container from a plurality of shipping containers in accordance with the shipping container selection instructions. The order fulfillment system further includes an AMR configured to receive AMR instructions from the processor, move to the shipping container distribution system in accordance with the AMR instructions, receive the selected shipping container from the shipping container distribution system, move to a station in a product guidance area while holding the selected shipping container in accordance with the AMR instructions, receive the product into the selected shipping container at the station, and move the selected shipping container to a location for further processing while holding the selected shipping container with the product therein in accordance with the AMR instructions.

[0008] According to a further aspect of the present invention, a carton loading and sealing system is provided. The carton loading and sealing system includes an autonomous mobile robot (AMR), a processor operable to generate AMR instructions, a shipping container delivery system configured and operable to deliver a shipping container to the AMR, and a loading and sealing device operable to load and seal the shipping container as the AMR moves through the loading and sealing device with the shipping container loaded. The AMR may be configured and operable to receive the AMR instructions from the processor and, in accordance with the AMR instructions, move to and through the sealing device to seal the shipping container.

[0009] According to a further aspect of the present invention, there is provided an autonomous mobile robot (AMR) for transporting a receptacle. The AMR includes a mobile cart, a control system for controlling operation of the autonomous mobile robot, a first belt having an upper surface, a first lug secured to the upper surface of the first belt, a second belt having an upper surface, and a second lug secured to the upper surface of the second belt. The control system is operable to control and adjust the position of the first lug relative to the second lug to move between a first position where a spacing between the first lug and the second lug is suitable for allowing a receptacle to be positioned between the first lug and the second lug or removed from between the first lug and the second lug, and a second position where a spacing between the first lug and the second lug provides for the first lug and the second lug to engage with a side surface of the receptacle to secure the receptacle between the first lug and the second lug.

[0010] According to a further aspect of the present invention, an autonomous mobile robot (AMR) for transporting a receptacle is provided. The AMR includes a mobile cart, a control system for controlling operation of the autonomous mobile robot, and a receptacle securing mechanism operable to releasably secure the receptacle to the mobile cart during transport within a warehouse when the receptacle is carrying at least one product of a product order and when the receptacle is empty of any product. The control system is operable to control and coordinate operation of the receptacle securing mechanism between a first state in which the shipping container is secured to the mobile cart and movable within the warehouse, and a second state in which the receptacle is removable from the mobile cart, both when the receptacle is carrying at least one product of the product order and when the receptacle is empty of any product.

[0011] According to a further aspect of the present invention, a product unloading system is provided. The product unloading system includes a product rack for storing products. The product rack includes a plurality of storage levels for storing products thereon, the plurality of storage levels being spaced apart and vertically arranged within the product rack. The product rack further includes a plurality of elevated platforms configured for an autonomous mobile robot (AMR) to travel thereon, each of the plurality of elevated platforms being disposed proximate to a respective one of the plurality of storage levels. The product unloading system further includes an elevator system including a lifting platform for lifting the AMR between ground level and the plurality of elevated platforms. The product unloading system further includes a product picking robot for retrieving products from a storage level of the plurality of storage levels and unloading the products onto a receptacle held by the AMR in a corresponding one of the plurality of storage levels.

[0012] According to a further aspect of the present invention, a fulfillment system is provided. The order fulfillment system includes a processor operable to generate carton formation instructions, generate product removal instructions, and generate autonomous mobile robot (AMR) instructions. The order fulfillment system further includes a carton formation system configured to receive the carton formation instructions from the processor, select carton blanks from a plurality of magazines in accordance with the carton formation instructions, and form the carton blanks into erected cartons. The order fulfillment system further includes a product removal robot configured to receive product removal instructions from the processor and remove products from product racks at a product storage location in accordance with the product removal instructions. The order fulfillment system further includes an AMR configured to receive AMR instructions from the processor, move to the carton formation system in accordance with the AMR instructions, receive and move the erected cartons from the carton formation system in accordance with the AMR instructions, move to the product rack while holding the carton in accordance with the AMR instructions, receive the product from the product removal robot into the carton, and move the carton with the product therein to a location for further processing in accordance with the AMR instructions.

[0013] According to a further aspect of the present invention, a fulfillment system is provided. The fulfillment system includes a processor operable to generate receptacle delivery instructions and generate autonomous mobile robot (AMR) instructions. The fulfillment system also includes a carton delivery system configured to receive the receptacle delivery instructions from the processor and select a selected receptacle for delivery from a selection of receptacles in accordance with the receptacle delivery instructions. The fulfillment system includes an AMR configured to receive AMR instructions from the processor, move to the receptacle delivery system in accordance with the AMR instructions, receive the selected receptacle from the receptacle delivery system, move to a station in a product guidance area while holding the selected receptacle in accordance with the AMR instructions, receive the product in the selected receptacle at the station, and move to a location for further processing of the selected receptacle while holding the selected receptacle with the product therein in accordance with the AMR instructions.

[0014] According to a further aspect of the present invention, there is provided a fulfillment system including a processor operable to generate shipping container selection instructions and generate autonomous mobile robot (AMR) instructions, and a shipping container distribution system configured to receive the shipping container selection instructions from the processor and select a selected shipping container from a plurality of shipping containers in accordance with the shipping container selection instructions. The fulfillment system further includes an AMR configured to receive AMR instructions from the processor, and in accordance with the AMR instructions, move to a shipping container distribution system, receive a selected shipping container from the shipping container distribution system, and move to a station in a product guidance area while holding the selected shipping container in accordance with the AMR instructions, the product guidance area including a product tower, the product tower including a plurality of compartments for storing products, at least one of the plurality of compartments including one or more products, the one or more products corresponding to at least one stockkeeping unit, and in accordance with the instructions of the AMR, receive a first product into the selected shipping container at the station, and move to a predetermined product storage rack in a storage area while holding the selected shipping container, the storage area including a plurality of product storage racks that store products on pallets, receive a second product into the selected shipping container at the predetermined product storage rack, and in accordance with the instructions of the AMR, move the selected shipping container holding the first product and the second product therein to a location for further processing.

[0015] According to a further aspect of the present invention, there is provided a fulfillment system. The fulfillment system includes a processor operable to generate carton formation instructions, generate product removal instructions, and generate autonomous mobile robot (AMR) instructions. The fulfillment system also includes a carton formation system configured to receive the carton formation instructions from the processor, select a carton blank from a plurality of available carton blanks in accordance with the carton formation instructions, and form the carton blank into an erect carton. The fulfillment system also includes a product removal robot configured to receive product removal instructions from the processor and remove products from product storage locations in accordance with the product removal instructions. The fulfillment system further includes a reusable container, the reusable container containing a plurality of products used to fulfill the plurality of orders, the reusable container becoming an empty reusable container when the plurality of products are removed from the reusable container to fulfill the plurality of orders; an AMR configured to receive AMR instructions from the processor, move to a carton formation system in accordance with the AMR instructions, receive a stand-up carton from the carton formation system in accordance with the AMR instructions, move to a product loading station where the AMR moves while holding the stand-up carton, receive the products into the stand-up carton in accordance with the AMR instructions, and move the stand-up carton to a location for further processing while holding the stand-up carton, wherein further processing of the stand-up carton includes removing the stand-up carton from the AMR, thereafter moving to receive an empty reusable container in accordance with the AMR instructions, and moving to a location for further processing of the empty reusable container while holding the empty reusable container in accordance with the AMR instructions.

[0016] According to a further aspect of the present invention, a fulfillment system is provided. The fulfillment system includes a processor operable to generate shipping container delivery instructions, generate product retrieval instructions, and generate autonomous mobile robot (AMR) instructions. The fulfillment system also includes a shipping container delivery system configured to receive the shipping container delivery instructions from the processor and select a shipping container from a plurality of available shipping containers in accordance with the shipping container delivery instructions. The fulfillment system also includes a product retrieval robot configured to receive product retrieval instructions from the processor and retrieve products from the product storage location in accordance with the product retrieval instructions. The fulfillment system also includes a reusable container, the reusable container containing a plurality of products used to fulfill a plurality of orders, the reusable container becoming an empty reusable container once the plurality of products have been removed from the reusable container to fulfill the plurality of orders. The fulfillment system further includes an AMR configured to receive AMR instructions from the processor, move to the shipping container delivery system in accordance with the AMR instructions, receive the shipping container in accordance with the AMR instructions, move to a product loading station while holding the shipping container, and receive and move the products in the shipping container at the product loading station in accordance with the AMR instructions. Pursuant to the AMR's instructions, while retaining the shipping container, moving the shipping container to a location for further processing; further processing the shipping container includes removing the shipping container from the AMR, then, pursuant to the AMR's instructions, moving and receiving the empty reusable container on the AMR, and pursuant to the AMR's instructions, while retaining the empty reusable container, moving the empty reusable container to a location for further processing.

[0017] According to a further aspect of the present invention, a method for receiving products at a fulfillment center is provided. The method includes transmitting instructions to a first autonomous mobile robot (AMR), causing the first AMR to navigate to a crate-holding structure in a first transport trailer, the crate-holding structure holding a crate containing a plurality of products, and transporting the crate-holding structure to a product guidance area where individual products of the plurality of products can be removed from the crate. The method further includes transmitting instructions to a second AMR, causing the second AMR to navigate in the product guidance area to the crate-holding structure where the crate no longer contains products, transport the crate-holding structure to a second transport trailer, and navigate away from the second transport trailer without the crate-holding structure.

[0018] According to one aspect of the present disclosure, an autonomous mobile robot for transporting shipping containers is provided. The autonomous mobile robot includes a mobile cart, a control system for controlling operation of the autonomous mobile robot, and an outer case mounted to the cart. The outer cart includes a vacuum reservoir defining a plurality of apertures, a vacuum pump pneumatically coupled to the vacuum reservoir, the vacuum pump configured to create a negative pressure within the vacuum reservoir in response to commands received from the control system, and a plurality of suction cups mounted to the outer case, the plurality of suction cups corresponding to the plurality of apertures.

[0019] According to one aspect of the present disclosure, there is provided an outer casing for mounting on a mobile cart of an autonomous mobile robot (AMR) for transporting shipping containers, the outer casing including a control system for controlling operation of the AMR, the outer casing having a vacuum reservoir defining a plurality of apertures, a vacuum pump pneumatically coupled to the vacuum reservoir, the vacuum pump responsive to commands received from the control system to create a negative pressure within the vacuum reservoir, and a plurality of suction cups mounted on the outer casing, the suction cups corresponding to the plurality of apertures.

[0020] According to one aspect of the present disclosure, an autonomous mobile robot for transporting shipping containers is provided, the autonomous mobile robot including a base, at least three wheels configured to support the base, at least one of the wheels being a drive wheel operatively coupled to a drive motor, a control system for controlling operation of the drive motor corresponding to movement of the base and controlling movement of the drive wheels, a vacuum reservoir interconnected to the base and defining a plurality of openings, a vacuum pump pneumatically coupled to the vacuum reservoir, the vacuum pump responsive to commands received from the control system to create a negative pressure within the vacuum reservoir, and a plurality of suction cups interconnected to the base, the plurality of suction cups corresponding to the plurality of openings.

[0021] According to one aspect of the present disclosure, a method of fulfilling an order is provided that includes moving an autonomous mobile robot to a shipping container loading station, receiving an empty shipping container on the autonomous mobile robot, generating a suction force with at least some of the suction cups to hold the empty shipping container on the autonomous mobile robot, and moving the autonomous mobile robot to the item loading station while the suction force is being generated with at least some of the suction cups to hold the shipping container on the autonomous mobile robot.

[0022] Other aspects and features of the present invention will become apparent to those of ordinary skill in the art upon review of the following description of specific embodiments of the invention in conjunction with the accompanying figures.

[0023] 1A and 1B are diagrams illustrating exemplary embodiments of the present invention. [Brief explanation of the drawings]

[0024] [Figure 1A] FIG. 1A is a top right front perspective view of a portion of a carton forming system according to an exemplary embodiment of the present application. [Figure 1B]FIG. 1B is a schematic flow chart diagram illustrating the power and control subsystems of a portion of the carton forming system of FIG. 1A, in accordance with an embodiment of the present invention. [Figure 2] FIG. 2 is a top right rear perspective view of the carton forming system of FIG. 1A. [Figure 3] FIG. 3 is a top right side perspective view of the carton forming system of FIG. 1A. [Figure 4] FIG. 4 is a front schematic elevational view of the carton forming system of FIG. 1A with some components omitted. [Figure 5] FIG. 5 is a schematic rear elevational view of the carton forming system of FIG. 1A with some components omitted. [Figure 6A] FIG. 6A is a top right perspective view of a magazine subsystem according to an embodiment of the present application. [Figure 6B] FIG. 6B is a top right perspective view of the magazine subsystem of FIG. 6A with some components omitted. [Figure 6C] FIG. 6C is a right side elevational view of the magazine subsystem of FIG. 6A with some components omitted. [Figure 6D] FIG. 6D is a top view of the magazine subsystem of FIG. 6A. [Figure 7] FIG. 7 is a right side perspective view of the carton forming system of FIG. 1A, with some components removed to show the blank intake system, two erector heads with moving devices, and the folding and sealing device. [Figure 8] 8 is a top right rear perspective view of the components of FIG. 7. FIG. [Figure 9] 9 is a top right front perspective view of the components of FIG. 7. FIG. [Figure 10A] FIG. 10A is a plan view of a conventional slotted case blank of generally flattened tubular configuration. [Figure 10B] FIG. 10B is a front elevational view of a blank for the conventional slotted case of FIG. 10A. [Figure 10C]FIG. 10C is a side elevational view of a blank for the conventional slotted case of FIG. 10A. [Figure 10D] FIG. 10D is a perspective view of the conventional slotted case blank of FIG. 10A. [Figure 10E] FIG. 10E is another perspective view of the conventional slotted case blank of FIG. 10A. [Figure 11] FIG. 11 is a schematic right perspective view of the blank of FIG. 10A configured in an open configuration. [Figure 12] FIG. 12 is a schematic right perspective view of the blank of FIG. 11 after successive steps of forming the blank into an upstanding carton. [Figure 13] FIG. 13 is a schematic right perspective view of the blank of FIG. 12 after successive steps of forming the blank into an upstanding carton. [Figure 14] FIG. 14 is a schematic right perspective view of the blank of FIG. 13 after successive steps of forming the blank into a stand-up carton. [Figure 15] FIG. 15 is a schematic right perspective view of the blank of FIG. 14 after successive steps of forming the blank into an upstanding carton. [Figure 16] FIG. 16 is a schematic right perspective view of the blank of FIG. 15 after successive steps of forming the blank into an upstanding carton. [Figure 17] FIG. 17 is a schematic right perspective view of the carton forming system of FIG. 1A in sequential steps of converting the blank of FIG. 10A into an erect carton in accordance with an embodiment of the present invention, but showing only a single transfer device, an erector head, and a portion of the folding and sealing device. [Figure 18] 18 is a schematic right perspective view of the carton forming system of FIG. 17 in sequential steps of converting the blank of FIG. 10A into an erect carton in accordance with an embodiment of the present invention. [Figure 19] 19 is a schematic right perspective view of the carton forming system of FIG. 17 of sequential steps in converting the blank of FIG. 10A into an upstanding carton, according to an embodiment of the present invention. [Figure 20]20 is a schematic right perspective view of the carton forming system of FIG. 17 of sequential steps in converting the blank of FIG. 10A into an upstanding carton, according to an embodiment of the present invention. [Figure 21] 21 is a schematic right perspective view of the carton forming system of FIG. 17 of sequential steps in converting the blank of FIG. 10A into an upstanding carton, according to an embodiment of the present invention. [Figure 22] 22 is a schematic right perspective view of the carton forming system of FIG. 17 of sequential steps in converting the blank of FIG. 10A into an upstanding carton, according to an embodiment of the present invention. [Figure 23] 23 is a schematic right perspective view of the carton forming system of FIG. 17 of sequential steps in converting the blank of FIG. 10A into an upstanding carton, according to an embodiment of the present application. [Figure 24] 24 is a schematic right perspective view of the carton forming system of FIG. 17 in sequential steps of converting the blank of FIG. 10A into an upstanding carton, according to an embodiment of the present invention. [Figure 25] 25 is a schematic right perspective view of the carton forming system of FIG. 17 of sequential steps in converting the blank of FIG. 10A into an upstanding carton, according to an embodiment of the present invention. [Figure 26] FIG. 26 is a rear elevational view showing the components of the carton forming system of FIG. [Figure 26A] FIG. 26A is a schematic perspective view of a portion of the folding and sealing device of the carton forming system of FIG. 1A. [Figure 27] 27 is a schematic right perspective view of the carton forming system of FIG. 17 in sequential steps of converting the blank of FIG. 10A into an erect carton, according to an embodiment of the present invention. [Figure 28] 28 is a schematic right perspective view of the carton forming system of FIG. 17 of sequential steps in converting the blank of FIG. 10A into an upstanding carton, according to an embodiment of the present invention. [Figure 29] 29 is a schematic right perspective view of the carton forming system of FIG. 17 of sequential steps in converting the blank of FIG. 10A into an upstanding carton, according to an embodiment of the present invention. [Figure 30]FIG. 30 is a top right perspective view of a first embodiment of an erector head in accordance with aspects of the present invention. [Figure 31] FIG. 31 is a side elevational view of the erector head of FIG. 30. [Figure 32] 32 is a bottom right perspective view of the erector head of FIG. 30. FIG. [Figure 33] 33 is a bottom view of the erector head of FIG. 30. FIG. [Figure 34A] FIG. 34A is a top right perspective view of a second embodiment of an erector head in accordance with aspects of the present invention. [Figure 34B] FIG. 34B is a right side elevation view of the erector head of FIG. 34A. [Figure 35A] FIG. 35A illustrates the erector head of FIG. 34A in a step of opening a carton blank, according to an embodiment of the present invention. [Figure 35B] FIG. 35B illustrates the erector head of FIG. 34A in another step of opening the carton blank, according to an embodiment of the present application. [Figure 35C] FIG. 35C illustrates the erector head of FIG. 34A in a further step of opening the carton blank, according to an embodiment of the present invention. [Figure 36] FIG. 36 illustrates the erector head and sealing device of FIG. 34A during the step of erecting a carton blank, thereby forming an erected carton, in accordance with an embodiment of the present invention. [Figure 37] FIG. 37 illustrates the erector head and sealing device of FIG. 34A during the step of erecting a carton blank, thereby forming an erected carton, in accordance with an embodiment of the present invention. [Figure 38] FIG. 38 illustrates the erector head and sealing device of FIG. 34A during the step of erecting a carton blank, thereby forming an erected carton, in accordance with an embodiment of the present invention. [Figure 39]FIG. 39 illustrates the erector head and sealing device of FIG. 34A during the step of erecting a carton blank, thereby forming an erected carton, in accordance with an embodiment of the present invention. [Figure 40] FIG. 40 illustrates the erector head and sealing device of FIG. 34A during the step of erecting a carton blank, thereby forming an erected carton, in accordance with an embodiment of the present invention. [Figure 41] FIG. 41 illustrates the erector head and sealing device of FIG. 34A during the step of erecting a carton blank, thereby forming an erected carton, in accordance with an embodiment of the present invention. [Figure 42] FIG. 42 illustrates the erector head and sealing device of FIG. 34A during the step of erecting a carton blank, thereby forming an erected carton, in accordance with an embodiment of the present invention. [Figure 43] FIG. 43 illustrates the erector head and sealing device of FIG. 34A during the step of erecting a carton blank, thereby forming an erected carton, in accordance with an embodiment of the present application. [Figure 44] FIG. 44 illustrates the erector head and sealing device of FIG. 34A during the step of erecting a carton blank, thereby forming an erected carton, in accordance with an embodiment of the present invention. [Figure 45] FIG. 45 is a schematic perspective view of an alternative embodiment of a carton forming system in accordance with an aspect of the present invention. [Figure 46] FIG. 46 is a plan view of a carton blank for a tray processed in accordance with an embodiment of the present invention. [Figure 47] FIG. 47 is a perspective view of a carton blank for an overlapping regular slotted case (RSC) processed in accordance with an embodiment of the present invention. [Figure 48] FIG. 48 is a perspective view of a carton blank for an overlapping regular slotted case (RSC) fabricated in accordance with an embodiment of the present invention. [Figure 49]FIG. 49 is a perspective view of an HSC case formed in accordance with an embodiment of the present invention. [Figure 50] FIG. 50 illustrates a carton forming system according to an embodiment of the present invention, presented as an alternative to the carton forming system of FIG. 1A. [Figure 51] FIG. 51 is a plan view of a carton forming system presented as an alternative to the carton forming system of FIG. 50, in accordance with an embodiment of the present invention. [Figure 52] FIG. 52 is a schematic plan view of an order fulfillment location in accordance with an embodiment of the present invention. [Figure 53] FIG. 53 is a top right perspective view of an exemplary autonomous mobile robot having a cart carrying an outer case in accordance with an embodiment of the present invention. [Figure 53A] FIG. 53A is a top right perspective view of the exemplary autonomous mobile robot of FIG. 53 with the addition of a shipping container. [Figure 54] FIG. 54 is a cross-sectional perspective view of the autonomous mobile robot of FIG. 53 in accordance with an embodiment of the present invention. [Figure 55A] 55A is a cross-sectional view of a portion of the outer case of the autonomous mobile robot of FIG. 53, in accordance with an embodiment of the present invention. [Figure 55B] 55B is a cross-sectional view of a portion of the outer casing of the autonomous mobile robot of FIG. 53, in accordance with an embodiment of the present invention. [Figure 56] FIG. 56 is a schematic plan view of a portion of a fulfillment center. [Figure 56A] FIG. 56A is a schematic plan view of one embodiment of an order fulfillment center. [Figure 57] FIG. 57 is a diagram illustrating exemplary steps in a method for fulfilling an order, according to an aspect of the present invention. [Figure 58] FIG. 58 illustrates a further exemplary autonomous mobile robot in accordance with an embodiment of the present invention. [Figure 59]FIG. 59 is a schematic plan view of a carton forming system having multiple magazines, which is an alternative embodiment of the carton forming system of FIGS. 1-44 in accordance with an aspect of the present invention, with some components of the magazines omitted for clarity. [Figure 60] 60 is a rear right side perspective view of the carton forming system of FIG. 59 according to an embodiment of the present invention. [Figure 60A] FIG. 60A is an enlarged view of a portion of the carton forming system of FIG. 60 illustrating additional components in accordance with an embodiment of the present invention. [Figure 61] 61 is a rear left side perspective view of the carton forming system of FIG. 59 according to an embodiment of the present invention. [Figure 62] 62 is a rear perspective view of the carton forming system of FIG. 59 according to an embodiment of the present invention. [Figure 63] 63 is a rear perspective view of a portion of the carton forming system of FIG. 59 according to an embodiment of the present invention. [Figure 64] FIG. 64 is a schematic diagram of an order fulfillment system in accordance with an embodiment of the present invention. [Figure 65] FIG. 65 illustrates a sample label formed and used in the system of FIG. 64, in accordance with an embodiment of the present invention. [Figure 66] FIG. 66 is a diagram illustrating another sample label formed and used in the system of FIG. 64, in accordance with an embodiment of the present invention. [Figure 67] FIG. 67 is a diagram showing a sample case packaging diagram generated and used in the system of FIG. [Figure 68] FIG. 68 is a front left perspective view showing an example of a case top sealer arrangement according to an embodiment of the present invention. [Figure 69] FIG. 69 is a schematic plan view of an order fulfillment location in accordance with an exemplary embodiment of the present invention. [Figure 70] 70 is a perspective view of a portion of a product unloading system of the order fulfillment center of FIG. 69 according to an exemplary embodiment of the present invention. [Figure 71] FIG. 71 is a top schematic view of an embodiment of the order fulfillment center of FIG. 69, in accordance with an exemplary embodiment of the present invention. [Figure 72] 72 is a perspective view of a plurality of case induction stations of the order fulfillment center of FIG. 69. [Figure 73] 73 is a perspective view of the order verification, case sealing and labeling station of the order fulfillment center of FIG. 69. [Figure 74] FIG. 74 is a perspective view of a shipping staging station of the order fulfillment center of FIG. 69. [Figure 75] FIG. 75 is a perspective view of a tower used to store products according to an exemplary embodiment of the present invention. [Figure 76] FIG. 76 is a schematic plan view of an order fulfillment location that can be considered a hybrid between the order fulfillment center of FIG. 52 and the order fulfillment center of FIG. 69, in accordance with an exemplary embodiment of the present invention. [Figure 76A] FIG. 76A is a schematic plan view of the order fulfillment location of FIG. 76 with additional reference to multiple partitions, in accordance with an exemplary embodiment of the present invention. [Figure 77] FIG. 77 illustrates a robotic picker arm used in a depalletization step involving pallets, according to an exemplary embodiment of the present invention. [Figure 78A] FIG. 78A is a side view of a destrapper-debander end effector engaged by the robotic picker arm of FIG. 77 for a depalletization process in accordance with an exemplary embodiment of the present invention. [Figure 78B] FIG. 78B is a top view of the destrapper-debander end effector of FIG. 78A. [Figure 79] FIG. 79 is a perspective view of a standardized storage case according to an exemplary embodiment of the present invention. [Figure 80] FIG. 80 is a perspective view of a pallet constructed using the standardized storage case and standardized pallet base of FIG. 79 in accordance with an exemplary embodiment of the present invention. [Figure 81] FIG. 81 is a perspective view of multiple crates stacked on the autonomous mobile robot of FIG. 53, in accordance with an exemplary embodiment of the present invention. [Figure 82A] FIG. 82A is a schematic plan view of an order fulfillment location as an alternative to the order fulfillment center of FIG. 76, in accordance with an exemplary embodiment of the present invention. [Figure 82B] FIG. 82B is a schematic plan view of an order fulfillment location as an alternative to the order fulfillment center of FIG. 82A, according to an exemplary embodiment of the present invention. [Figure 83] FIG. 83 is a perspective view of multiple crates supported on a structure on the autonomous mobile robot of FIG. 53, in accordance with an exemplary embodiment of the present invention. [Figure 84] FIG. 84 is a perspective view of multiple crates supported on a further structure on an autonomous mobile robot in accordance with an exemplary embodiment of the present invention. [Figure 85] FIG. 85 is a diagram illustrating a layout of a transport trailer in accordance with an exemplary embodiment of the present invention. [Figure 86] FIG. 86 is a diagram illustrating a customer order processing matrix according to an exemplary embodiment of the present invention. [Figure 87] FIG. 87 is a schematic diagram of an order fulfillment center at the center of a network of suppliers of products stored at the order fulfillment center, according to an exemplary embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0025] The adage "Garbage in, garbage out" (often abbreviated as GIGO) is a common phrase in computer science and information technology. It conveys a simple yet important principle: the quality of the output or result is only as good as the input data.

[0026] In short, if you feed a computer system or algorithm inaccurate, incomplete, or poor-quality data, you can expect the output or results to be similarly flawed or unreliable. No matter how sophisticated a system is, if the input data is flawed, the output is likely to be flawed as well.

[0027] This principle applies to a variety of systems, not just computers. It can also be applied to areas such as decision-making, problem-solving, general information processing, and automation. It emphasizes the importance of ensuring all inputs are accurate, well-structured, and relevant to the problem at hand in order to obtain meaningful and reliable results. Chaos refers to extreme disorder and unpredictability in a system. The automation industry knows from experience that chaos cannot be fully automated. Chaos theory describes complex systems that are highly sensitive to their initial conditions. This means that slight changes in the initial conditions can lead to vastly different outcomes over time. Such systems are nonlinear, making their behavior difficult to accurately predict.

[0028] Automation is the use of machines, computers, or algorithms to perform tasks without human intervention. Automation relies on established rules, algorithms, or processes to perform tasks efficiently and consistently. Chaotic systems are difficult to automate effectively because of their inherent unpredictability and sensitivity to initial conditions. Because automation relies on predictability and well-defined processes, it can be difficult to create algorithms or machines that can accurately handle chaotic situations.

[0029] Order fulfillment, and more specifically, order fulfillment based on collecting items for an order from multiple types of product storage areas, can present various challenges in providing efficient methods and systems for fulfilling orders. Automating the consolidation of products needed to fulfill an order can be challenging, especially considering the number of different products a fulfillment center may store and manage. For example, some fulfillment centers may store and manage millions of different products to fulfill orders. Additionally, there may be little control over how the products stored at a fulfillment center arrive at the fulfillment center.

[0030] 1A, 1B, 2, and 3 show an example of a carton / case forming system 100, in various configurations and from various angles, that may be used as part of a product order fulfillment system. The carton forming system 100 may include a frame 109. The frame 109 may be made of plastic or glass and may have integral therewith a series of panels 103, which may or may not be transparent or translucent. One or more of the panels 103 may be configured to operate as hinged doors to provide access to an interior portion of the carton forming system 100. The carton forming system 100 may also include a magazine 110 adapted to receive, hold, and move a plurality of carton blanks 111 while the carton blanks 111 are in a substantially flat orientation. The carton forming system 100 may include at least a first erector head 120a and a second erector head 120b for removing the carton blanks from the magazine 110. The erector heads 120a, 120b can pick up carton blanks 111 from the magazine 110 and then, with the assistance of other components of the carton forming system 100, manipulate the carton blanks 111 so that they are transformed into erect cartons.

[0031] The erector heads 120a, 120b can be moved by a movement subsystem. The movement subsystem may include one or more movement devices. For example, the first erector head 120a may be attached to and moved by the first movement device 115a. The second erector head 120b may be attached to and moved by the second movement device 115b. In some embodiments, only a single erector head and movement device may be provided, but this may result in a lower production rate of erected cartons compared to when multiple, particularly two or even more, movement devices and erector heads are provided, as shown in the drawings.

[0032] Carton forming system 100 may also include a folding and sealing device 130, which may be configured to fold one or more flaps of each carton blank and provide sealing of the one or more flaps as part of the process in forming a fully erect carton. In cooperation with erector heads 120a, 120b, folding and sealing device 130 may be configured to alternately process carton blanks 111 conveyed by both first erector head 120a and second erector head 120b. Carton forming system 100 may also include a carton discharge conveyor 117 for receiving and moving carton blanks 111 once they are fully erected.

[0033] The structural / mechanical components of the carton forming system 100 may be made from any suitable material. For example, the frame members and many of the parts and members that make up the erector heads 120a, 120b, the moving devices 115a, 115b, the folding and sealing device 130, and the magazine 110 may be made from steel or aluminum, or any other suitable material. Aluminum is particularly suitable for most parts. However, the plates that hold the suction cups on the erector heads and the flanges that attach to the gearbox shafts can be made from stainless steel for strength and hardness. The parts and components can be attached together by conventional methods, such as bolts, screws, or welding.

[0034] An example power and data / communications configuration scheme for carton forming system 100 is shown in FIG. 1B. The components of carton forming system 100, and the operation of carton forming system 100 as a whole, may be controlled by a programmable logic controller (“PLC”) 132. PLC 132 is accessible to a human operator via a human-machine interface (HMI) module 133 secured to frame 109. HMI module 133 may communicate electronically with PLC 132. PLC 132 may be any suitable PLC, including, for example, a unit selected from the Logix 5000 series of devices manufactured by Allen-Bradley / Rockwell Automation, such as a ControlLogix 5561 device. HMI module 133 may be an Allen-Bradley / Rockwell Automation Panelview part number 2711P-T15C4D1 module. It should be noted that not all of the sensors, motors, servo motors, drives, vacuum devices, vacuum generators and vacuum cups described below are specifically identified in FIG. 1B.

[0035] Power can be provided to the PLC 132 / HMI 133 and all of the various servo motors and DC motors described further herein. Compressed / pressurized air can also be provided to vacuum generators and pneumatic actuators via valve devices, such as solenoid valves, controlled by the PLC 132, as described further herein. The servo motors can be connected to and communicate with servo drives that are in communication with and controlled by the PLC 132. Similarly, the DC motors can be connected to DC motor drives that are in communication with and controlled by the PLC 132. Additionally, various other sensors are in communication with the PLC 132 and may be provided with power (although not shown).

[0036] 10A-10E and 11A, an example of one type of tubular carton blank 111 that can be processed by system 100 to form regular slotted cases (RSCs) is disclosed. It will be apparent that other types of carton blanks, tubular carton blanks, and tubular carton blanks of different sizes can be processed by system 100.

[0037] Each carton blank 111 may be provided in a generally initially formed and flattened tubular configuration, as shown in Figures 10A, 10B, 10C, 10D, and 10E. Each carton blank 111 has a height dimension "H," a length dimension "L," and a major panel length "Q" (see Figure 10A). In response to each of these three dimensions being input into PLC 132 for a given carton blank 111 to be processed by carton forming system 100, PLC 132 can determine whether carton forming system 100 can process the given carton blank 111 without requiring manual intervention to make adjustments to one or more components of carton forming system 100. If PLC 132 determines that adjustments can be made without human intervention, PLC 132 can make the necessary adjustments to the position and / or movement of at least some of the components forming carton forming system 100, including the path of movement of erector heads 120a, 120b as they move through the processing sequence.

[0038] However, in some carton forming systems 100, depending on the size of the carton blank 111, the PLC 132 may determine that some human intervention would facilitate making setup adjustments to the position / orientation of at least some of the components of the carton forming system 100 to enable the carton forming system 100 to process the carton blank 111, and may notify the operator of the carton forming system 100 accordingly.

[0039] The carton blank 111 may have opposing major panels A and C integrally interconnected with a pair of opposing minor panels B and D to form a generally cubic-shaped blank when open. An overlapping strip of carton blank material may be provided between panels B and A, which may be sealed by conventional means, such as a suitable adhesive, to provide an overlap seam joint near "P" (see FIG. 10A). This overlap may join panels A, B, C, and D into a continuous blank having a generally flattened tubular configuration, as shown in FIG. 10A. A number of such carton blanks 111 in a flattened configuration may be delivered to a carton forming system 100, which may erect the carton blanks 111 into a generally open tubular configuration, such as that shown in FIG. 11.

[0040] Also, as shown in FIGS. 10A-10E and 11, the carton blank 111 can have a first set of upper major and minor flaps E, H, L, I disposed on one side of each major and minor panel A, B, C, D, and a second set of major and minor flaps F, G, K, J disposed on the opposite, lower / bottom side of each major and minor panel A, B, C, D. The panels and flaps can be connected to adjacent flaps and / or panels by predetermined creases / fold lines (shown in dashed lines). These creases / fold lines can be formed, for example, by weakened areas of the material and / or by creases created by a crease-forming device. The effect of the fold lines is such that one panel, such as panel A, can rotate relative to an adjacent panel, such as panel D or panel B, along the fold line. The flaps can also be folded and rotated about the fold lines connecting the flaps to their respective panels.

[0041] As shown in FIG. 11 , the carton blank 111 may be designated with a first datum line "Wl" that passes through the midpoint of the fold line between panel D and flap K and the midpoint of the fold line between panel B and flap J. The first datum line Wl may be determined by the PLC 132 for a particular carton blank 111 or a group of carton blanks 111 being processed based on input of the carton blank's 111 dimensions H, L, and Q. The carton blank 111 may also be designated with a second datum line "W2," which may be determined by the PLC 132, that passes along the fold line between panel A and flap F and is generally parallel to the second datum line W2. The PLC 132 can also determine the relative position of the bottom of the erect carton because it is aligned with a vertical datum plane that passes through the first datum line Wl and the second datum line W2. Aligning the position of the second datum line W2 and the position of the datum plane with other components within carton forming system 100 can be demonstrated to ensure that the carton is properly positioned during processing through system 100. Additionally, the vertical distance R between the first datum line Wl and the second datum line W2 can be calculated by PLC 132. This calculation ensures that PLC 132 knows where the erector head needs to be positioned so that the top plate A, and accordingly the first datum line Wl, are properly positioned throughout the processing of the blank through carton forming system 100.

[0042] The carton forming system 100 may be shown to be capable of tracking and correcting the position of the carton blank 111, particularly the vertical position of the first reference line W1 of the carton blank 111, as the carton blank 111 moves longitudinally through the carton forming system 100 and as various components of the carton forming system 100 engage the carton blank 111 during its movement. This may be shown to ensure that the carton blank 111 being processed is properly positioned relative to the system components, and that the system components engage the carton blank 111 at the correct position on the carton blank 111 during processing of the carton blank 111.

[0043] As described below, the carton blank 111 can be transformed from a generally flattened tubular configuration to an open tubular configuration, and the flaps folded and sealed to form a desired stand-up carton configuration. Stand-up cartons can be configured as open-top cartons with upwardly facing openings or side-facing openings suitable for loading onto a carton loading conveyor.

[0044] The carton blank 111 may have flaps that interconnect the flap surfaces to bond or otherwise interconnect the flaps to adjacent flaps (or in some embodiments, the flaps to panels), in combination with a connecting mechanism (e.g., application of adhesive, sealing tape, or mechanical connections such as those provided in so-called "Klick-lok™" carton blanks), providing a material that can hold the carton in its desired erected configuration.

[0045] The carton blank 111 may be made of any suitable material(s) configured and adapted to allow the necessary folding / bending / displacement of the material to reach the desired configuration. Examples of suitable materials include chipboard, corrugated cardboard, creased corrugated cardboard, etc. It should be noted that the carton blank 111 may also be formed of a material that is rigid or semi-rigid and cannot be easily folded by itself, but is divided into separate panels and flaps separated by creases or hinge-type mechanisms to allow the carton blank 111 to be formed upright.

[0046] Turning now to the components of carton forming system 100, a variety of specific configurations of suitable magazine 110 may be employed in carton forming system 100. Referring now particularly to Figures 3, 6A, 6B, 6C, 6D, and 7, magazine 110 may be configured to hold a plurality of carton blanks 111 in a vertically stacked and flattened configuration and may be operable, under the control of PLC 132, to longitudinally move the stack of carton blanks 111 in a direction generally parallel to longitudinal axis Y to a pickup position where first erector head 120a or second erector head 120b can remove a carton blank 111 from magazine 110.

[0047] The magazine 110 may consist of a single conveyor or other blank delivery device configured to deliver the carton blanks 111 to a pickup location. In the embodiment shown in FIGS. 1A-9, two conveyors (infeed conveyor 204 and alignment conveyor 206) are disclosed. However, as described below in connection with other embodiments, the blank delivery device may be configured with multiple infeed conveyors to deliver carton blanks 111 from multiple magazines holding carton blanks 111 having different configurations. This allows the carton forming system 100 to automate the selective, sequential erection of cartons of different sizes, types, and / or configurations.

[0048] 1A-9 , the infeed conveyor 204 may be configured and operable to move a stack of carton blanks 111 from a stack input location (where the stack may be loaded onto the infeed conveyor 204, such as by a human or robotic device) to a location where the stack of carton blanks 111 is transferred to a horizontally and laterally aligned alignment conveyor 206. The alignment conveyor 206 may be positioned longitudinally downstream from the infeed conveyor 204 and may be used to move the stack of carton blanks 111 to a pickup location. The magazine 110 may load and initially hold a number of carton blanks 111 in a vertical stack, the stack resting on the infeed conveyor 204. A rear wall 212 attached to the bottom of the magazine frame, generally designated 202, may be configured to prevent one or more stacks from tipping backward when initially loaded onto the infeed conveyor 204. The rear wall 212 may have a generally planar, vertically and laterally oriented surface facing the stack of carton blanks 111. The rear wall 212 and infeed conveyor 204 may have an appropriate length so that a sufficient number of stacks of carton blanks 111 can be stored in series on the infeed conveyor 204. The PEC 132 may control the operation of the infeed conveyor 204 to move one stack at a time to the alignment conveyor 206.

[0049] The infeed conveyor 204 may have one or more stacks of carton blanks 111 arranged longitudinally on the infeed conveyor belt 214 so that they can be sequentially fed onto the alignment conveyor 206. A sensor may be provided near the infeed conveyor 204 to monitor the number of stacks waiting on the infeed conveyor 204, and the sensor may be operable to send a warning signal to the PEC 132 that can alert an operator that the magazine 110 is low and needs to be replenished (e.g., because only stacks being processed by the erector head 120 remain on the alignment conveyor 206). The sensor may be Allen-Bradley part number 42GRP-9000-QD.

[0050] Of particular note, multiple stacks of carton blanks 111 may be provided on the in-feed conveyor 204. Each stack may include some information indicator that can be read by an information reading device, such as an electronic or optical reader. For example, a barcode may be provided on the stack of carton blanks 111, such as on the top carton blank 111 or the bottom carton blank 111 of the stack. The barcode may be read by an appropriately positioned barcode reader. The barcode reader may be in communication with the PLC 132. The barcode may provide information that indicates characteristics of the carton blanks 111 in the stack. For example, the barcode may identify the size and / or type of carton blank 111 in a particular stack. Other information indicators and reading systems may also be used, such as radio frequency identifier (RFID) tags / chips and RFID readers. The information may then be automatically provided by the information reader to the PEC 132, which may determine, without manual adjustments to any components, whether the current configuration of the carton forming system 100 is capable of handling the processing of a particular type / size of carton blank 111. It is contemplated that within a certain range of types / sizes of carton blanks 111, the carton forming system 100 may be able to handle the processing of different types / sizes of carton blanks 111 without manual adjustments to any components of the system 100.The barcode / RFID tag, as described above, can provide information regarding the dimensions of the carton blank 111, and the PEC 132 can then determine adjustments, if any, to (a) the operation of the erector apparatus, (b) the magazine 110 and the tamping apparatus therein, (c) to provide an appropriate path for movement of the transfer subsystem to provide proper pickup of the blanks from the magazine and proper handling by the erector apparatus and the folding and sealing apparatus, and (d) to components of the folding and sealing apparatus to enable processing of a particular carton blank 111 or a particular stack of carton blanks 111. As a result, the carton forming system 100 can automatically process at least several different types / sizes / configurations of carton blanks 111 to form different erect cartons without manual operator adjustments to any of the components of the carton forming system 100.

[0051] The in-feed conveyor 204 may include a series of lateral and horizontal rollers 210 mounted for free rotation to the bottom of the magazine frame 202. The rollers 210 may enable generally horizontal longitudinal downstream movement of the stacks toward the alignment conveyor 206. An in-feed conveyor belt 214 may be provided and may be driven by a suitable in-feed motor 291, such as a direct current (DC) motor or a variable frequency drive motor (see FIG. 1B). The in-feed motor 291 may be a DC motor and may be controlled by the PLC 132 via a DC motor drive (all sold by Oriental as model AXH-5100-KC-30).

[0052] The in-feed conveyor belt 214 can have an upper belt portion supported on rollers 210. When commands are given to the PLC 132 (such as by a human operator via the HMI module 133), the upper belt portion of the in-feed conveyor belt 214 can move longitudinally downstream toward the alignment conveyor 206. In this manner, the in-feed conveyor belt 214 can move a stack of carton blanks 111 longitudinally downstream, with the stack of carton blanks 111 at its outer transverse portion also supported on the rollers 210. The PLC 132 can control the in-feed motor 291 via the motor drive, such that the in-feed conveyor 204 can be operated to move and transfer the stack toward and to the alignment conveyor 206.

[0053] The alignment conveyor 206 may also include a series of laterally oriented rollers 208 mounted for free rotational movement on the bottom of the magazine frame 202. The alignment conveyor belt 216 may be driven by an alignment motor 292 having a corresponding motor drive, similar to the in-feed motor 291. The alignment motor 292 may also be controlled by the PLC 132. The alignment conveyor belt 216 may include an upper belt portion supported on the rollers 208, upon which the stack of carton blanks 111 may be supported. The in-feed conveyor belt 214 may be operated to further move the stack of carton blanks 111 longitudinally until the front face of the stack abuts the generally planar, vertically and laterally oriented inward face of the leading end wall 218.

[0054] The infeed conveyor belt 214 of the infeed conveyor 204 and the alignment conveyor belt 216 of the alignment conveyor 206 may be made from any suitable material, such as, for example, Ropanyl.

[0055] A gap sensor 242, such as an Allen-Bradley Electronic Eye Model 42KL-D1LB-F4, may be positioned in the horizontal gap between the infeed conveyor belt 214 and the alignment conveyor belt 216. The gap sensor 242 may be positioned and operable to detect the presence of the leading edge of the stack of carton blanks 111 as the stack begins to move across the gap between the infeed conveyor belt 214 and the alignment conveyor belt 216. Upon detecting the leading edge, the gap sensor 242 can send a digital signal to the PLC 132 (see FIG. 1B ), thereby indicating that the stack has moved to a position where the alignment conveyor 206 can begin moving. The PLC 132 can then activate the alignment motor 292 for the alignment conveyor 206 so that the top of the alignment conveyor belt 216 begins to move downstream through the stack. In this manner, the stack of carton blanks 111 can be “handed off” from the infeed conveyor 204 to the alignment conveyor 206.

[0056] When the trailing end of the stack of blanks 111 passes gap sensor 242, a signal is sent to PLC 132 (see FIG. 1B), which can respond by sending a signal to stop infeed motor 291, which drives infeed conveyor belt 214 of infeed conveyor 204. Infeed conveyor 204 is then ready to load another stack of blanks 111, while alignment conveyor belt 216 moves the stack of carton blanks 111 into a pick-up position so it can continue operation.

[0057] The presence of the stack of carton blanks 111 at the pick-up position may be detected by a presence sensor 240, which may be the same type of sensor as the gap sensor 242. The presence sensor 240 may detect the presence of the leading edge of the stack of carton blanks 111 at the pick-up position and send a digital signal to the PLC 132, thereby signaling that the stack is at the pick-up position. At the pick-up position, the stack of carton blanks 111 may be "squared up," after which, once properly aligned, a single carton blank 111 may be serially removed from the stack of carton blanks 111 by alternating engagement of the erector heads 120a, 120b with the uppermost carton blank 111 in the stack.

[0058] The magazine 110 may be configured and operable to allow the stack of carton blanks 111 to be properly positioned and oriented at a pickup location for proper engagement by one of the erector heads 120 a, 120 b. During longitudinal movement of the stack of carton blanks 111 by the infeed conveyor 204 and the alignment conveyor 206, the left side of the stack of carton blanks 111 may be supported and guided by a left guide wall 200. The left guide wall 200 may be attached to the bottom of the lower frame 202, and the left guide wall 200 may be generally vertically oriented and extend longitudinally for substantially the entire length of the infeed conveyor 204 and the alignment conveyor 206.

[0059] The right side of the magazine 110 adjacent the infeed conveyor 204 may remain generally open, while the right side of the alignment conveyor 206 may have a right guide wall 201 .

[0060] Possible mounting arrangements for left guide wall 200 and right guide wall 201 are illustrated in further detail in Figures 6A-6D. In this regard, lower frame portion 202 may include bottom support plates 251, 255, 259, and 263 that are supported on the ground / floor with bottom support plates 251, 255, 259, and 263 spaced apart from one another and oriented in a generally laterally parallel relationship to one another. Each of support plates 251, 255, 259, and 263 has one of tracks 253, 257, 261, and 265 attached to its upper surface. Left guide wall 200 may be supported by connector block 267 that fits over and is laterally slidable relative to tracks 253 and 261. Similarly, the right guide wall 201 may be supported by a connector block 269 that fits over and is slidable laterally relative to the tracks 257 and 265 .

[0061] A drive mechanism can be provided to drive each of the left and right guide walls 200, 201 on their respective tracks. For the left guide wall 200, a drive mechanism can be provided that is in electronic communication with the PLC 132. As an example, a servo motor 258 with a gear head can be provided and in electronic communication with the PLC 132 through a servo drive (see FIG. 1B). An example that can be used is an Allen-Bradley servo motor MPL-B1530U-VJ42AA in combination with an Allen-Bradley servo drive 2094-BC01-MP5-S and an Apex gear head AE050-010FORMPL-A1520.

[0062] The lead screw rod 262 may be interconnected to a servo motor / gear head 258. The lead screw rod 262 may pass through a nut, such as a brass nut 264. The brass nut 264 may be secured to a plate 293. The plate 293 may be interconnected to spaced apart, generally vertically oriented bar members 294. The bar members 294 may be interconnected to support a frame (not shown) that forms part of the left guide wall 200. By operating the servo motor / gear head 258, rotation of the servo can rotate the threaded rod 262. As the threaded rod 262 passes through the nut 264, the nut 264 is moved laterally, either inward or outward, thereby causing the left guide wall 200 to slide inward or outward on the tracks 252, 261, depending on the direction of rotation of the threaded rod 262. An encoder is provided within or associated with the servo motor 258, and the encoder rotates in relation to the rotation of the servo drive's respective drive shaft. The encoder communicates with the servo drive and provides a signal to the servo drive, which can then communicate that information to the PLC 132. Thus, the PLC 132 can determine the longitudinal position of the threaded rod 262 in real time, and thus the lateral position of the left guide wall 200, and operate the servo motor 258 to adjust the position of the left guide wall 200. A particular type of encoder that can be used is known as an “absolute” encoder. Once the encoder is calibrated so that the position of the threaded rod 262 is “zero,” the encoder can maintain its zero position calibration even if power to the carton forming system 100 is lost. However, because the left guide wall 200 does not move during processing of the carton blank 111, the mechanism for adjusting the lateral position of the left guide wall 200 can alternatively be a simple hand-cranked mechanism instead of a servo drive motor in communication with the PLC 132.It should be noted that the proper position of the left guide wall 200 during processing of a stack of carton blanks 111 is the position shown in FIG. 7, with the left guide wall 200 approximately abutting the left edge of the carton blanks 111 in each stack. Proper positioning of the left guide wall 200 can be shown to ensure that the first reference line W1 is properly laterally aligned as the blanks are flattened and moved through the folding and sealing device 130, as described in detail below, to achieve proper folding and sealing of the carton blanks 111 into erect cartons.

[0063] Similarly, the right guide wall 201 may be provided with a drive mechanism 260 (which may be the same type of component used for the left guide wall 200) that is in electronic communication with the PLC 132. By way of example, a servo motor with a gear head, designated "drive mechanism 260," may be provided and may be in electronic communication with the PLC 132 through a servo drive. A lead screw rod 266 may be interconnected to the servo motor / gear head 266 (which may be such as servo motor / gear head 268). The lead screw rod 266 may pass through a nut, such as a brass nut (not visible) like nut 264. The nut may be secured to a plate 295. The plate 295 may be interconnected to spaced apart, generally vertically oriented bar members 296. The bar members 296 may be interconnected to a sidewall support frame, generally designated 271 (see FIG. 6C), that forms part of the right guide wall 201. By operating the drive mechanism 260, the rotation of the servo can rotate the threaded rod 266. As the threaded rod 266 passes through the nut, the nut is moved laterally either inward or outward, causing the right guide wall 201 to slide along the tracks 257, 265. An encoder can be provided within or associated with the drive mechanism 260, and the encoder can rotate in conjunction with the rotation of the respective drive shafts of the servo motors. The encoder can communicate with the servo drive and provide a signal to the PLC 132. Thus, the PLC 132 can determine the longitudinal position of the threaded rod 266 in real time, and therefore the lateral position of the right guide wall 201. Thus, the PLC 132 can operate the drive mechanism 260 to adjust the position of the right guide wall 201. An "absolute" encoder can also be used in this application.

[0064] During operation of the carton forming system 100 in erecting a carton, the left guide wall 200 may remain stationary, while the right guide wall 201 may be moved laterally as part of the blank stack alignment procedure to provide general longitudinal alignment of the side edges of the carton blanks 111 in the stack as they are held between the left guide wall 200 and the right guide wall 201.

[0065] A lateral tamping tool may be secured to the right guide wall 201 and may be used to affect the lateral alignment of the leading and trailing edges of the carton blanks 111 in the stack, i.e., so that the leading and trailing edges of the carton blanks 111 in the stack are generally aligned with the vertical axis Z in FIG. 7 . The lateral tamping device, generally designated 275, may include a horizontally and longitudinally oriented support plate 270 that may be attached at either end to a vertical member of the sidewall support frame 271. A block track 272 may be attached to the outer surface of the horizontally and longitudinally oriented support plate 270. A slider block 273 may be secured to the block track 272 for longitudinal sliding movement along it. Attached to the slider block 273 may be a pair of upright support plates, the upper ends of which are secured to a double-acting pneumatic actuator 276, such as Festo Model DFM-25-80-PA-KF Part Number 170927. The double-acting pneumatic actuator 276 can have one or more piston arms (not visible in FIGS. 6B and 6C because the piston arms are retracted). The piston arms of the double-acting pneumatic actuator 276 can reciprocate longitudinally back and forth between retracted and extended positions. Referring to FIG. 1B, the pneumatic actuator can be supplied with pressurized air transmitted through an electronic solenoid valve to retract and extend the piston arms. The solenoid valve can be implemented as a Festo model CPE14-MlBh-5J-l / 8 and can be controlled by the PLC 132. Alternatively, the double-acting pneumatic actuator 276 can be provided with a linear servo drive system (similar to that described in connection with the movement of the left guide wall 200 and the right guide wall 201). Such a servo drive system can be controlled by the PLC 132.The PLC 132 can adjust the movement of both the left guide wall 200 and the right guide wall 201, as well as the double-acting pneumatic actuator 276 for the lateral tamping device, so that the magazine 110 is automatically adjusted to handle a wide range of carton blank 111 sizes.

[0066] It should be noted that during operation of carton forming system 100 in erecting a carton, slider block 273 does not move along block track 272. Slider block 273 and the components directly or indirectly attached thereto (including double-acting, pneumatic actuator 276) may be shown not to move longitudinally during operation. However, the longitudinal position of slider block 273 can be adjusted during setup of carton forming system 100 when processing a particular size of carton blank 111.

[0067] The end of the piston arm of the double-acting pneumatic actuator 276 may have attached thereto a transverse plate 278 that may pass through a longitudinally extending slot 279 through the right guide wall 201. The end of the transverse plate 278 distal from the piston arm attachment is attached to a vertical tamping plate 280 located laterally inward from the inner surface of the right guide wall 201. Retraction of the piston arm of the double-acting pneumatic actuator 276 may cause the transverse plate 278 to engage the rear edges of the carton blanks 111 in the stack, laterally aligning the front and rear edges of the carton blanks 111 as the front edges of the carton blanks 111 are forced up against the inner surface of the leading end wall 218. While the actuator 276 is illustrated as pneumatic, it will be apparent that other non-pneumatic alignment devices may be used. For example, a linear servo drive in communication with the PLC 132 may be employed. The linear servo drive performs the same function as the double-acting pneumatic actuator 276, but the linear servo drive can electronically position the vertical tamping plate 280, thereby eliminating the need for an operator to manually adjust the vertical tamping plate 280 during system setup.

[0068] By operating the PLC 132 and appropriate adjustments of the right guide wall 201 and vertical tamping plate 280, the carton blanks 111 can be moved to a precisely known pickup position and the orientation of the carton blanks 111 can be "squared up" in the stack of blanks held against the leading end wall 218, thus ensuring that the carton blanks 111 are in the proper position for engagement by the erector heads 120a, 120b.

[0069] In particular, once the stack of carton blanks 111 has reached approximately the pickup position, PLC 132 can signal drive mechanism 260 to cause drive mechanism 260 to move right guide wall 201 laterally inward toward the side of the stack of carton blanks 111. PLC 132 can instruct drive mechanism 260 to move a sufficient distance to bring the end of the carton blank 111 along its length into contact with the longitudinally-aligned inner surface of right guide wall 201. However, PLC 132 does not move right guide wall 201 to an extent that would create forces on the stack of carton blanks 111 that would buckle and / or damage the carton blanks 111. Such damage is shown to occur in response to the carton blanks 111 being compressed to a significant degree between left guide wall 200 and right guide wall 201. PLC 132 may be able to determine how much to move right guide wall 201 toward left guide wall 200 depending on the size dimensions of carton blank 111 input into PLC 132, including dimension H (see FIG. 10A ). The amount of slight compression can be fine-tuned, such as by trial and error, for different sized carton blanks 111. It should be noted that for many sizes of carton blank 111, manufacturers of carton blank 111 adhere to industry standard carton sizes.

[0070] Once longitudinal alignment is achieved by movement of the right guide wall 201, the PLC 132 can activate the double-acting pneumatic actuator 276 to engage the vertical tamping plate 280 with the trailing edges of the carton blanks 111 in the stack. The PLC 132 can move the drive mechanism 260 a sufficient distance to longitudinally contact the trailing edges of the carton blanks 111 with the laterally aligned inner surfaces of the vertical tamping plate 280. However, the amount of retraction of the piston arm can be configured to prevent the vertical tamping plate 280 from moving to an extent that would create forces on the stack of carton blanks 111 that could cause buckling and / or damage to the carton blanks 111. In particular, buckling and / or damage can occur in response to the carton blanks 111 being too compressed between the vertical tamping plate 280 and the leading end wall 218. By appropriate manual positioning and fastening, such as by tightening an appropriately placed screw through slider block 273, double-acting pneumatic actuator 276 can be secured in the appropriate longitudinal position on block track 272.

[0071] Incidentally, the double-acting pneumatic actuator 276 can ride on the left guide wall 200. For a particular size / shape of carton blank 111, the double-acting pneumatic actuator 276 can be manually adjusted forward and backward so that when the double-acting pneumatic actuator 276 is retracted, the vertical tamping plate 280 is in the proper position to push the carton blank 111 up against the leading end wall 218 without compressing the carton blank 111.

[0072] The sliding assembly of the component including the double-acting pneumatic actuator 276 may also have a pointer or indicator, and the fixed portion of the magazine 110 may have a numerical scale to assist in quickly manually adjusting the double-acting pneumatic actuator 276 to the correct position on the block track 272 for a known carton size.

[0073] To review, exemplary steps in a tamping sequence to ensure the carton blank 111 is properly squared at the pick-up location include:

[0074] 1. The right guide wall 201, under the control of the PLC 132, expands to a width sufficient to allow a stack of carton blanks 111 to enter onto the alignment conveyor 206 even if the stack is misaligned and / or if the carton blanks 111 in the stack are not perfectly square with respect to each other and to the X and Y axes.

[0075] 2. The alignment conveyor belt 216 advances the stack of carton blanks 111 until the carton blanks 111 abut against the leading end wall 218.

[0076] 3. The double-acting pneumatic actuator 276 is extended, which then retracts the right guide wall 201 to contact the side of the stack of carton blanks 111 and press the right guide wall 201 against the left guide wall 200. This aligns the carton blanks 111 so that their side edges are aligned with each other and with the longitudinal side walls of the left and right guide walls 200 and 201.

[0077] 4. The double-acting pneumatic actuator 276 is then retracted, causing the vertical tamping plate 280 to push the stack of carton blanks 111 forward, thereby aligning the carton blanks 111 in the stack so that the leading and trailing edges of the carton blanks 111 are vertically aligned with each other and the inner surface of the vertical tamping plate 280 is vertically aligned with the inner surface of the leading end wall 218.

[0078] 5. The carton blank 111 is then properly positioned so that the erector heads 120a, 120b can begin picking up the blank from the stack.

[0079] Turning now to other components of the carton forming system 100, at least a first engagement device may be provided to engage a panel of the carton blank 111, thus holding and moving the blank, in order to remove the blank from the magazine 110. If the carton blank 111 is a tubular blank, the carton forming system 100 may include a first engagement device for engaging one panel (e.g., panel A) of the carton blank 111, and a second engagement device for engaging a second panel (e.g., panel B) of the carton blank 111. The first and second engagement devices may be comprised of one or more suction cups for applying a suction force to the panel that acts generally normal to the surface of the engaged panel, as described further below. Other types of suitable engagement devices may also be employed. The first and second engagement devices may be rotatable relative to each other so that the first panel can be rotated relative to the second panel. The first and second engagement devices may be mounted on a single common erector head.

[0080] Referring to FIG. 7, the carton forming system 100 may include a transfer subsystem that may be implemented as a pair of transfer devices, each of which supports and moves one of the erector heads 120a, 120b. Each of the erector heads 120a, 120b may include a dedicated transfer device that is independently driven and controlled. Thus, the first erector head 120a may be supported and moved by the first transfer device 115a. Similarly, the second erector head 120b may be supported and moved by the second transfer device 115b. The first transfer device 115a may be configured substantially identically to the second transfer device 115b. The first transfer device 115a may be configured as a mirror image of the second transfer device 115b. In this manner, the first moving device 115a may support the first erector head 120a from the right side, and the second moving device 115b may support the second erector head 120b from the left side, such that both erector heads 120a, 120b are moved along a common longitudinal and vertical path. The common path of the erector heads 120a, 120b may lie substantially in a plane parallel to both the vertical axis Z and the longitudinal axis Y in FIG. 7, or may be a parallel periodic path. Thus, the movement of the erector heads 120a, 120b may be only in the vertical Z direction and the longitudinal Y direction (i.e., directions parallel to the Z and Y axes in FIG. 7), with no substantial movement in the horizontal X direction (i.e., directions parallel to the X axis in FIG. 7). When the movement of the erector heads 120a, 120b is limited to only the Z and Y directions, the respective moving devices can be constructed with relatively less complexity than when movement in all three directions is required.

[0081] The movement of the erector heads 120a, 120b by their respective movement devices 115a, 115b can be synchronized so that the erector heads 120a, 120b move along the same longitudinal and vertical paths while moving out of phase with each other so that one erector head does not interfere with the other, as described further below. Thus, the relative positions of the two erector heads 120a, 120b can be arranged so that the erector heads 120a, 120b do not collide or otherwise interfere with each other during operation of the carton forming system 100.

[0082] While only the detailed structure of the second movement device 115b will be described herein, it will be understood that the first movement device 115a may be configured in substantially the same manner as a mirror image of the second movement device 115b. With particular reference to FIGS. 4, 5, 7, 8, 9, and 17, the second movement device 115b may include a vertical movement device and a horizontal movement device. The vertical movement device may include a generally hollow vertical support tube 169, which may be generally rectangular in cross section. The support tube 169 may be formed from a single tubular piece of material or may be formed into opposing, vertically extending, and oriented surfaces 164, 165, 166, and 168 interconnected using conventional mechanisms such as bolts, welding, or the like. The support tube 169 may be secured to a horizontally extending brace plate 182, which may be interconnected to a vertically extending brace plate 180. The lower portion of the vertically extending brace plate 180 may be interconnected to the lower end of the support tube 169 by a series of angled plates 183 .

[0083] A freely rotatable "b" pulley wheel 155b may be attached to the upper end of the support tube 169. A second erector head 120b may be fixedly attached to the support tube 169 at the lower end of the vertically extending and oriented surfaces 164, 166 by a horizontally extending mounting plate. The horizontally extending mounting plate may be coupled to the support tube 169. The support tube 169 may engage with a pair of spaced-apart mounting blocks 190a, 190b and may be bolted together through bolt holes 191a, 191b in the mounting blocks 190a, 190b. The bolt holes 191a, 191b may also extend through the mounting plate at the bottom of the support tube 169. Thus, as the second erector head 120b is interconnected to the support tube 169, the second erector head 120b may be shown to move in space with the support tube 169.

[0084] A horizontal movement device may be provided to support the support tube 169 and the connected second erector head 120b and facilitate horizontal movement of the support tube 169 and the second erector head 120b. The horizontal movement device may include a slide block 158 that can use a rail system for horizontal movement. The horizontal movement device may include a pair of short, spaced-apart, longitudinally and horizontally extending inner blocks, each fitted with a longitudinally extending rail 160, 162 that holds the inner block securely but allows it to slide horizontally relative to the longitudinally extending rails 160, 162. An example of a suitable rail system is the Bosch Rexroth ball rail system, in which the rails are made of steel and the blocks have ceramic ball races inside them, allowing the blocks to slide on the rails. The longitudinally extending rails 160, 162 may be oriented generally horizontally and attached to the frame 109. The slide block 158 may be mounted on longitudinally extending rails 160, 162 for horizontal sliding movement along the longitudinally extending rails 160, 162. Four freely rotatable pulley wheels, "a" pulley wheel 155a, "c" pulley wheel 155c, "d" pulley wheel 155d, and "f" pulley wheel 155f, are secured to the front surface of the slide block 158. A drive belt may be shown passing around the four freely rotatable pulley wheels, as described below. The slide block 158 may also use a rail system that allows the support tube 169 to be coupled to the slide block 158 and move vertically relative to the slide block 158. Thus, vertically and longitudinally extending rails may extend vertically along the back surface of the support tube 169. The support block may have runner blocks interconnected to vertical rails on the support tube 169. Thus, the support tube 169 can slide horizontally relative to the slide block 158. Again, the preferred rail system is the Bosch Rexroth ball rail system referred to herein.

[0085] Drives may also be provided to drive the horizontal and vertical movement devices. For example, the drive may include a pair of drive motors interconnected by a drive belt, which in turn interconnects the horizontal and vertical movement devices. For example, the drive may include a left belt drive motor 150 (which may be a servo motor such as Allen-Bradley model MPL-B330P-MJ24AA), which may be mounted on a longitudinally extending beam member 108 connected to the frame 109 (see FIGS. 1A, 2, and 3). The left belt drive motor 150 may have a left drive wheel 152. Similarly, a right belt drive motor 154, which may also be a servo motor like the left belt drive motor 150, may also be mounted on the beam member 108 connected to the frame 109. The right belt drive motor 154 may have a right drive wheel 156. The left drive wheel 152 may be longitudinally spaced from the right belt drive motor 154 and horizontally aligned with the right belt drive motor 154. Both the left belt drive motor 150 and the right belt drive motor 154 can be driven in both directions at various speeds, and such rotation can be controlled via servo drive by the PLC 132 (see FIG. 1B). Both the left belt drive motor 150 and the right belt drive motor 154 can be provided with two separate ports 364a, 364b. One of the ports 364a, 364b can be for supplying a power line, and the other of the ports 364a, 364b can be for a communication line to facilitate communication with the PLC 132. It should be noted that all servo motors described herein can be similarly equipped. The left belt drive motor 150 and the right belt drive motor 154 can also be provided with a third input to enable an electric braking mechanism.

[0086] The first movement device 115a may also include a continuous drive belt 153. The continuous drive belt 153 may be made, for example, of urethane with steel wires threaded therethrough. The drive belt 153 may be engaged and driven by a left belt drive motor 150 and a right belt drive motor 154 under the control of the PLC 132. The PLC 132 may independently control the operation of both the left belt drive motor 150 and the right belt drive motor 154 through their respective servo drives. The drive belt 153 may be shown extending continuously from a starting position on the lower left side of the support tube 169, where the drive belt 153 is fixedly attached to a right belt block 159a that is attached to the support tube 169. From the starting position, the drive belt 153 extends upward to the "f" pulley wheel 155f, around the top of the "f" pulley wheel 155f at the first drive belt portion 153g. From the "f" pulley wheel 155f, the drive belt 153 extends horizontally along the second drive belt portion 153h to the left drive wheel 152. The drive belt 153 then passes around the left drive wheel 152, is engaged on the third drive belt portion 153a below the "a" pulley wheel 155a, and extends upward along the fourth drive belt portion 153b to the "b" pulley wheel 155b. From there, the drive belt 153 extends downward around the "b" pulley wheel 155b over the fifth drive belt portion 153c to the "c" pulley wheel 155c, and then extends around the "c" pulley wheel 155c along the sixth drive belt portion 153d to the right drive wheel 156. After passing around and being engaged by the right drive wheel 156, the drive belt 153 continues from around the right drive wheel 156 to the seventh drive belt portion 153e and then to the top of the "d" pulley wheel 155d. From the "d" pulley wheel 155d, the drive belt 153 extends vertically downward along the eighth drive belt portion 153f to the right belt block 159a, where it terminates. The drive belt 153 vertically supports the support tube 169 both at its lower portion, where it is interconnected to the support tube 169 by the right and left belt blocks 159a and 159a, and at its upper portion, where the drive belt 153 passes through the "b" pulley wheel 155b.Therefore, it can be shown that the drive belt 153 indirectly supports the second erector head 120b in the vertical direction. Furthermore, by adjusting the relative rotation of the left drive wheel 152 and the right drive wheel 156, the relative lengths of all belt portions can be adjusted through the operation of the left belt drive motor 150 and the right belt drive motor 154. Therefore, the relative vertical position of the support tube 169 with respect to the slide block 158 can be adjusted. Furthermore, by adjusting the relative rotation of the left drive wheel 152 and the right drive wheel 156 through the operation of the left belt drive motor 150 and the right belt drive motor 154, the horizontal position of the slide block 158 on the rails 160, 162 can be adjusted, and therefore the horizontal positions of the support tube 169 and the second erector head 120b can be changed. It will be appreciated that by adjusting the direction and speed of rotation of the drive wheels 152, 156 relative to one another, the support tube 169 can be moved vertically and / or horizontally in space within physical constraints imposed by, among other things, the positions of the left and right drive wheels 152, 156, the length of the drive belt 153, and the length of the support tube 169. The following will be understood with particular reference to FIG. 17.

[0087] It can be shown that if both the left drive wheel 152 and the right drive wheel 156 remain stationary, the position of the support tube 169 does not change.

[0088] When the left drive wheel 152 and the right drive wheel 156 both rotate in the same clockwise direction at the same relative speed, the support tube 169, and correspondingly the second erector head 120b, can be shown to move horizontally from right to left.

[0089] When the left drive wheel 152 and the right drive wheel 156 both rotate in the same counterclockwise direction at the same relative speed, the support tube 169, and correspondingly the second erector head 120b, can be shown to move horizontally from left to right.

[0090] When the left drive wheel 152 rotates counterclockwise and the right drive wheel 156 rotates in the opposite clockwise direction, but both the left drive wheel 152 and the right drive wheel 156 rotate at the same rotational speed relative to each other, the support tube 169, and correspondingly, the second erector head 120b, can be shown to move straight down vertically.

[0091] If the left drive wheel 152 rotates clockwise and the right drive wheel 156 rotates in the opposite counterclockwise direction, but both the left drive wheel 152 and the right drive wheel 156 rotate at the same rotational speed relative to each other, the vertically extending and oriented surfaces 164, 166 can be shown to move straight up vertically.

[0092] It will be appreciated that by varying the speed and direction of the left drive wheel 152 and the right drive wheel 156 in different ways, the motion of the support tube 169 and the corresponding second erector head 120b can be created to have both a vertically upward or vertically downward component and a horizontally left-right component. Any desired path within these two degrees of freedom (vertical and horizontal) can be created for the support tube 169 and the corresponding second erector head 120b. For example, a path having a curved path portion can be created. By controlling the rotational direction and speed of the left belt drive motor 150 and the right belt drive motor 154 independently of each other, the PLC 132 can move the support tube 169 and the corresponding second erector head 120b along any vertical and horizontal path, allowing the second erector head 120b to transport the carton blank 111 through the various processing steps performed by the carton forming system 100. It should be noted that there are physical constraints on this path imposed by the spacing between left drive wheel 152 and right drive wheel 156, "b" pulley wheel 155b, and the bottom of support tube 169.

[0093] Furthermore, by providing two opposing movement devices 115a, 115b, the movements of the first erector head 120a and the second erector head 120b can be coordinated and synchronized, and it will be understood that even if the first erector head 120a and the second erector head 120b move along the same path, the movements of the first erector head 120a and the second erector head 120b are out of phase. For example, the phases of the first erector head 120a and the second erector head 120b may be out of phase by 180 degrees.

[0094] Therefore, the movement of one erector head 120 does not interfere with the movement of the other. An encoder may be provided on each of the left belt drive motor 150 and the right belt drive motor 154, and the encoder may rotate in relation to the rotation of each of the left drive wheel 152 and the right drive wheel 156. The encoders may be in communication with the PLC 132. Thus, the PLC 132 can know / determine / monitor the position of the drive belt 153 in space in real time, and therefore determine and know the position of the second erector head 120b in space at any point in time. A specific type of encoder that may be used is known as an “absolute” encoder. Thus, by calibrating the encoders of both the left belt drive motor 150 and the right belt drive motor 154, the carton forming system 100 can be zeroed so that the zero position of the erector head 120 in both the Z and Y directions is set within the PLC 132. The zero position may be set with the erector head 120 in its leftmost horizontal and vertically raised position. The PLC 132 can then track, in substantially real time, the position of the second erector head 120b as it moves through the processing sequence for a given carton blank 111.

[0095] The encoders associated with PLC 132, left belt drive motor 150 and right belt drive motor 154, and the servo drives of each of devices 115a, 115b can be set to a zero position for each of two separate erector heads 120a, 120b. PLC 132 can then track, in substantially real time, the positions of both erector heads 120a, 120b as they move independently through the processing sequence for a given carton blank 111.

[0096] Also associated with the second movement device 115b is a first, generally horizontally oriented track device 114 having a first track input end 114a and a first track output end 114b. A second, generally vertically oriented track device 118 is also provided having a second track input end 118a and a second track output end 118b. The first and second track devices 114, 118 may each have a hollow cavity extending along their length. Hoses carrying pressurized air / vacuum and electrical / communication wires may be housed within the cavities of the first and second track devices 114, 118. The first track device 114 may allow such hoses and wires to move longitudinally as the support tube 169 and second erector head 120b move longitudinally. The second track device 118 can allow such hoses and wires to move vertically as the support tube 169 and second erector head 120b move vertically. The hoses and wires can extend from the outside, enter the first track input end 114a, and exit the first track output end 114b. Once exiting the first track output end 114b, the hoses and wires can extend to enter the second track input end 118a and exit the second track output end 118b. From the second track output end 118b, these hoses and wires can then pass through the first input hose 191 and the second input hose 192 on the second erector head 120b (see FIG. 30). In this way, both pressurized air / vacuum and / or electrical communication lines can be motorized onto the moving second erector head 120b from locations external to the frame 109. An example of a suitable caterpillar device that may be employed is the Ignus E-Chain Cable Carrier System, model number 240-03-055-0. It should be noted that electrical communication between PLC 132 and second erector head 120b may, in other embodiments, be achieved using commercially available wireless technology.

[0097] The second erector head 120b is shown in isolation in Figures 30, 31, 32, and 33. The first erector head 120a may be configured similarly to the second erector head 120b, but may be supported from the right side by the first mover device 115a, in contrast to the second erector head 120b, which may be supported from the left side by the second mover device 115b.

[0098] Second erector head 120b can have a body generally designated 300. Body 300 may be comprised of multiple components. Many of the components of second erector head 120b may be made from high-strength materials such as metals (e.g., aluminum, steel, etc.), hard and strong plastics, or other suitable materials, including composites.

[0099] Second erector head 120b can generally be configured to accommodate a range of carton blank 111 sizes that can be formed into cartons. Second erector head 120b can be configured to be easily attached to support tube 169 using mounting blocks 190a, 190b, bolts, or the like to allow for easy replacement of erector head 120. Easy replacement of erector head 120 may be indicated in some circumstances to allow carton forming system 100 to be easily adapted to form cartons of different sizes / shapes from carton blanks 111 of different configurations.

[0100] In one embodiment, the second erector head 120b may include a rotatable paddle 310 connected to a distal end portion 314a of a paddle arm 314. The paddle arm 314 may have a proximal end portion 314b opposite the distal end portion 314a. The proximal end portion 314b may be formed with a circular opening that facilitates connection of the paddle arm 314 to a paddle shaft 316. The paddle 310 may rotate with the paddle shaft 316 about the longitudinal axis of the paddle shaft 316. The paddle shaft 316 may be connected to a rotary actuator 399, such as a double-acting rotary pneumatic actuator manufactured by Festo, technical part number DSM-32-270-CC-FW-AB. The rotary actuator 399 may rotate the paddle shaft 316 clockwise and counterclockwise about the axis of the paddle shaft 316 up to 270 degrees. The rotary actuator 399 may be supplied with pressurized air via hoses (not shown) connected to a first port 395 and a second port 397. These hoses may also be connected to a solenoid valve device 340 that may be controlled by the PLC 132. In this manner, the clockwise and counterclockwise rotation of the paddle 310 may be controlled by the PLC 132.

[0101] Additionally, bottom suction plate 327, formed as part of body 300 of second erector head 120b, is generally shaped like a square cross to provide flanged openings for the suction cups. A suction plate suction cup 312 is disposed in each of the flanged openings of bottom suction plate 327. While many types of suction cups can be employed in second erector head 120b, it should be noted that a preferred type of suction cup is model B40.10.04AB manufactured by Piab. Two of suction plate suction cups 312 are attached to first generally longitudinally oriented support block 319a, and the other two suction cups are attached to second generally longitudinally oriented support block 319b.

[0102] The first and second support blocks 319a, 319b are generally longitudinally oriented in a spaced-apart, parallel relationship, and the first and second support blocks 319a, 319b are joined to other components of the body 300. The first and second support blocks 319a, 319b each have an open passageway interconnecting each suction plate suction cup 312 with an outlet from a vacuum generator 330. The vacuum generator 330 may be any suitable vacuum generator, such as, for example, a Pisco Model VCH12-016C. Each of the suction plate suction cups 312 may be shown having an inlet interconnected to a hose (not shown) capable of carrying pressurized air to the vacuum generator 330. The vacuum generator 330 converts pressurized air supplied to a vacuum inlet port into a vacuum at one of multiple vacuum outlet ports. The vacuum outlet ports are interconnected to selected suction plate suction cups 312 of the plurality of suction plate suction cups 312 via passages in the first and second support blocks 319a and 319b, enabling the selected suction plate suction cups 312 to apply vacuum. A solenoid valve device 340, which may be, for example, a Festo model CPE14-M1BH-5L-1 / 8, may be disposed along the compressed air flow path between the vacuum generator 330 and a source of compressed air, which may be an air compressor (see FIG. 1B). The solenoid valve device 340 is in electronic communication with and can be controlled by the PLC 132. In this manner, the PLC 132 can turn on and off the supply of vacuum to each of the suction plate suction cups 312. To properly control the flow of compressed air, the valve of the solenoid valve device 340 can be actuated between an open position and a closed position by a solenoid responsive to a signal from the PLC 132. An electrical line carrying signals to and from the PLC 132 may also pass through the first input hose 191 to operate the solenoid valve device 340 .

[0103] The first downwardly extending end portion 323a of the first support block 319a has a first opening 331a configured to receive a laterally mounted shaft 342. The laterally mounted shaft 342 may be mounted for rotation within the first opening 331a. The second downwardly extending end 323b of the second support block 319b has a second opening 331b configured to receive the laterally mounted shaft 342. The laterally mounted shaft 342 may be mounted for rotation within the second opening 331b.

[0104] One end of the laterally mounted shaft 342 may have attached thereto a gear wheel arrangement 360 configured to rotate with the laterally mounted shaft 342. The gear wheel 360 may be interconnected to a drive wheel of a gear box 362 to form a miter gear connection. The gear box 362 may be driven by a servo motor 364 mounted above the gear box 362. The servo motor 364 may also be an Allen-Bradley model MPL-B1530U-VJ44AA, and the gear box 362 may also be an Apex model AER050-030FOR MPL-A1520 AB SERVO MOTOR.

[0105] In FIG. 30 , servo motor 364 is shown with two separate servo motor ports 364 a, 364 b (individually or collectively 364). One of servo motor ports 364 may be for supplying power lines, while the other servo motor port may be for communication lines to facilitate communication with the servo drive and PLC 132. Note that all servo motors described herein may be similarly equipped. Servo motor 364 may be controlled by and communicate with PLC 132 through connection with a servo drive (see FIG. 1B ). Encoders may be provided within or associated with servo motor 364. The encoders may rotate in conjunction with the rotation of the respective drive shafts of servo motors 364. The encoders may communicate and provide signals to the servo drive and, therefore, PLC 132. PLC 132 may determine the rotational position of laterally mounted shaft 342. Thus, when provided with an appropriate signal from PLC 132, servo motor 364 can be operated to rotate laterally mounted shaft 342 in a particular desired direction at a particular desired rotational speed for a desired period of time. In this manner, PLC 132 can control the rotational position of horizontally mounted shaft 342.

[0106] A rotor device, generally designated 350, is mounted on the laterally mounted shaft 342 between first end portion 323a and second end portion 323b. Rotor device 350 is fixedly attached to the laterally mounted shaft 342 and may be shown to rotate with the laterally mounted shaft 342. Rotor device 350 includes a rotor arm 351 having one end fixedly attached to the laterally mounted shaft 342. A mounting block 353 is attached to the opposite end of rotor arm 351.

[0107] The mounting block pneumatic actuator device 325 secured to the mounting block 353 may be, for example, model DFM-12-80-PA-KF or part number 170905 manufactured by Festo. The mounting block pneumatic actuator device 325 is supplied with pressurized air, which can actuate a device controlled by a solenoid valve device 340 in the supply line. The solenoid valve device 340 is in communication with and controlled by the PLC 132 (see FIG. 1B). The mounting block pneumatic actuator device 325 can be actuated to reciprocate the piston arm 326 between an extended position and a retracted position. The PLC 132 can send a signal to the solenoid valve device 340 to actuate the mounting block pneumatic actuator device 325 to extend the piston arm 326 at a specific angular position of the rotor arm 351 and / or a specific position of the second erector head 120b. The specific angular position or specific position may be provided by an encoder associated with the servo motor 364. Similarly, the PLC 132 can send a signal to the solenoid valve device 340 to retract the piston arm 326 to a particular angular position of the laterally mounted shaft 342, and / or to retract the piston arm 326 to a particular angular position of the rotor arm 351, and / or to retract the piston arm 326 to a particular position of the second erector head 120b.

[0108] The PLC 132, acting through the solenoid valve device 340, can activate the mounting block pneumatic actuator device 325 at approximately the same time that the suction plate suction cups 312 contact the surface of the downward-facing panel D and / or when the rotor arm 351 is about to or has just begun to rotate. The piston arm 326 can fully extend by the time the rotor arm 351 has rotated approximately 45 degrees.

[0109] A mounting block 328 attached to the distal end of each piston arm 326 may be configured to support a pair of piston arm suction cups 320. Each mounting block 328 may have an open passageway (not shown) interconnecting each piston arm suction cup 320 with an outlet from a vacuum generator 330. The vacuum generator 330 may be any suitable vacuum generator device, such as, for example, a Pisco Model VCH12-016C. As indicated above, each vacuum generator 330 has an inlet port interconnected to a hose (not shown) capable of carrying pressurized air to the vacuum generator 330. The vacuum generator 330 converts pressurized air supplied to the inlet port into a vacuum at one of the outlet ports. The outlet port is interconnected to one of the piston arm suction cups 320 via a passageway in the mounting block 328, enabling the suction cup to exert a vacuum force. A solenoid valve device 340 may be positioned along the pressurized air flow path passing between each vacuum generator 330 associated with a piston arm suction cup 320 and a pressurized air source. The solenoid valve device 340 may be electronically interconnected (via a wireless communication connection or via a wired communication connection) to and controlled by the PLC 132. In this manner, the PLC 132 may also turn on and off the supply of vacuum force to each of the piston arm suction cups 320.

[0110] 11 , suction plate suction cups 312 can be employed to engage and hold top panel A of carton blank 111. Once carton blank 111 is removed from the top of the stack of carton blanks 111, rotator arm 351 can be rotated approximately 180 degrees so that piston arm suction cups 320 of rotator 350 can engage and hold bottom panel D of carton blank 111. Once piston arm suction cup 320 engages panel D, rotator arm 351 can be rotated 90 degrees back in the opposite rotational direction. Opposing vacuum forces generated by upper suction plate suction cup 312 and lower piston arm suction cup 320 can be shown to transform carton blank 111 from a flattened configuration to an open configuration as panel D is rotated substantially 90 degrees relative to panel A. The air suction force that can be generated on the outer surfaces of piston arm suction cups 320 and suction plate suction cups 312 can be shown to be sufficient, when activated, to enable piston arm suction cups 320 and suction plate suction cups 312 to engage and hold top plate A in a stationary position relative to second erector head 120b and rotate panel D relative to panel A to open tubular carton blank 111 into a generally rectangular configuration. The vacuum generated by piston arm suction cups 320 and suction plate suction cups 312 can also be released by PLC 132 sending a signal to solenoid valve device 340 at the appropriate time.

[0111] Each erector head 120a, 120b may be configured to handle a wider range of different sizes / dimensions of carton blanks 111 by including additional piston arm suction cups and suction plate suction cups located at different positions on the erector head 120a, 120b. The piston arm suction cups 320 and suction plate suction cups 312 may each be "self-plugging" or "self-sealing" suction cups that may automatically block if they do not engage and seal with the surface of a particular blank being processed. This automatic blocking may be achieved by interconnecting a pressurized air / vacuum source thereto to maintain vacuum / suction force against other suction cups engaging panels of the carton blank 111. In this manner, each of the erector heads 120a, 120b may be adapted to handle a wider variety of sizes / dimensions of carton blanks 111 and the cartons / cases that may be formed therefrom.

[0112] Opening of the carton blank 111 may be assisted by extension of the piston arm 326 of the mounting block pneumatic actuator device 325 during rotation of the rotor arm 351. Preferably, the piston arm 326 may be fully extended when the rotor arm 351 has rotated anywhere in the range of approximately 30-60 degrees and returned to the 90-degree position, preferably when the rotor arm 351 is at approximately 40-50 degrees, and most preferably when the rotor arm 351 is at approximately 45 degrees. This generally tangential extension of the piston arm 326, and therefore the piston arm suction cup 320, relative to the rotation of the rotor arm 351 may be provided to compensate for the offset of the axis of rotation of the rotor arm 351 compared to the axis of rotation of the carton blank 111, which extends along the fold line between panels A and D. When the rotor arm 351 is rotated to 90 degrees, the effect of the extension of the piston arm 326 ensures that panel D is also oriented at 90 degrees relative to panel A.

[0113] 11 , the PLC 132 can send a signal to the solenoid valve device 340, which causes the rotary actuator 399 to rotate the paddle shaft 316, and thus the paddle 310. The paddle 310 can then engage the trailing flap K of the carton blank 111, causing the trailing flap K to fold about its fold line where the trailing flap K joins panel D. The trailing flap K can thus be folded inward toward the bottom opening of the carton blank 111. The leading bottom flap J can also be folded about its fold line where it joins panel B by engagement with an upper folding rail / plow 700 and a lower folding rail / plow 701, which form part of the folding and sealing device 130. As the carton blank 111 held by the second erector head 120b is moved longitudinally downstream into the folding and sealing device 130, the leading bottom flap J can be folded inward so that both bottom flaps K and J are folded inward, and the formation of the bottom of the carton begins.

[0114] Another notable feature of the second erector head 120b is that a carton position sensor device may be provided, which may include a reciprocating sensor rod 380. The reciprocating sensor rod 380 extends through an opening 381 in the bottom suction plate 327 below the level of the plane of the suction plate suction cups 312 when not in contact with a carton blank 111. When the second erector head 120b is motorized vertically downward to remove a carton blank 111 from a stack of carton blanks 111 in the magazine 110, the movement of the second erector head 120b immediately before the suction plate suction cups 312 contact the top surface of the carton blank 111 may be shown to be generally vertically downward. Before the suction plate suction cups 312 contact the surface of panel A of the carton blank 111, the sensor rod 380 may be shown to engage the surface of panel A, causing the spring mechanism that biases the sensor rod 380 downward to push the resiliently displaced sensor rod 380 upward. This upward movement of the sensor rod 380 relative to the bottom suction plate 327 can physically activate a sensor (not shown), which in response can send a signal to the PLC 132. The sensor can be an inductive proximity sensor. A metal cylinder affixed to the sensor rod 380 can be sensed by the sensor circuit. The sensor can be an Allen-Bradley 871FM-D8NP25-P3. In response to receiving the signal, the PLC 132 slows down the left and right belt drive motors 150 and 154 to move downward the last few centimeters (e.g., 3.5 cm) so that contact between the suction plate suction cups 312 and the top surface of panel A occurs at a slower speed, and the PLC 132 knows how far to lower the second erector head 120b vertically downward to establish proper contact between the suction plate suction cups 312 and panel A.It should also be noted that the sensor rod 380 and associated sensor device may be used to ensure that once the carton blank 111 is engaged with the magazine 110, the PLC 132 knows whether the carton blank 111 remains engaged with the second erector head 120b until it reaches the appropriate release position, such as after carton erection is complete.

[0115] The particular arrangement of suction cups and rotating paddles on erector head 120 can be designed based on the configuration of the carton blank and the particular panels and flaps that need to be rotated. It will also be understood that in the illustrated erector head 120, the suction cups are used to apply a holding and / or rotating force to the panels of carton blank 111. However, it will be apparent that alternative engagement mechanisms for suction plate suction cups 312 and piston arm suction cups 320 may be employed.

[0116] 1-15 and 17, in folding and sealing apparatus 130, the rail and plow devices may be configured to properly fold any remaining flaps of carton blank 111 in preparation for sealing, thereby producing an open carton configuration suitable for delivery to a discharge conveyor, such as discharge conveyor 117. Folding and sealing apparatus 130 may include components of upper folding rail / plow 700, lower folding rail / plow 701, carton support plate 703, discharge chute 750, upper flap closure device 705, lower flap closure device 707, right compression device 706, left compression device 704, and glue applicator 709 (see FIG. 1). Glue applicator 709 may have one or more nozzles positioned to apply glue to flaps, such as flaps J and K. Each of the rails and actuator devices of the folding and sealing device 130 may be supported by rods or other members to interconnect the components to the support frame 109 .

[0117] The upper flap actuator 705 may include an upper pneumatic actuator device 704a having its piston arm connected to the upper plow 708a. Similarly, the lower flap actuator device 707 may include a lower pneumatic actuator device 704b having its piston arm connected to the upper plow 708b. The upper pneumatic actuator device 704a and the lower pneumatic actuator device 704b may be manufactured by Festo, part number 170928, model DFM-25-100-PA-KF.

[0118] The right compression device 706 may include a central pneumatic actuator device 710 with extendable and retractable support rods 712, 714 horizontally aligned and positioned on either side of the central pneumatic actuator device 710. The central pneumatic actuator device 710 may be a Festo model DNC-32-100-PPV-A part number 163309. Referring particularly to FIG. 26 , the central pneumatic actuator device 710 may have piston arms that connect the ends of the support rods 712, 714, as well as a longitudinally extending sealing plate 716. The longitudinally extending sealing plate 716 may have a longitudinally extending upper rail 717 a and a longitudinally extending lower rail 717 b attached thereto. The upper rail 717a may be positioned to engage with the upper major flap F, and the lower rail 717b may be positioned to engage with the lower major flap G when the piston arms of the central pneumatic actuator device 710 are extended horizontally and laterally inward to push the flaps F and G into engagement with the flaps K and J located below them.

[0119] The left compression device 704 includes a left actuator arm 711 that can be actuated by a left actuator device 719 that includes a vertically and longitudinally disposed left compression plate 720 attached to the end of the actuator arm. The left actuator device 719 can be a double-acting pneumatic actuator (not shown) that is supplied with pressurized air through a hose, with the airflow controlled by a solenoid valve device 340 that can be controlled by the PLC 132. Other embodiments are possible. For example, referring to FIG. 26A , a servo-driven actuator for the left actuator arm 711 can be provided that includes a mounting block 741 that is movable along rail guides 745 secured to a horizontally and longitudinally extending plate that forms part of a left support frame 746. The mounting block 741 can slide horizontally along the rail guides 745. An L-shaped plate 743 can interconnect the left actuator arm 711 to the mounting block 741. The mounting block 741 may also be connected at its underside with nuts and bolts to a continuous drive belt 757 made of any suitable material, such as a urethane timing belt with steel wires running through it, the same material that may be used for the belts for the first and second mover units 115a and 115b. The continuous drive belt 757 may extend between a freely rotating pulley 759 attached to the end of the left support frame 746 and a drive wheel of a left servo motor 761. The left servo motor 761 may be an Allen-Bradley model AB·MPL-B320P-MJ22AA servo drive and absolute encoder, interconnected to the PLC 132. The servo drive may be an Allen-Bradley model AB2094-BM01-S servo drive. The left servo motor 761 may be coupled to an APEX·GEARBOX model AE070-005 belt drive wheel.

[0120] PLC 132 may use an encoder (which may be an absolute encoder) to control the rotation of a drive wheel driven by left servo motor 761. Thus, the movement of continuous drive belt 757 is controlled, allowing PLC 132 to determine the position of left actuator arm 711 in real time. As a result, PLC 132 can determine the position of left compression plate 720 in real time. Depending on the type and thickness of the material from which carton blank 111 is formed, the position of left compression plate 720 relative to the plates of right compression device 706 can be adjusted by PLC 132 to ensure the appropriate degree of compression of the flaps of carton blank 111 placed therebetween.

[0121] Each of upper pneumatic actuator device 704a, lower pneumatic actuator device 704b, and central pneumatic actuator device 710 may be a double-acting cylinder and may be supplied with pressurized air controlled via an electronic valve device (not shown), which may be a model CPE14-MlBh-5J-l / 8 valve unit, in communication with and controlled by PLC 132. PLC 132 may thus extend and retract piston arms to effect closure and sealing of flaps during processing of carton blanks 111.

[0122] The upper pneumatic actuator device 704a and the upper plow 708a may be appropriately positioned and angled downward (such as at about 45 degrees to the vertical) so that they can fold the major flap F sufficiently so that it can be engaged by the right compression device 706. Similarly, the lower pneumatic actuator device 704b and the lower plow 708b may be appropriately positioned and angled upward (such as at about 45 degrees to the vertical) so that they can substantially simultaneously fold the major flap G sufficiently so that it can be engaged by the right compression device 706, or at least so that the right compression device 706 can simultaneously compress both flaps F and G toward the minor flaps J and K having upper surfaces that include some adhesive.

[0123] The adhesive applicator 709 may have appropriately positioned nozzles, the operation of which may be controlled by the PLC 132. The adhesive applicator 709 may apply appropriate adhesive to flaps, such as leading minor flap J and trailing minor flap K, as they fold inward to form part of the carton bottom. An example of a suitable, known applicator that may be employed for the adhesive applicator 709 is a Model ProBlue 10 applicator manufactured by Nordson. An example of a suitable adhesive that may be employed for the corrugated carton blank 111 is Cool-Lok 034250A-790 adhesive available from Lanco Adhesives. The adhesive applicator 709 may be in electronic communication with the PLC 132, which may be operable to send signals to the adhesive applicator 709 to apply adhesive at the appropriate times during positioning of the erector heads 120a, 120b.

[0124] The left compression device 704 may be used to enter the carton from the left side and compress flaps F, G, J, and K between the left compression plate 720, the upper rail 717a of the right compression device 706, and the lower rail 717b of the right compression device 706. This compression may be present to help ensure that the panels are compressed together so that the adhesive can properly bond the flaps together to create a rigid carton bottom.

[0125] In some embodiments, once the left and right compression devices 704, 706 have completed compressing the flaps, the PLC 132 sends a signal to the solenoid valve device, causing the left and right compression devices 704, 706 to retract. The carton blank 111 may then be indicated as fully opened for a stand-up carton suitable for loading one or more items. The second erector head 120b can then convey the stand-up carton to the discharge chute 750, which can then release the stand-up carton so that it drops onto the discharge conveyor 117, which can then move the stand-up carton for further processing. In other embodiments, such as the illustrated embodiment, the upright carton 111 can be released and dropped onto the support plate 703, where it can remain until the next carton blank 111, carried by another erector head moved by another moving device (e.g., the first erector head 120a moved by the first moving device 115a), moves to a location where the next carton blank 111 is to be folded, sealed, and compressed. In doing so, the next carton blank 111 can push the previous carton downstream, causing it to fall onto the discharge conveyor 117. Carton discharge conveyors are well known in the art, and any suitable known carton conveyor can be utilized for the discharge conveyor 117.

[0126] Other examples of transfer devices that may be employed to transfer the upright cartons from the folding and sealing device 130 to the carton discharge conveyor include a "blow-off" system, which may use one or more jets of compressed air, a suction cup system, the use of pushing arms, or simply allowing the upright cartons to fall freely.

[0127] A discharge sensor 243 (see FIG. 2), such as an Allen-Bradley Electronic Eye Model 42KL-P2LB-F4, may be located near the bottom of the discharge chute 750. The discharge sensor 243 may be positioned and operable to detect the presence or absence of an upright carton at the input to the discharge conveyor 117. In this manner, the PLC 132 may digitally signal the presence of an upright carton at the bottom of the discharge chute 750 and may prevent another upright carton from being discharged down the discharge chute 750. If an upright carton is at the bottom of the discharge chute 750, the carton forming system 100 may be stopped by the PLC 132 until the malfunction of the discharge conveyor 117 is corrected.

[0128] The overall operation of the carton forming system 100 will now be further described.

[0129] As a first step, an operator can access PLC 132 via HMI 133 and power up carton forming system 100. In response to power up, carton forming system 100 is initialized by PLC 132, with all components positioned in a "start" position. Carton forming system 100 can be authorized to begin operation, such as by placing a stack of carton blanks 111 at the input end of infeed conveyor 204 and instructing PLC 132 via HMI 133 to begin processing the stack of carton blanks 111.

[0130] The PLC 132 can then send a command to the drive motor of the infeed conveyor 204 to begin driving the infeed conveyor belt 214 to move the stack of carton blanks 111 downstream. At some point before the stack of carton blanks 111 reaches the alignment conveyor 206, under the control of the PLC 132, the right guide wall 201 can be indicated to be driven by the drive mechanism 260 to spread the stack of carton blanks 111 wide enough to allow the stack of carton blanks 111 to enter the alignment conveyor 206 even if the stack is misaligned and / or the carton blanks 111 in the stack are not perfectly square with each other. The stack of carton blanks 111 can then be indicated to move downstream until the leading edge of the stack of blanks passes the downstream edge of the infeed conveyor 204, and the gap sensor 242 can be indicated to send a signal to the PLC 132 indicating that the leading edge of the stack has reached the input to the alignment conveyor 206. In response to receiving the signal, PLC 132 can command the drive motor of infeed conveyor 204 to initiate driving of alignment conveyor belt 216, which moves stack of carton blanks 111 downstream toward leading wall 218 of magazine 110. When the leading edge of the stack of carton blanks 111 reaches leading wall 218, presence sensor 240 can send a signal to PLC 132 indicating that the leading edge of the stack of blanks has reached leading wall 218. In response to receiving the signal, PLC 132 can initiate a tamping sequence to "square" the stack of carton blanks 111, as previously described herein.

[0131] To review, a tamping sequence for ensuring that the carton blanks 111 are properly square at the pickup location may include the following steps: The tamping actuator 276 is actuated by pressurized air controlled by the PLC 132 and associated valves and then extended. The right guide wall 201 then contracts to contact the sides of the stack of carton blanks 111, thereby forcing the stack of carton blanks 111 against the left guide wall 200. This pressing may be manifested as aligning the carton blanks 111 so that their side edges are aligned with each other and with the respective longitudinal sidewalls of the left and right guide walls 200 and 201. The tamping actuator 276 then retracts, and the vertical tamping plate 280 presses the stack of carton blanks 111 forward, thereby aligning the carton blanks 111 in the stack so that their leading and trailing edges are aligned perpendicularly with each other and with the inner surfaces of the vertical tamping plate 280 and the inner surface of the leading end wall 218. The stack of blanks 111 is then properly positioned so that the erector heads 120a and 120b can begin picking up blanks from the stack.

[0132] PLC 132 control on second mover device 115b can indicate that one of the erector heads, such as second erector head 120b, is positioned at the calibrated zero position for second erector head 120b. PLC 132 can then operate left belt drive motor 150 and right belt drive motor 154 to accomplish the following sequence of operations:

[0133] First, as shown in FIG. 17, the second erector head 120b can be moved to the pickup position.

[0134] When second erector head 120b is motored vertically downward to remove the top carton blank 111 from a stack of carton blanks 111 in magazine 110, the movement of the second erector head just before suction plate suction cups 312 contact the top surface of carton blank 111 may be shown as generally vertically downward. Before suction plate suction cups 312 contact the surface of panel A of carton blank 111, sensor rod 380 may be shown engaging the surface of panel A, thereby forcing sensor rod 380 upward. This upward movement of sensor rod 380 relative to bottom suction plate 327 may be shown as physically actuating sensor rod 380 and sending a signal to PLC 132 in response. PLC 132 can respond to receiving the signal by slowing down left belt drive motor 150 and right belt drive motor 154 so that the last few centimeters (e.g., 3.5 centimeters) of downward movement toward contact between suction plate suction cups 312 and the top surface of panel A occur at a much slower speed. PLC 132 also knows how far to lower second erector head 120b vertically downward to establish proper contact between suction plate suction cups 312 and panel A. It will be apparent that sensor rod 380 and associated sensor devices can also be used to enable PLC 132 to recognize whether a given carton blank 111, once engaged with magazine 110, remains engaged with second erector head 120b until the appropriate release position is reached, such as after erection of the carton blank 111 is complete.

[0135] The PLC 132 may also be shown to activate the solenoid valve device 340 on the second erector head 120b to generate a suction force on the suction plate suction cups 312 and, optionally, on the piston arm suction cups 320 (although the suction of the piston arm suction cups 320 may be delayed).

[0136] With second erector head 120b in the pick-up position as shown in Figure 17 and suction applied by suction plate suction cups 312, second erector head 120b can engage panel A (see suction cup profile position in Figure 10A) and begin to lift a given carton blank 111 upward, as shown in Figure 18. PLC 132 may be configured to know how high to lift the top surface of a given carton blank 111 so that, once released, first reference line W1 is properly positioned vertically so that the components of folding and sealing apparatus 130 can perform their respective functions, as previously described herein.

[0137] Preferably, when second erector head 120b reaches a determined vertical position, and preferably while second erector head 120b is not moving longitudinally toward folding and sealing apparatus 130, PLC 132 sends a signal to rotate servo motor 364. Rotation of servo motor 364 can be directed to rotate laterally mounted shaft 342 in a particular desired direction at a particular desired rotational speed for a desired period of time. PLC 132 can control the rotational position of laterally mounted shaft 342 to rotate rotator device 350, fixedly mounted to laterally mounted shaft 342, together with laterally mounted shaft 342. Thus, rotator device 350 can be rotated to the position shown in FIG. 19, where suction-engaged piston arm suction cup 320 may be shown attached to the underside of a given carton blank 111, specifically panel D.

[0138] In the next operation, the "blank opening" operation, the PLC 132 can be controlled to indicate that the opposing forces provided by the upwardly acting suction plate suction cups 312 and the opposing downwardly acting piston arm suction cups 320 begin to separate the flattened predetermined carton blank 111. This force is continued by the upper suction plate suction cups 312 and the lower piston arm suction cups 320 as the rotator 350 is imparted with a 90 degree back rotation, moving the predetermined carton blank 111 to the position shown in FIG.

[0139] During backward rotation of the rotator device 350, the mounting block pneumatic actuator device 325 may be supplied with pressurized air controlled via the solenoid valve device 340. The PLC 132 may send a signal to the solenoid valve device 340 to operate the mounting block pneumatic actuator device 325 to extend the piston arm 326 at a particular angular position of the rotor arm 351 and / or a particular angular position of the second erector head 120b provided by an encoder associated with the servo motor 364. The PLC 342, acting via the solenoid valve device 340, may activate the mounting block pneumatic actuator device 325 approximately at the same time that the piston arm suction cup 320 contacts the surface of the downward panel D and rotation of the rotor arm 351 is about to begin or has just begun. By the time the rotor arm 351 has rotated approximately 45 degrees, the piston arm 326 may be fully extended. The piston arm 326 may continue to be extended and remain extended when the rotor device 350 is in the 90 degree position illustrated in FIG.

[0140] Once a given carton blank 111 is opened, the second erector head 120b can securely hold the blank by the suction force exerted on panel A by the suction plate suction cups 312 and on panel D by the piston arm suction cups 320. Also, once opened, flaps K and J must be folded inward toward the bottom opening of the given carton blank 111. In the embodiment shown in FIG. 21 , activation of the paddle 310 closes the trailing minor flap K. Accordingly, the PLC 132 can send a signal to the solenoid valve device 340. This signal causes the rotary actuator 399 to rotate the paddle shaft 316, thus rotating the paddle 310. The paddle 310 can then engage the trailing minor flap K of the given carton blank 111 and fold the trailing minor flap K around its fold line where the trailing minor flap K joins panel D. Thus, the trailing minor flap K can be folded inward toward the bottom opening of a given carton blank 111 .

[0141] The leading bottom flap J may also be folded about its fold line joining the leading bottom flap J and panel B by engagement of the leading bottom flap J with upper folding rail / plow 700 and lower folding rail / plow 701, which form part of the folding and sealing apparatus 130. This folding may occur as the second erector head 120b is moved longitudinally downstream toward the folding and sealing apparatus 130. As a given carton blank 111 held by the second erector head 120b is moved longitudinally downstream toward the folding and sealing apparatus 130, the leading bottom flap J may be folded inward by the upper folding rail / plow 700 and lower folding rail / plow 701, such that both bottom flaps K and J are folded inward to begin forming the bottom of the carton, as shown in FIG.

[0142] Also, when flaps K and J are folded inward, adhesive applicator 709, under the control of PLC 132 or in accordance with other controls or triggers, can apply appropriate adhesive to appropriate locations on flaps K and J through appropriately positioned nozzles. The application of adhesive can occur before, during, or after PLC 132 causes second mover device 115b to move second erector head 120b to a downstream position where major flaps F and G can be folded and compressed onto minor flaps K and J. As shown in FIG. 23 , adhesive can be applied while second mover device 115b moves second erector head 120b to a downstream position for folding and compressing to close the bottom opening.

[0143] The upper flap actuator 705 may then be actuated by the PLC 132 acting through a valve arrangement to cause the upper pneumatic actuator device 704a to extend a piston arm connected to the upper plow 708a. Similarly, the lower flap actuator 707 may then be actuated by the PLC 132 to cause the lower pneumatic actuator device 704b to extend a piston arm connected to the lower plow 708b, as shown in Figures 24 and 25.

[0144] 26, the right-side compression device 706 with the central pneumatic actuator 710 may then extend its piston arms so that a longitudinally extending sealing plate 716, having upper and lower rails 717a and 717b mounted thereon, engages the upper and lower major flaps F and J. The upper rail 717a may be positioned to engage the upper major flap F, and the lower rail 717b may be positioned to engage the lower major flap G, when the piston arms of the actuator device 710 extend horizontally and laterally inward to push the major flaps F and G into engagement with the underlying flaps K and J. The upper and lower flap actuators 705 and 707 may be retracted by the PLC 132 when the compression device 706 engages the major flaps F and G.

[0145] 27, the left compression device 704 can then be used to enter the carton blank 111 from the left side and compress flaps F, G, J, and K between the left compression plate 720 of the left compression device 704, the upper rail 717a of the right compression device 706, and the lower rail 717b of the right compression device 706. This compression can be shown to help establish that the panels are compressed together to ensure that the adhesive properly bonds the flaps together to create a rigid carton bottom.

[0146] The compression is held for a short time (e.g., about 0.5 seconds) to allow the adhesive to sufficiently solidify / cure and the flaps to adhere together, and then the compression can be released by withdrawing the left compression device 704 and the right compression device 706, as shown in FIG. 28. The carton is then considered a fully upright carton and is released from the folding and sealing device 130 and the second erector head 120b. The release may be commanded to occur in response to the PLC 132 causing the piston arm suction cups 320 and the suction plate suction cups 312 to turn off suction force via the solenoid valve device 340. Additionally, the PLC 132 may rotate the rotator device 350 an additional 90 degrees backward to the horizontal, ready position shown in FIG. 29.

[0147] The second erector head 120b can then release the upright carton, which can drop onto the support plate 703 and remain in place on the support plate 703 until the next carton blank 111 is on the support plate 703. The next carton blank 111, carried by another erector head moved by another moving device (e.g., the first erector head 120a moved by the first moving device 115a), is moved to a location where the next carton blank 111 is folded, sealed, and compressed, thereby pushing the fully upright carton downstream to the discharge chute 750, where it can drop onto the discharge conveyor 117.

[0148] The entire sequence of movement of a given carton blank 111 as it is processed by carton forming system 100 is illustrated in isolation in FIGS. 10A, 10B, 10C, 10D, and 11-16. In FIGS. 10A, 10B, 10C, and 10D, the given carton blank 111 is illustrated in its flattened, tubular configuration. In FIG. 11, the given carton blank 111 is illustrated in its open configuration after being opened by an erector head, such as second erector head 120b. In FIG. 12, the given carton blank 111 is illustrated with trailing minor flap K folded inward, and in FIG. 13, the given carton blank 111 is illustrated with leading minor flap J also folded inward. In FIG. 14, the given carton blank 111 is illustrated with major bottom flaps F and G folded inward. In Figure 15, a given carton blank 111 is shown with flaps J, K, F, and G compressed or ready to be compressed to seal the bottom of the stand-up carton. Finally, in Figure 16, the stand-up carton is shown with its opening facing upward so that it can be loaded with one or more articles.

[0149] While the second erector head 120b is handling the carton blank 111, the first erector head 120a, supported and moved by the first moving device 115a, can perform the same processing out of phase with the second erector head 120b. For example, the cyclical movement and motion of the first erector head 120a can be 180 degrees out of phase with the movement and motion of the second erector head 120b. By providing the first erector head 120a and the second erector head 120b to operate simultaneously but out of phase, one can be shown not to interfere with the other. As a result, the capacity of the carton forming system 100 to process the carton blank 111 is significantly increased compared to a system having only a single erector head. It is noteworthy that even using only a single erector head, the processing capacity of the carton forming system 100 is considered relatively high. The relatively high throughput is due, in part, to the relatively short "stroke" (i.e., longitudinal distance) traveled by the erector heads as they pick, erect, fold, seal, and compress the blanks. This relatively short stroke means that the components do not move as far as those of conventional carton erectors. When using two erector heads with movement devices, carton forming system 100 can process approximately 35 carton blanks per minute.

[0150] It will be appreciated that with relatively few modifications to the components of carton forming system 100, carton forming system 100 can be converted from being capable of processing blanks for open-top cartons to being capable of processing blanks that can be made into open-top trays. Figure 46 shows a plan view of a blank for a tray that can be processed according to some embodiments. Examples of other blanks that can be processed and cartons formed are illustrated in Figures 47, 48, and 49, and include blanks for so-called wraparound half slot cases (HSCs) and HSC blanks, as well as blanks for wraparound RSCs.

[0151] It will be apparent that carton forming systems may be arranged in different manners than carton forming system 100 of Figure 1A. For example, several arrangements for carton forming systems are disclosed in patent documents filed as U.S. Patent Application No. 16 / 230,979 on December 21, 2018, and published as U.S. Patent No. 10,556,713 on February 11, 2020, and U.S. Patent Application No. 16 / 808,140 on March 3, 2020, and published as U.S. Patent Application Publication No. 2021 / 0138756 A1 on May 13, 2021, all of which are incorporated herein by reference in their entireties.

[0152] 50, in overview, a carton forming system 6000, presented as an alternative to the carton forming system 100 of FIG. 1A, includes a magazine 6110 adapted to receive and hold a plurality of knock-down carton blanks 111, and an end effector 6120 for removing the knock-down carton blanks 111 from the pickup area and placing the knock-down carton blanks 111 on a shuttle 6140. As described below, the end effector 6120 and the shuttle 6140 cooperate to manipulate the knock-down carton blanks 111 to erect the knock-down carton blanks 111 in a sleeve.

[0153] The carton forming system 6000 may also include a folding device, generally designated 6130, configured to fold one or more flaps of each sleeve, and a sealing station 6135 at which the flaps of the carton blank 111 are sealed. The carton forming system 6000 may also include a carton redirection station 6116 and a carton discharge conveyor 6117 for receiving and removing cartons once they are fully erected.

[0154] The operation of the carton forming system 6000 components may be controlled by a PLC. The PLC may be accessed by a human operator via a human-machine interface (HMI) module secured to the frame 6109 of the carton forming system 6000. The HMI module may communicate electronically with the PLC. The PLC may be any suitable PLC, including, for example, a unit selected from the Allen-Bradley / Rockwell Automation Logix 5000 series of devices, such as the ControlLogix 5561 device. The HMI module may be an Allen-Bradley / Rockwell Automation Panel view part number 2711P-T15C4D1 module.

[0155] Turning now to the various portions of the carton forming system 6000 with reference to FIG. 50 , the magazine 6110 may be configured to hold a stack including a plurality of vertically stacked knock-down carton blanks 111 and may be operable, under the control of a PLC, to move the stack of carton blanks 111 in a horizontal direction generally parallel to the horizontal axis X to a pickup position where the end effector 6120 can remove a carton from the magazine 6110.

[0156] The magazine 6110 may be comprised of a single conveyor or other blank supply device for delivering the carton blanks 111 to the pickup location. In the illustrated embodiment, two conveyors are disclosed: an infeed conveyor 6204 and an alignment conveyor 6206. The infeed conveyor 6204 is configured and operable to move a stack of carton blanks 111 from a stack input location (where the stack can be loaded onto the infeed conveyor 6204 by a human, robotic device, or the like) to a location where the stack of carton blanks 111 is transferred to the alignment conveyor 6206 for horizontal and lateral alignment. The alignment conveyor 6206 may be located downstream relative to the infeed conveyor 6204 and may be used to move the stack of carton blanks 111 to the pickup location. The magazine 6110 can load and initially hold a number of carton blanks 111 in a vertical stack, with the stack resting on the infeed conveyor 6204. The rear wall 6202 attached to the frame 6109 may be configured to prevent the stack from falling backward when initially loaded onto the infeed conveyor 6204. The rear wall 6202 may have a generally planar, vertically and laterally oriented surface facing the stack of carton blanks 111. The infeed conveyor 6204 may have an appropriate length to accommodate a satisfactory number of serially aligned stacks of carton blanks 111 on the infeed conveyor 6204. The PLC may control the operation of the infeed conveyor 6204 to move one stack at a time to the alignment conveyor 6206.

[0157] Once the in-feed conveyor 604 has one or more stacks of carton blanks 111 longitudinally disposed thereon, the stacks may be fed, in turn, onto the alignment conveyor 6206. A sensor (not shown) may be provided adjacent the in-feed conveyor 6204 to monitor whether there are stacks waiting on the in-feed conveyor 6204, and the sensor may be operable to send a warning signal to the PLC that may alert an operator that the magazine 6110 is low and needs to be refilled. The sensor may be Allen Bradley part number 42GRP-9000-QD.

[0158] Of particular note, multiple stacks of blanks may be provided on the infeed conveyor 6204, and each stack may have associated information that can be read by an information reader 6205, such as an electronic or optical reader. For example, a barcode may be provided on each stack of carton blanks 111, such as the top or bottom carton blank 111 in the stack. The barcode may be read by a barcode reader associated with the infeed conveyor 6204. The barcode reader may be in communication with a PLC. The barcode may provide information indicative of characteristics of the carton blanks 111 in a stack. For example, the barcode may identify the size and / or type of carton blank 111 in a particular stack. Other information indicators, such as, for example, RFID tags / chips and RFID readers, may be used. This information is automatically provided to the PLC by the information reader, allowing the PLC to determine whether the current configuration of the carton forming system 100 can handle the processing of a particular type / size of blanks without making manual adjustments to any of the components. It is contemplated that, within a range of types / sizes of carton blanks 111, the carton forming system 6000 of FIG. 50 can process different types / sizes of carton blanks 111 without manually adjusting the components of the carton forming system 6000 of FIG. 50. The barcode / RFID tag, as previously described herein, can provide information regarding the dimensions of the carton blank 111, after which the PLC can determine what, if any, adjustments need to be made to (a) the components of the magazine 6110, (b) the movement of the end effector 6120, (c) the movement of the shuttle 6140, and (d) at least some of the components of the folding device 6130 and some components of the sealing station 6135 to be able to process a particular stack of carton blanks 111.As a result, the carton forming system 6000 of FIG. 50 can automatically process at least some different types of carton blanks 111 to form different upright cartons without manual operator adjustments to any of the components of the carton forming system 6000.

[0159] The belt of the infeed conveyor 6204 can be driven by a suitable motor, such as a DC motor or a variable frequency drive motor, via a DC motor drive (all sold by Oriental as model AXH-5100-KC-30) controlled by a PLC.

[0160] When the PLC is given a command (e.g., by a human operator via an HMI module), it can operate the infeed conveyor 6204 to move the stack of carton blanks 111 horizontally downstream. The PLC can control the motor via the motor drive and thus the infeed conveyor 6204 to move the stack towards and transfer to the alignment conveyor 6206.

[0161] The alignment conveyor 6206 may be driven by a motor with a corresponding motor drive. The motor for the alignment conveyor 6206 may be controlled by a PLC. The alignment conveyor 6206 may operate to move the stack of carton blanks 111 further horizontally until the front of the stack abuts a planar front stop picket wall 6218.

[0162] The belts of each of the infeed conveyor 6204 and alignment conveyor 6206 may be made from any suitable material, such as, for example, ropanyl.

[0163] During horizontal movement of the stack of carton blanks 111 by the infeed conveyor 6204 and the alignment conveyor 6206, the left side of the stack of carton blanks 111 may be supported and guided by a left side wall 6200, which may be fixed to the frame 6109. The left side wall 6200 may be generally vertically oriented and extend horizontally for substantially the entire length of the infeed conveyor 6204 and the entire length of the alignment conveyor 6206.

[0164] The outside of the magazine 6110 adjacent the infeed conveyor 6204 may remain open, while the outside of the alignment conveyor 6206 is shown as having a movable outer guide wall 6201 .

[0165] 50, the left side wall 6200 is fixed and the outer guide wall 6201 may be moved laterally as part of a blank stack alignment procedure to provide general longitudinal alignment of the edges of the carton blanks 111 in the stack being prepared for processing as the stack is held between the left side wall 6200 and the outer guide wall 6201. Specifically, the PLC may position the outer guide wall 6201 based on the height dimensions of the knock-down carton blanks 111 in the stack being prepared for processing based on information previously read by the information reader 6205.

[0166] To pick up the blank, the end effector 6120 may have one or more suction cups that provide a suction force to the panel acting generally normal to the surface of the panel being engaged. Other types of suitable engagement devices may also be employed.

[0167] The end effector 6120 is shown as having a dedicated, independently driven and controlled movement device 6115 that allows the end effector 6120 to move in the plane defined by both the vertical axis Z and the horizontal axis Y. When movement of the end effector 6120 is limited to only the Z and Y directions, a relatively less complex movement device can be constructed than when movement in all three directions is desired.

[0168] The movement device 6115 may be generally rectangular in cross section and includes a vertically oriented support tube to which an end effector 6120 is mounted by a mounting block so that the end effector 6120 moves in space with the support tube.

[0169] The folding device 6130 is shown as having opposing horizontally reciprocating fin plows, an upstream fin plow and a downstream fin plow, which are slidably supported on horizontal rails 6512 extending in the X direction.

[0170] The horizontal rails 6512 along which the fin plows travel are attached at their ends to the bases of L-shaped supports, one of which is associated with reference numeral 6560a. The L-shaped supports ride within channels 6562 in vertical ribs 6109a, 6109b of the frame 6109. A servo motor 6568 is geared to a common drive shaft 6570 to rotate pinions (not shown) within hubs 6572a, 6572b. The pinions mesh with ring gear portions of shafts 6574a, 6574b to rotate shafts 6574a, 6574b, thereby adjusting the vertical position of shafts 6574a, 6574b. Shafts 6574a, 6574b are rotatably coupled to the tops of the L-shaped supports. As a result, operating the servo motor 6568 in one rotational direction raises the L-shaped support and therefore the fin plow, and operating the servo motor 6568 in the opposite rotational direction lowers the L-shaped support.

[0171] Similarly, the vertical rails along which the folding plow travels via the support arms and carriage are attached to linear supports that ride in channels in the vertical ribs of frame 6109. A common drive shaft also rotates a pinion (not shown) in hub 6572c, which meshes with a ring gear portion of shaft 6574c to rotate shaft 6574c and thereby adjust the vertical position of shaft 6574c. Shaft 6574c is rotatably coupled to the top of the linear supports. As a result, operating servo motor 6568 in one rotational direction raises the linear supports, and thus the folding plow, while operating servo motor 6568 in the opposite rotational direction lowers the linear supports. Furthermore, because all supports are adjusted by the common drive shaft 6570, they are all adjusted to the same vertical range by operation of the servo motors.

[0172] The sealing station 6135 includes a tape sealer 6640 and a flap turn-back rod 6632 that is supported by the fin support rail 6512 and moves up and down with the fin plow. The sealing station 6135 also includes a pair of opposing conveyor belts: an upper conveyor belt driven by an upper conveyor belt servo motor 6602 and a lower conveyor belt 6610 driven by a lower conveyor belt servo motor 6612. The tape sealer 6640 is positioned between the upper and lower conveyor belts. The lower conveyor belt 6610 and support platform 6614 are supported by the factory floor. The upper conveyor belt is attached to a subframe 6622. The servo motor 6568 has a second drive shaft operatively associated with a drive train (not shown) such that operation of the servo motor 6568 adjusts the vertical position of the subframe 6622, and therefore the vertical position of the upper conveyor belt relative to the lower conveyor belt 6610. Furthermore, note that the drive shaft and the common drive shaft 6570 are driven by the same servo motor 6568, such that vertical adjustment of the upper conveyor belt is mirrored by vertical adjustment of the fin plow. However, the drive train is configured with a 2:1 drive ratio such that the drive shaft rotates twice for every rotation of the common drive shaft 6570. As a result, vertical adjustment of the fin plow, folding plow, tape sealer, and flap support rods provides 2 ncm of vertical adjustment of the upper conveyor belt. This ensures that the centerline of the carton sleeve remains at the height of the fin and tape sealer at any position on the upper conveyor belt.

[0173] The sealing station 6135 terminates at a carton redirection station 6116. The carton redirection station 6116 has a pair of deflectors 6650, 6652 that redirect the upright cartons from their lying-down position at the sealing station 6135 to an upright position on the discharge conveyor 6117 with their open tops facing upward as they drop from the end of the sealing station onto the discharge conveyor 6117. The discharge conveyor 6117 may be implemented as a simple endless belt conveyor driven by a discharge conveyor servo motor 6648.

[0174] In another embodiment of the present invention, shown schematically in FIG. 51 , a carton forming system 5100 is configured substantially similarly to the carton forming system 6000 of FIG. 50 , except as described below. In the carton forming system 5100 of FIG. 51 , multiple magazines M1-M5 may be supported by one or more frame structures above a common in-feed conveyor 6204′, which may be configured generally similarly to the in-feed conveyor 6204 of FIG. 50 . The magazines M1-M5 may be vertically spaced apart longitudinally above the in-feed conveyor 6204′. The in-feed conveyor 6204′ feeds an alignment conveyor 6206′, which may be similar to the alignment conveyor 6206 of FIG. 50 . Except as described below, the remainder of the carton forming system 5100 of FIG. 51 may be the same as the carton forming system 6000 of FIG. 50 .

[0175] Magazines M1-M15 can each contain one or more stacks of product packaging, such as case blanks like carton blank 111, that are generally processed by carton forming system 6000 of FIG. 50, with at least some, and possibly each, of magazines M1-M15 containing packaging / case blanks of a different type / size and / or configuration compared to the other magazines. The size, configuration, and type of case blanks (and cases that may be formed therefrom) may be varied to provide a range of case sizes, configurations, and types that can be automatically processed by carton forming system 5100 of FIG. 51 without requiring manual intervention to alter components of carton forming system 5100 of FIG. 51. The PLC of carton forming system 5100 of FIG. 51 can be programmed such that the specific dimensions / overall size / configuration (e.g., regular slot carton or "RSC") / type of each of the carton blanks held in each one of magazines M1-M5 is stored in the PLC's memory.

[0176] Each magazine M1-M5 provides a vertical stack of case blanks above the infeed conveyor 6204' and may be operable, under PLC control, to dispense a single case blank in a flat orientation onto the infeed conveyor 6204' on demand. An example of a suitable type of vertical case dispensing magazine arrangement is that which forms part of the 310E Case Erector manufactured by Wepackit, Inc. of Orangeville, Ontario, Canada (see www.wepackitmachinery.com / 310E / 310E.pdf).

[0177] The PLC provides case formation commands, causing any of the magazines M1-M5 to dispense carton blanks of the appropriate configuration / size onto the infeed conveyor 6204' as needed for delivery to the alignment conveyor 6206'. The PLC is thought to selectively move and transport one carton blank at a time from any one of the magazines M1-M5 onto the infeed conveyor 6204'. Thus, separate individual case blanks can be serially and longitudinally fed by the infeed conveyor 6204' to the alignment conveyor 6206' in a desired order. The particular sequence / order of carton blanks placed on the infeed conveyor 6204' of the carton forming system 5100 of FIG. 51 can be determined and selected by the PLC or another control system so that the case blanks can arrive at the alignment conveyor 6206' in the desired order as desired for processing the blanks within the carton forming system 5100 of FIG. 51.

[0178] The PLC can maintain a record in its memory of the order in which the case blanks are placed on the infeed conveyor 6204'. For example, this information includes the type / size / configuration of the case blanks and, if the carton forming system 5100 of FIG. 51 includes a labeler, label information for the labels to be applied to the carton blanks. A new record can be added each time a new carton request is received, and optionally, records can be deleted once a carton is formed (and labeled). In this manner, such records can be maintained in sequential order in the PLC's memory using conventional shift register techniques. In this manner, a record of the next carton blank scheduled to arrive on the alignment conveyor 6206' can be provided at the output of the shift register as that carton blank arrives, and the type / configuration / size of that carton blank and its label information can be determined from the provided output.

[0179] Additional features that may be employed in the carton forming system 6000 are disclosed in U.S. Patent Application Publication No. 2021 / 0138756 A1, published May 13, 2021, in the name of HJ Paul Langen, the entire contents of which are incorporated herein by reference.

[0180] FIG. 52 shows an order fulfillment location 5200 in a plan view. The order fulfillment location 5200 can be thought of as being physically organized, in a logical or physical manner, into areas or regions associated with various functions. The order fulfillment location 5200 includes a product storage guidance area 5202, a tower storage area 5204, a shipping container guidance area 5206, a product guidance area 5208, an autonomous mobile robot movement area 5210, and a route distribution and accumulation area 5212. In practice, depending on the size of the order fulfillment location 5200, the order fulfillment location 5200 can include multiple areas illustrated in FIG. 52, and in some cases, one or more areas can be omitted. The product guidance area 5208 may be surrounded by multiple walls and a roof.

[0181] In product storage guidance area 5202, various products may be shown arriving at order fulfillment location 5200, for example, in multiple transport trailers.

[0182] Arriving products are often organized on pallets and may be stored in multiple towers, which are placed in tower storage area 5204. Humans and / or robots 5999 may unload the products delivered to order fulfillment system 5200 (e.g., which products may be delivered on pallets by transport trailer). Humans and / or robots 5999 may store the unloaded products in the towers. Once filled with products, a given tower is moved by a tower transport AMR (described below) so that the given tower is located within tower storage area 5204. The process of storing products arriving at order fulfillment location 5200 in multiple towers is described in more detail below.

[0183] The shipping container guide area 5206 may be populated with multiple carton forming systems according to the carton forming system 100 design disclosed herein.

[0184] According to an aspect of the present invention, multiple autonomous mobile robots (AMRs) may be deployed for movement within the autonomous mobile robot movement area 5210.

[0185] As will be described in more detail below, the AMR may be controlled to visit a shipping container guidance area 5206 to obtain a shipping container.

[0186] The AMR and shipping container combination may then be controlled to visit one or more stations in product guiding area 5208. At a given station in product guiding area 5208, one or more products may be received in the shipping container carried by the AMR. The stations in product guiding area 5208 may be associated with providing products stored in tower storage area 5204.

[0187] Upon receiving the products that complete the order, the AMR may then be controlled to move around the autonomous mobile robot travel area 5210 so that further order fulfillment functions are performed. In some examples, the AMR may then be controlled to move the shipping container to a location within the autonomous mobile robot travel area 5210 where the weight of the shipping container may be verified. The shipping container is then sealed and labeled.

[0188] The weight-checked, sealed, and labeled shipping containers are then received at the route distribution collection area 5212 where they are loaded onto delivery vehicles by humans and / or robots 5998.

[0189] FIG. 53 is a top right perspective view of an AMR 5300 according to an embodiment of the present invention.

[0190] FIG. 53A is a top right perspective view of the AMR 5300 of FIG. 53 with the addition of a shipping container 5309.

[0191] The AMR 5300 may have a base that forms part of a mobile cart 5304. Other components may be attached to or interconnected with the base of the cart 5304. The AMR 5300 may include an outer case 5302 carried by the cart 5304. Features of the cart 5304 may be familiar from known autonomous mobile robots. Indeed, the cart 5304 is expected to include a rechargeable power source, such as a battery (not explicitly shown), and a transmission (not explicitly shown). The transmission, or drive motor, may be configured to move the cart 5304 on a set of drive wheels (not shown). The rechargeable power source, transmission, and drive wheels may be attached to the base of the cart 5304. A typical modern AMR can travel for up to three hours between charges. The AMR 5300 can be configured to return to a designated charging station as needed. At the designated charging station, the AMR 5300 can establish a connection between a charging circuit (not shown) and an external energy source, such as a wall outlet.

[0192] In addition to the set of drive wheels, the cart 5304 may also include a set of stabilizing wheels 5306S, which may be caster wheels, to facilitate rolling movement of the cart 5304 during operation. Including the drive wheels and stabilizing wheels 5306S, there are at least three wheels in total that combine to support and drive movement of the cart 5304 across a surface. The cart 5304 may also be expected to include a control system (not explicitly shown), which may be implemented as a processor in communication with a memory. The AMR 5300 may include a transceiver used to establish a wireless connection with a controller that forms part of the overall system, which will be described in more detail below.

[0193] Details of an example design of the AMR 5300 are described in U.S. Provisional Patent Application No. 63 / 424,676, the contents of which are incorporated herein by reference. Details of this example design include a description of a plurality of suction cups attached to the outer casing 5302. As shown in FIG. 53A, the suction cups may be shown to act to maintain a shipping container 5309 on the AMR 5300.

[0194] FIG. 54 is a cross-sectional perspective view of an AMR 5300. An outer case 5302, which may be made from a suitable material such as molded plastic, fiberglass, aluminum, or other metal, is shown using dotted lines to indicate the contents of the outer case 5302 held within an interior cavity of the outer case 5302. The contents of the outer case 5302 may include a vacuum reservoir 5402 and a plurality of suction cups 5404 attached to the outer case 5302. The suction cups 5404 may be attached generally vertically upward with the contact surface facing upward. In other embodiments, the suction cups 5404 may additionally or alternately be oriented in other directions, such as laterally.

[0195] Preferably, the plurality of suction cups 5404 are attached to the outer case 5302 in a manner with the contact surfaces of the suction cups 5404 facing upwards, which maintain the top surface 5412 of the outer case 5302 flush. Indeed, the top surface 5412 of the outer case 5302 may appear to have a plurality of recesses corresponding to the plurality of suction cups 5404. The suction cups 5404 may be implemented using, for example, 2" piGRIP suction cups manufactured by PIAB of Tabby, Sweden. The cart 5304 of the AMR5300 may be fitted with a vacuum pump 5406 in pneumatic communication with the vacuum reservoir 5402. The vacuum pump 5406 may be driven by an integral electric motor (not shown). Examples of electric vacuum pumps suitable for use as the vacuum pump 5406 include those available from McMaster-Carr of Cleveland, Ohio, and Thomas of Sheboygan, Wisconsin. The vacuum reservoir 5402 is also in pneumatic communication with the plurality of suction cups 5404 through a corresponding plurality of openings / apertures in the vacuum reservoir 5402. A plurality of openings / apertures in the vacuum reservoir 5402 and each of the suction cups 5404 ( and each valve 5502, described below), is a sliding plate 5408. The sliding plate 5408 may be made from a suitable material, such as formed plastic, fiberglass, aluminum, or other metal, and may be configured with perforations / openings corresponding to each opening in the vacuum reservoir 5402. The sliding plate 5408 may be movable between a closed position / state in which the openings in the vacuum reservoir and the openings for each valve 5502 / suction cup 5404 combination (described further below) are blocked, and an open position / state in which the openings in the vacuum reservoir and the openings for each valve 5502 / suction cup 5404 combination (described further below) are open, thereby generating a suction force at the upper contact surface of each valve 5502 / suction cup 5404 combination.

[0196] The slide plate 5408 can be moved between open and closed positions by actuation of an electric actuator 5410. One example of a type of actuator that can be employed as the electric actuator 5410 is a solenoid valve type actuator, such as the Model AL4092600UX0438 Open Frame Actuator Linear Mini Push-Pull Solenoid Electromagnet, DC 4.5V, 40g / 2mm manufactured by uxcell Corporation of Hong Kong, China. Another example of a type of electric actuator that can be employed as the electric actuator 5410 is the Model VSM0632 6mm Micro Linear Stepper Motor Screw Motor with Bracket manufactured by Vic Tech Motor Corporation of Changzhou, China. A further example of an electric actuator that can be employed as the electric actuator 5410 is a linear potentiometer type actuator, such as the LMCR8 series models manufactured by P3 America, Inc. of San Diego, California.

[0197] Figure 55A shows a cross-sectional view of a portion of the outer casing 5302 in conjunction with a number of suction cups 5404, a vacuum reservoir 5402 and a sliding plate 5408. The cross-sectional view of Figure 55A shows that each suction cup 5404 incorporates a one-way valve 5502. The one-way valve 5502 can be implemented, for example, using a piSave Sense flow control / check valve manufactured by PIAB of Tabby, Sweden.

[0198] 55A, the sliding plate 5408 is in a first open position. In the first open position, the holes in the sliding plate 5408 are aligned with the openings in the vacuum reservoir 5402. The alignment illustrated in FIG. 55A may be shown to allow for the possibility of air flow through each suction cup 5404, into the one-way valve 5502 of the suction cup 5404, through the one-way valve 5502 of the suction cup 5404, and into the negative pressure vacuum reservoir 5402. In particular, when the sliding plate 5408 is in the first open position, the flow of air through the suction cups 5404 is controlled by the one-way valve 5502.

[0199] Figure 55B shows in cross section the same portion of the outer case 5302 shown in Figure 55A. In Figure 55B, the sliding plate 5408 is in the second, closed position. In the second, closed position, the perforations in the sliding plate 5408 are not aligned with the openings in the vacuum reservoir 5402. The lack of alignment shown in Figure 55B appears to disallow or block the flow of air through the one-way valve 5502 in the suction cup 5404, into the suction cup 5404, and into the vacuum reservoir 5402.

[0200] During operation, the pressure within the vacuum reservoir 5402 is reduced by actions performed by the vacuum pump 5406. Indeed, the vacuum pump 5406, in response to commands received from the control system, may cause the integrated electric motor to generate negative pressure within the vacuum reservoir 5402. When the control system controls the drive wheels 5306D to steer the AMR 5300, the sliding plate 5408 may be maintained in the second position, thereby reducing leakage of vacuum pressure.

[0201] FIG. 56A illustrates an embodiment of the basic concept of a fulfillment center 7000 utilizing AMR devices such as the AMR 5300 of FIG. 53 and / or the AMR 5800 illustrated in FIG. 58 and described below.

[0202] Of the multiple AMRs in the system, each AMR, such as AMR 5800 (and / or AMR 5300), can be programmed to move from station to station along a path 7680 as follows: 1. Each AMR 5300 / 5800 moves to one of a number of case guide stations 7628 where a case erector transports an erected, bottom-sealed carton onto the AMR 5300 / 5800. 2. Each AMR 5300 / 5800 then moves to one or more product guide stations within product guide area 7608, which may be manual and / or robotic product guide stations, where an operator and / or robot places one or more ordered products into a standing carton. Robotic product guide stations are sometimes referred to as product transfer devices. 3. Each AMR 5300 / 5800 then travels to one of several order verification stations 7630 to verify that the contents of the case match the ordered products. 4. Each AMR5300 / 5800 then moves to and passes through the top sealer 7620 and case labeler 7624. 5. Each AMR 5300 / 5800 then moves to the finished case discharge conveyor 7626. 6. Each AMR5300 / 5800 then moves to the charging station 7622 or back to one of the case guide stations 7628 where a case assembler transfers the assembled and bottom-sealed case onto the AMR5300 / 5800, allowing the cycle to repeat.

[0203] The case erector of the case guide station 7628 may be a Model MC-17169 case erector manufactured by AFA Systems, Inc. of Ontario, Canada, or other case erectors described herein. The case guide station 7628 may also be referred to as a shipping container delivery system. The case top sealer 7620 and case labeler 7624 may be devices also available from AFA Systems. The case erector of the case guide station 7628 is disclosed in U.S. Patent Application Publication No. 2021 / 0138756 A1, published May 13, 2021, the entire contents of which are incorporated herein by reference.

[0204] FIG. 68 illustrates an example arrangement of a case top sealer 7620 (which may also provide an example case sealer for other order fulfillment systems described herein) in a front left perspective view. It is understood that the example case top sealer 7620 of FIG. 68 has many of the same features and components as known case top sealers. However, the example case top sealer 7620 of FIG. 68 may be distinguished from known case top sealers in that the upstanding cartons are maintained on the AMR 5300 / 5800 while being acted upon by the components of the example case top sealer 7620 of FIG. 68. That is, the example case top sealer 7620 of FIG. 68 may be considered a “drive-through” sealing device. The AMR 5300 / 5800 may utilize only its own drive mechanism to move through and be powered by the sealing device 7620.

[0205] Components of the example case top sealer 7620 of FIG. 68 may include a pair of laterally spaced, longitudinally extending guide belts 6802. The pair of laterally spaced, longitudinally extending guide belts 6802 may be made of a suitable material, such as rubber. Each guide belt 6802 may be arranged to loop around a pair of freely rotatable pulley wheels, which may be rotatable about generally vertically oriented axles. The guide belts 6802 may be shown operable to guide a standing carton through the example case top sealer 7620 during longitudinal movement of the AMR 5300 / 5800 with the standing carton loaded thereon. The guide belts may be shown contacting respective opposing sides of a standing carton during longitudinal movement of the AMR 5300 / 5800 with the standing carton secured thereon through the example case top sealer 7620 of FIG. 68.

[0206] In an embodiment of the present invention, the movement and positioning of the guide belt 6802 can be sensed by a guide belt movement sensor (not shown). Output from the guide belt movement sensor can be displayed to indicate the movement of the AMR 5300 / 5800 and erected carton through the case top sealer 7620 and can be transmitted to an order fulfillment processor, the operation of which is described in further detail below. Conveniently, the position of the pulley wheels is laterally adjustable to vary the distance between the guide belts 6802, thereby accommodating erected cartons of different sizes.

[0207] In common with known case top sealers, the components of the example case top sealer 7620 of FIG. 68 may include one or more folding rails 6806, one or more flap kickers, such as a rear flap kicker 6808, and a sealing system 6804. In operation, as the guide belts 6802 guide an upstanding carton through the example case top sealer 7620 during longitudinal movement of the AMR 5300 / 5800 having the upstanding carton thereon, the rear flap kicker 6808 may act to close the trailing top flaps, and the folding rails 6806 (and / or one or more other flap kicker devices) may act to close the leading and side top flaps. Similar to known case top sealers, following or in conjunction with the top flaps being closed, the sealing system 6804 may act to apply tape or other adhesive to seal the carton and hold the top flaps in the closed position.

[0208] 68 is considered a "drive-through" sealing device, the case labeler 7624 is considered a "drive-through" case labeler such that the AMR 5300 / 5800 moves entirely under its own power through the case labeler 7624. In fact, the case top sealer 7620 and case labeler 7624 may be juxtaposed such that an open, stand-up carton is closed, sealed, and labeled as the AMR 5300 / 5800 transports the stand-up carton through the juxtaposed case top sealer 7620 and case labeler 7624.

[0209] Figure 56 illustrates in plan view a portion 5600 of an order fulfillment center. The fulfillment center portion 5600 includes a charging station 5602, a shipping container guide station 5604, a plurality of product loading stations 5606A, 5606B, 5606C (collectively or individually 5606), a dunnage guide station (not shown), an inspection station (not shown), a rework station (not shown), an order verification station (not shown in Figure 56), a closure station 5616, and a dispatch staging station 5618. The shipping container guide station 5604 is also referred to as a shipping container distribution system.

[0210] FIG. 57 illustrates exemplary steps in a method for fulfilling an order.

[0211] 56, the control system may control the drive wheels 5306D to move the AMR 5300 from the charging station 5602 to the shipping container guide station 5604 (step 5702, FIG. 57). When the AMR 5300 arrives at the shipping container guide station 5604, the control system may control the electric actuator 5410 to move the slide plate 5408 to a first position. Minimizing vacuum leakage in the reservoir is believed to be an important step in minimizing the number and duration of operation of the vacuum pump 5406. Frequent operation of the on-board vacuum pump 5406 may be shown to reduce the cycle time (time between recharging sessions) of the AMR 5300.

[0212] At the shipping container guide station 5604, a shipping container 5309 of appropriate size to fulfill a customer order may be received onto the top surface 5412 of the outer case 5302 (step 5704, FIG. 57) (see FIG. 53A). Under conditions where the shipping container 5309 does not completely cover the top surface 5412 of the outer case 5302, a subset of the one-way valves 5502 may indicate that they are sensing coverage by the shipping container. In response to the sensing, the subset of the one-way valves 5502 may operate to open autonomously. The remaining one-way valves 5502 may remain closed. The shipping container 5309 may be a flexible (e.g., plastic) type bag, envelope, tray, carton, case, or box. When the shipping container 5309 is not filled with items, the shipping container 5309 may have a relatively low mass / weight and therefore may be prone to shifting if not secured to the top surface 5412 by suction force(s), especially during movement of the cart 5304 during operation.

[0213] The AMR 5300 may generate a suction force on each suction cup 5404 of at least some of the plurality of suction cups 5404 (step 5706, FIG. 57), thereby holding the shipping container 5309 on the AMR 5300.

[0214] The combination of the sliding plate 5408 moving to the first position and the subset of one-way valves 5502 autonomously opening may be shown to allow the suction cups 5404 to act on the shipping container 5309 to maintain the shipping container 5309 in place on the top surface 5412 of the outer case 5302. In some embodiments, the footprint of the shipping container 5309 is such that when placed and held on the top surface 5412, the boundaries of the shipping container 5309 do not extend beyond the perimeter of the top surface 5412.

[0215] In the absence of a shipping container completely covering the top surface 5412 of the outer case 5302, only a subset of the plurality of suction cups 5404 corresponding to a subset of the autonomously opened one-way valves 5502 act on the shipping container 5309. The one-way valves 5502 may be configured and operative such that only when a surface area of ​​the object (e.g., a portion of the underside of the shipping container 5309) covers a corresponding suction cup 5404, the corresponding state of the valve changes from a substantially non-operational mode (which may only allow a very low level of airflow into the suction cup 5404 / valve 5502 combination) to an operational mode that provides a substantially increased (e.g., full) suction force to be generated by that suction cup created by a substantially increased (e.g., maximum) developed airflow into the suction cup 5404 / valve 5502 combination. By activating only those suction cups 5404 that are covered by a portion of the surface of the shipping container, energy consumption by the AMR 5300 may be reduced when compared to embodiments in which all of the one-way valves 5502 are opened simultaneously and all of the suction cups 5404 are activated, regardless of whether the contact surface of the shipping container 5309 covers all or only a portion of the contact surface of the suction cups 5404. For example, a smaller vacuum pump may be used, resulting in lower pump investment and reduced energy consumption.

[0216] The one-way valve 5502 may indicate that the AMR 5300 is adaptable to various sizes and shapes of shipping containers to maintain the shipping container in place on the top surface 5412 of the outer case 5302. That is, the AMR 5300 may be adapted to maintain the shipping container 5309 in place when the shipping container is a regular slotted bottom-up case, a paper box with an open top or side, a cardboard box with an open top or side, a flexible bag with an open end, or an envelope with an open top or side. In general, the AMR 5300 may be considered to be efficiently adaptable to maintain the shipping container in place for various sizes of shipping containers, such as when the shipping container is any type of shipping container having a bottom portion that can cover one or more suction cups and an opening on the top, side, or end of the shipping container.

[0217] The shipping container 5309 is held in place on the top surface 5412 of the outer case 5302, allowing the shipping container 5309 to remain secured to the AMR 5300. In other words, the shipping container 5309 can be prevented from shifting or falling while the AMR 5300 performs operations such as transporting the shipping container 5309 to various stations around the fulfillment center (see FIG. 56 ), loading the shipping container 5309 with products, closing and labeling the shipping container 5309, etc. It will be appreciated that the embodiments disclosed herein can be particularly advantageous when the shipping container 5309 is empty or contains lighter weight items that are accordingly more likely to move around on or fall off the top surface 5412, especially when the cart 5304 is moving during operation.

[0218] In some embodiments, while suction force is being generated by each suction cup 5404 of at least some of the plurality of suction cups 5404 to hold the shipping container 5309 on the AMR 5300, the control system of the cart 5304 can subsequently execute instructions to move the AMR 5300 from the shipping container guide station 5604 to one or more item loading stations 5606 (step 5708, FIG. 57) by instructing the transmission to appropriately move the set of drive wheels 5306D.

[0219] Thus, the AMR 5300 may be shown moving the shipping container 5309 from the shipping container guide station 5604 to the first product loading station 5606A (step 5708, FIG. 57), where the AMR 5300 may maintain its hold on the shipping container 5309 while the shipping container 5309 receives the product loaded therein (step 5710, FIG. 57). The loading of the product into the shipping container 5309 may be performed autonomously, for example, by a commanded product loading robot (not shown), or may be performed manually, for example, by a human. The AMR 5300 may transport the shipping container 5309 from the first product loading station 5606A to the second product loading station 5606B, where the shipping container 5309 may be loaded with additional product.

[0220] If the AMR 5300 determines that it has not yet visited the complete set of product loading stations 5606 for a particular customer order (step 5712, FIG. 57), the control system can move the AMR 5300 (step 5714, FIG. 57) to transport the shipping container 5309 to additional product loading stations 5606.

[0221] Once the AMR 100 determines that it has visited the complete set of product loading stations 5606 for a particular customer order (step 5712, FIG. 57), the control system may move the AMR 5300 (step 5714, FIG. 57) to transport the shipping container 5309 from the last product loading station 5606 to a top closure and labeling system (not shown) at closure station 5616.

[0222] The top closure and labeling system may be designed to accept regular slotted cases, envelopes, or bags, among other shipping containers. The shipping container 5309 can be closed and labeled by the top closure and labeling system without the shipping container 5309 leaving its fixed position on the top surface 5412 of the outer case 5302.

[0223] Advantageously, as proposed herein, it is shown that the number of fulfillment operations that can be performed when items are loaded directly into a shipping container 5309 secured to an AMR 5300 is significantly reduced compared to the number of fulfillment operations that currently need to be performed with conventional fulfillment operations.

[0224] Upon visiting the closure station 5616, the control system may move the AMR 5300 (step 5716, FIG. 57) to transport the shipping container 5309 from the closure station 5616 to an appropriate dispatch staging station 5618. At the dispatch staging station 5618, the control system of the AMR 5300 may control the electric actuator 5410 to move the sliding plate 5408 to a second position. It should be understood that when the sliding plate 5408 is in the second position, the vacuum cups 5404 do not act to maintain their grip on the shipping container 5309, and the shipping container 5309 is released from the AMR 5300 (step 5718, FIG. 57). Thus, the shipping container 5309 is removed from the AMR 5300 and deposited at the dispatch staging station 5618, for example, onto an appropriate dispatch staging conveyor.

[0225] In addition to the item loading station 5606, closing station 5616, and shipping staging station 5618 described above, the AMR 5300 may be shown transporting shipping containers 5309 to and from various other stations or areas, such as a dunnage induction station, an inspection station, a rework station, and an order confirmation station.

[0226] Once the shipping container 5309 is removed from the AMR 5300, the AMR 5300 may be controlled to return to the shipping container guide station 5604 to obtain a new shipping container, which is appropriate for the next customer order to be fulfilled.

[0227] Conveniently, the one-way valves 5502 and their ability to open autonomously in response to sensing that a shipping container 5309 is covering them can be shown to minimize vacuum loss when any portion of the suction cup 5404 is not covered by a shipping container, thereby giving the AMR 5300 a feature of universality.

[0228] Additionally, the sliding plate 5408 may be shown to function as a vacuum cutoff, thereby ensuring that a shipping container of any size secured to the AMR 5300 can be released at any time in the fulfillment process without losing vacuum within the vacuum reservoir 5402.

[0229] In particular, it is contemplated that the combination of outer case 5302 and vacuum pump 5406 may be used in combination to retrofit existing versions of cart 5304. Of course, for proper operation, the cart's control system would receive appropriate software updates. Furthermore, the AMR 5300 may be integrally formed; that is, there may be no discernible distinction between the cart 5304 and the elements that have been described herein as housed by the outer case 5302.

[0230] Features of the cart 5304 of FIG. 53 may be familiar from known autonomous mobile robots. Indeed, the cart 5304 is expected to include a rechargeable power source, such as a battery (not explicitly shown), and a transmission (not explicitly shown). The transmission or drive motor may be configured to move the cart 5304 on a set of drive wheels 5306D. The rechargeable power source, transmission, and drive wheels 5306D may be mounted to the base of the cart 5304. A typical modern AMR can travel for up to three hours between charges. The AMR 5300 may be configured to return to a designated charging station 5602 as needed. At the designated charging station 5602, the AMR 5300 can establish a connection between a charging circuit (not shown) and an external energy source, such as a wall outlet.

[0231] It will be apparent that other mechanisms for maintaining shipping containers on the AMR are available. Figure 58 illustrates an AMR 5800 as an alternative to the AMR 5300 of Figure 53, in accordance with an embodiment of the present invention.

[0232] The AMR 5800 may have a base that forms part of a mobile cart 5804. Other components may be attached to or interconnected with the base of the cart 5804. Similar to the AMR 5300 of FIG. 53, the AMR 5800 of FIG. 58 may include an on-board control system (not shown). The AMR 5800 may include a first belt 5802A and a second belt 5802B carried by the cart 5804. The first belt 5802A may be controlled, for example, by an on-board control system (not shown), in a manner independent of the manner in which the second belt 5802B is controlled. Attached to the first belt 5802A may be a first lug 5812A. Attached to the second belt 5802B may be a second lug 5812B.

[0233] Through an on-board control system controlling the first belt 5802A, the first lug 5812A may be urged toward or away from the second lug 5812B. Similarly, through an on-board control system controlling the second belt 5802B, the second lug 5812B may be urged toward or away from the first lug 5812A. In this manner, by manipulating the positions of the first lug 5812A and the second lug 5812B relative to one another, the on-board control system can control the first belt 5802A and the second belt 5802B to provide a gap between the first lug 5812A and the second lug 5812B suitable for easily loading an erected shipping container of selected dimensions (e.g., a selected length and / or width of the base of an erect carton). By further manipulating the positions of the first lug 5812A and the second lug 5812B relative to one another, the onboard control system can control the first belt 5802A and the second belt 5802B to close the gap between the first lug 5812A and the second lug 5812B and secure the upright carton between the first lug 5812A and the second lug 5812B. The action of the first lug 5812A and the second lug 5812B may be provided to prevent the upright carton from inadvertently falling off the AMR 5800. For example, in the embodiment shown in FIG. 58, the shipping container 5809 is maintained on the AMR 5800 while being acted upon by the first lug 5812A and the second lug 5812B. When the upright carton with articles therein arrives at a location where it is to be unloaded from the AMR 5800, the onboard control system can control the second belt 5802B to disengage the second lug 5812B from the upright carton. The onboard control system can also control the first belt 5802A, and thus the first lug 5812A, to urge the upright carton with one or more articles therein onto an input conveyor associated with further processing of the upright carton. For example, the input conveyor may be associated with a carton sealer, as described below.In another aspect of the present application, a robotic arm (not shown) can pick the stand-up carton from the AMR5800 and place the stand-up carton on an input conveyor associated with further processing of the stand-up carton.

[0234] Thus, the AMR5800 may be used to transport shipping containers and may comprise a mobile cart, a control system for controlling the operation of the autonomous mobile robot, a first belt having an upper surface including a first lug, and a second belt having an upper surface including a second lug. The control system may be operable to control and adjust the spacing of the first lug relative to the second lug so that the spacing between the first lug and the second lug moves between a first position suitable for positioning or removing a shipping container between the first lug and the second lug on the upper surfaces of the first and second belts, and a second position suitable for engaging the sides of the shipping container to secure the shipping container between the first lug and the second lug on the upper surfaces of the first and second belts. The upper surfaces of the first and second belts may be configured to support a shipping container thereon, such that when the shipping container is secured between the first and second lugs, the shipping container is supported on the first and second surfaces of the belts. The behavior of the AMR 5800 shown in FIG. 58 is similar to the behavior of the AMR 5300 shown in FIG. 53 (described with reference to FIG. 56).

[0235] 57, some of the steps are different when AMR 5800 shown in FIG. 58 is used instead of AMR 5300 shown in FIG. 53. In particular, step 5706 depicts generating a suction force in each of at least some of the suction cups 5404, thereby retaining shipping container 5309 on AMR 5300. In the context of AMR 5800 shown in FIG. 58, step 5704 would be expected to include retaining shipping container 5809 on AMR 5800 through the action of lugs 5812A, 5812B. Step 5718 in FIG. 57 has been discussed as relating to releasing shipping container 5309 from AMR 5300 by reducing the suction provided by suction cups 5404. In the context of releasing a shipping container 5809 from the AMR 5800, the onboard control system can control the first belt 5802A and the second belt 5802B to discharge the shipping container 5809 from the AMR 5800 to the dispatch staging station 5618. In the context of both the AMR 5300 of FIG. 53 and the AMR 5800 of FIG. 58, step 5714 of moving the AMR 5300 / 5800 to the closure station can include the AMR 5300 / 5800 driving the shipping container through a case top sealer 7620 and a case labeler 7624 (see FIG. 56A), thereby closing open flaps, sealing the shipping container, and labeling the shipping container.

[0236] In an exemplary cycle through the fulfillment center portion 5600 shown in FIG. 56, the AMR 5800 may move to a shipping container guide station 5604, where erected and bottom-sealed cartons may be transferred onto the AMR 5800. The AMR 5800 may then move to one or more product loading stations 5606, where a human operator or robot can place one or more products into the erected and bottom-sealed cartons. The AMR 5800 may then move to an order verification station 7630 (see FIG. 56A) to verify the contents of the erected and bottom-sealed cartons. The AMR 5800 may further move to and pass through a closure station 5616. The loading station 5616 may be implemented to include a top sealer and labeling system. Thus, at the closure station 5616, the erected and bottom-sealed cartons may be top-sealed and labeled. The AMR 5800 may then move the top-sealed and labeled carton to a shipping staging station 5618, which may be implemented to include a finished case discharge conveyor. The AMR 5800 may release the top-sealed and labeled carton at the shipping staging station 5618. The AMR 5800 may then move to the charging station 5602. Alternatively, the AMR 5800 may return to the shipping container guide station 5604, where another upright and bottom-sealed carton is transferred onto the AMR 5800, thereby repeating the cycle outlined herein.

[0237] An order fulfillment system 1000 is illustrated schematically in Figure 64. The order fulfillment system 1000 of Figure 64 may be understood to operate in the context of the order fulfillment location 5200 of Figure 52. The order fulfillment system 1000 is illustrated in Figure 64 as including several components, including an order fulfillment processor 1300. The order fulfillment system 1000 may include, for example, multiple carton formation systems 1100A, 1100B, 1100C disposed in a shipping container guide area 5206. The carton formation systems 1100A, 1100B, 1100C may also be referred to as shipping container delivery systems.

[0238] The order fulfillment system 1000 may include multiple AMRs 1400A, 1400B, and 1400C. The order fulfillment system 1000 is illustrated in FIG. 64 as including multiple carton sealing devices 1500A, 1500B, and 1500C. Multiple customer ordering devices may also be provided, including a first customer ordering device 1200A, a second customer ordering device 1200B, and a third customer ordering device 1200C. The customer ordering devices 1200A, 1200B, and 1200C may be linked to the order fulfillment processor 1300. The first customer ordering device 1200A may be, for example, a telephone capable of communicating with a call center 1250. The call center 1250 may be adapted to receive an order from a customer operating the first customer ordering device 1200A, and then, via call center software, a call center operator may enter an order for one or more products. The orders may be communicated to the order fulfillment processor 1300 via a communications link. The second customer ordering device 1200B and the third customer ordering device 1200C may be personal computing devices, including, for example, mobile phones, personal computers, etc., capable of direct communication with the order fulfillment processor 1300, such as through wireless communications and / or land-based communications networks. The communications network may be, for example, an IPv4, IPv6, X.25, IPX-compliant, or similar network. Thus, the network may be the public Internet. Through operation of appropriate software on the customer ordering devices 1200B, 1200C and the order fulfillment processor 1300, the customer ordering devices 1200B, 1200C may be adapted to enter orders for one or more products into the order fulfillment processor 1300. For example, the customer ordering devices 1200B, 1200C may be adapted to execute an appropriate Hypertext Transfer Protocol (HTTP)-enabled browser to access data and services provided by an HTTP server application executed by the order fulfillment processor 1300. Through the use of an HTTP-enabled browser, the customer ordering devices 1200B, 1200C can enter orders for one or more products into the order fulfillment processor 1300.

[0239] The order fulfillment processor 1300 may be a mainframe computer, server, or other computing device capable of processing customer orders received directly or indirectly from the customer ordering devices 1200A, 1200B, 1200C. The order fulfillment processor 1300 may include a database containing information that may be stored in a suitable memory therein, including (a) information / details of all products that may be ordered by a customer through the order fulfillment system 1000, including the physical volume occupied by the space and / or actual physical dimensions (e.g., height, width, length, and / or diameter), optionally the weight of each product, and optionally a product code associated with each product, such as a Universal Product Code (UPC) or International Standard Book Number (ISBN) if the product is a book, (b) information / details of each of multiple types / sizes / configurations of cartons / carton blanks that may be used or have been used by the order fulfillment system 1000 to package one or more products ordered by a customer, including the dimensions of each type of carton / carton blank, and (c) information / details of each carton forming system (e.g., a carton forming system). For example, the database may include information / details about carton forming systems 1100A, 1100B, 1100C), including information / details about the cartons each carton forming system can form (such as the type, size, and / or configuration), and optionally, if the carton forming system includes multiple magazines, the type, size, and / or configuration of carton blanks provided in each of those magazines, as well as the corresponding type, size, and / or configuration of stand-up cartons that can be formed from each type of carton blank, and further optionally, the quantity of carton blanks provided in each of those magazines; (d) information / details about each customer, including the name and shipping address of the business entity to which orders processed by order fulfillment system 1000 should be shipped; and (e) information / details about where each product is located in a product storage facility, such as a warehouse building, that holds the products that may be ordered. The database may be continually updated to include new data.For example, the new data may include information / details regarding new inventory items, such as new items to be induced into the product storage induction area 5202 of the order fulfillment location 5200, or information / details regarding new types / sizes / configurations of cartons / carton blanks that may be used in the order fulfillment system 1000 to package one or more products ordered by a customer.

[0240] As mentioned above, the order fulfillment processor 1300 may also include an HTTP server application adapted to provide database information to and receive orders from the customer ordering devices 1200B, 1200C. Some or all of the aforementioned information / details may be manually entered into the order fulfillment processor 1300 by an operator of the order fulfillment system 1000. Additionally, or alternatively, the information / details of each available carton may be updated periodically or continuously. The PLC 132 of each carton forming system 1100A, 1100B, 1100C may be adapted to monitor the status of the carton blanks in its magazine during operation and provide information related to that status to the order fulfillment processor 1300. In this manner, the order fulfillment processor 1300 may be continuously provided with up-to-date information regarding the available carton blanks in each carton forming system's magazine.

[0241] The order fulfillment processor 1300 may also include a product packaging utility / software module that identifies a carton type (or carton types) suitable for packaging products in an order placed by a customer from among a plurality of available carton types. One example of such a product packaging utility is disclosed in U.S. Patent No. 6,876,958 to Chowdhury et al., issued April 5, 2005, and assigned to New Breed Corporation (hereinafter "Chowdhury"), the contents of which are incorporated herein by reference in their entirety. In particular, the Chowdhury product packaging utility processes each order placed by a customer and automatically identifies, from among available carton types, sizes, and configurations, a carton (or multiple cartons) suitable for packaging the ordered products. Chowdhury's product packaging utility identifies / determines appropriate cartons according to an algorithm / function that accesses and uses one or more electronically stored characteristics (e.g., dimensions, weight, etc.) of each product in an order and one or more electronically stored characteristics (e.g., dimensions, size, configuration, type, maximum volume that can be held, maximum weight that can be held, etc.) of available carton types. The algorithm identifies appropriate cartons so that the minimum number of cartons and the minimum size cartons suitable for packaging the products in the order can be provided. Thus, the identification of appropriate carton types / sizes / configurations can be optimized to provide optimal carton types / sizes / configurations that optimize packaging materials used and optimize carton space availability, and cartons identified as appropriate may be referred to as "optimal" cartons. It will be appreciated that the identification of appropriate carton types / sizes / configurations can also be identified or optimized according to other predefined criteria.The carton identification algorithm of Chowdhury's product packaging utility can also take into account other factors and constraints, such as, for example, the availability of each carton type / size / configuration, the maximum fill ratio of each carton type / size / configuration, the maximum number of products that can be placed in each carton type / size / configuration, whether certain products are prepackaged together and therefore must be placed in the same carton, etc. Thus, when the order fulfillment processor 1300 includes a product packaging utility such as the product packaging utility disclosed by Chowdhury, the order fulfillment processor 1300 can process customer orders for particular products by accessing information in memory and utilizing algorithms / functions to identify a suitable carton (or cartons) from among multiple available cartons in which to package those products.

[0242] It should be noted that carton size may be the overall interior usable volume of the carton in which items can be held. Size may also be the specific dimensions of the carton. Information regarding carton type may include a reference to the material (e.g., paperboard or corrugated board) from which the carton blank is made. Information regarding carton type may include a reference to the configuration, indicating that the carton is an open-top carton that is generally cubic when closed, or another configuration such as a conventional slotted case.

[0243] The product packaging utility disclosed by Chowdhury can generate, for each carton of a particular type / size / configuration identified for fulfilling an order, a packing list indicating the order in which each product should be placed in the carton and placement information indicating where each product should be placed in the carton. For example, the placement information can be expressed using three-dimensional coordinates in a coordinate system defined for the carton (e.g., 0,0,0) and / or descriptors of location within the carton (e.g., front, right side, second layer, etc.). It follows that if the order fulfillment processor 1300 includes a product packaging utility such as the product packaging utility disclosed by Chowdhury, the order fulfillment processor 1300 may generate a packing list and / or placement information for each identified carton. The order fulfillment processor 1300 may also generate a diagram illustrating the desired optimal physical placement of the products within each carton. Such a diagram can be readily generated using the placement coordinates of each product, as provided by the product packaging utility disclosed by Chowdhury.

[0244] For each carton of a particular type identified for fulfilling an order, order fulfillment processor 1300 may also be configured to select one of carton forming systems 1100A, 1100B, 1100C (individually or collectively 1100) to form the appropriate carton of the type / size / configuration identified by order fulfillment processor 1300. Order fulfillment processor 1300 may access and use information stored in its memory regarding the suitability of a carton forming system for processing the identified appropriate carton. For example, the suitability of a carton forming system may be determined by order fulfillment processor 1300 based on stored information regarding whether the carton forming system includes a magazine designated to hold the type / size / configuration of carton blanks required to form the identified carton. The suitability of a carton forming system may also be determined based on stored information regarding the quantity of the required carton blank type / size / configuration in the carton forming system's magazine. Such quantities may be measured using appropriate sensors located in each carton forming system and updated during operation. Alternatively, the order fulfillment processor 1300 may simply select the carton forming system randomly or according to a predefined sequence.

[0245] Once the order fulfillment processor 1300 selects an appropriate carton forming system (e.g., one of the carton forming systems 1100 of FIG. 64 ), the order fulfillment processor 1300 may generate a fulfillment order data structure (e.g., a file, object, message, etc.) that contains information for forming the appropriate carton blanks into erect cartons or that contains instructions for the selected carton forming system 1100. The generated fulfillment order data structure may be communicated over a communications link to the PLC 132 of the selected carton forming system 1100.

[0246] The fulfillment order data structure may include indicators of: (i) the type / size / configuration of the carton, as determined by the product packaging utility, to be formed by the selected carton forming system 1100; (ii) the particular magazine of the selected carton forming system 1100 that contains carton blanks for forming the appropriate carton; (iii) a list of the particular products from the customer order to be fulfilled that are to be loaded into the erect carton once formed, optionally identifying the products by associated product codes and optionally arranged in the order in which the products are to be loaded into the erect carton once formed; (iv) the station within the product guidance area 5208 of each particular product from the customer order to be fulfilled; and (v) customer shipping information for the carton, indicating the name and address of the recipient for that carton. In some cases, the fulfillment order data structure may include information for multiple cartons to be processed by the selected carton forming system 1100.

[0247] The fill order data structure may be received and processed by the PLC 132 of the selected carton forming system 1100. In particular, the PLC 132 of the selected carton forming system 1100 processes the fill order data structure to identify the requested type / size / configuration of the carton (or cartons) to be formed and the specific magazines of the carton forming system that contain carton blanks for forming each requested carton. Once the appropriate cartons and the specific magazines that contain carton blanks for forming the appropriate cartons have been identified, the PLC 132 of the selected carton forming system 1100 can then cause the appropriate carton blanks to be formed into cartons of the requested type / size / configuration.

[0248] Optionally, the data structure may be stored in the memory of the carton forming system's PLC 132 or in the memory of the order fulfillment processor 1300 for later retrieval when orders are picked and packed, as described below.

[0249] Once the cartons are erected for a particular customer product order, the erected cartons may then be physically transported to AMRs (collectively or individually referred to as 1400).

[0250] A stand-up carton formed from the carton blank and having dimensions of width W, height H, and length L can be loaded with items (i.e., products) numbered 1 through 6 arranged in a particular arrangement, as shown in Figure 67, and can also include some additional dunnage or packaging material (e.g., bubble wrap-type material) that can be inserted to maintain the stability and integrity of the items within the packaging arrangement during shipment to the customer. Given the particular arrangement of the items specified for the order, the AMR can be controlled to visit stations in a particular order (e.g., stations holding the largest items can be visited first) so that the stand-up carton is loaded in a manner consistent with the particular arrangement.

[0251] 59, 60, 60A, 61, 62, and 63, carton forming system 1100 may be comprised of the same or substantially the same components as carton forming system 100 of FIG. 1A described above, except where differences are noted below. As with carton forming system 100 of FIG. 1A, the structural / mechanical components of carton forming system 1100 may be made from any suitable materials. Carton forming system 1100 is particularly useful as part of customer order fulfillment system 1000, which may fulfill product orders placed or initiated by customers, as described above. However, carton forming system 1100 may be used in other applications as well.

[0252] As an alternative to a magazine such as magazine 110 of carton forming system 100 of FIG. 1A described above, carton forming system 1100 may include or utilize multiple magazines, such as the magazines labeled M1 through M16 in FIG. 60. Magazines M1 through M16 may each contain one or more stacks of product packaging, such as carton blanks, each of which may be generally similar to carton blank 111 processed by system 100, with at least some of magazines M1 through M16 containing packaging / carton blanks of a different type / size and / or configuration than the other magazines. The size, configuration, and type of carton blanks (and cartons that may be formed therefrom) may be varied to provide a range of carton sizes, configurations, and types that can be automatically processed by carton forming system 1100 without requiring manual intervention to change components of carton forming system 1100. The PLC 132 of the carton forming system 1100 can be programmed so that the particular dimensions / overall size / configuration (e.g., regular slotted carton or "RSC") / type of carton blanks held in each one of the magazines M1-M16 are stored in the memory of the PLC 132. Recall that alternatives to the RSC configuration include envelope and tray configurations. When such alternatives are used, some of the carton forming system 1100 may be replaced with envelope feeders or tray feeders.

[0253] It should also be noted that carton forming systems 1100 may be configured with magazines having a different set / selection of carton blank sizes / configurations / types than other magazines such that each of carton forming systems 1100 is operable to process different carton blanks. Carton forming systems 1100 can be configured with magazines to collectively process a predefined set of carton blank types, thereby providing a variety of carton sizes, configurations, and types.

[0254] Each of magazines M1-M16 may have its own carton blank transport apparatus, which may include a laterally oriented magazine conveyor 1203(1)-1203(16) (individually or collectively referred to with reference numeral 1203), respectively. Each magazine conveyor 1203 is controlled by PLC 132 of carton forming system 1100 to move a stack of carton blanks in each magazine M1-M16 to a position adjacent to a longitudinally oriented central carton blank infeed conveyor 1204. Each magazine M1-M16 may have a transport apparatus under the control of PLC 132 operable to extract and move carton blanks from the stacks in magazines M1-M16 adjacent to infeed conveyor 1204 and feed the carton blanks onto the central infeed conveyor 1204 for transporting the carton blanks in a manner as described above in connection with system 100.

[0255] Referring now to FIG. 60A , as a representative example of a magazine configuration, the magazine conveyor 1203 may include a frame 1215 supporting five generally parallel, spaced-apart continuous belts 1213, which may be made of any suitable flexible material, such as Ropanyl. Each of the continuous belts 1213 may extend between a plurality of rotatable idler wheels 1221 mounted on a freely rotatable shaft and a plurality of rotatable drive wheels 1223. The drive wheels 1223 may be mounted for rotation with a common drive shaft 1225 of a magazine conveyor servo motor 1219, which may be interconnected via a servo drive to the PLC 132 of the carton forming system 1100 and in communication with the servo drive. Each of the continuous belts 1213 may have an upper belt portion capable of supporting one or more stacks of carton blanks 1211 thereon. PLC 132 can provide instructions to form cartons (such as by order fulfillment processor 1300), and, as needed, PLC 132 can move the upper belt portion of infeed conveyor belt 214 toward infeed conveyor 1204 by operation of magazine conveyor servo motor 1219, which rotates drive wheel 1223. In this way, infeed conveyor belt 214 can move stacks of carton blanks 1211 to a position adjacent infeed conveyor 1204 as needed.

[0256] Positioned adjacent the end of each magazine conveyor 1203 adjacent the infeed conveyor 1204 may be a vertically and longitudinally oriented plate 1230. Each plate 1230 may be supported by a plurality of plate support members 1235, which may be part of the frame 1215. The longitudinally extending lower edge 1233 of the plate 1230 may be positioned to allow only the lowest carton blank 1211 in the stack of carton blanks (i.e., the blank immediately above the upper portion of the belt) to pass through a slot provided below the lower edge 1233 of the plate 1230 and the horizontal plane formed by the upper surface of the upper portion of the continuous belt 1213. In this manner, the slot 1231 may be provided to allow a single carton blank 1211 at a time from the bottom of the stack to be pushed laterally through the slot 1231 and onto the infeed conveyor 1204.

[0257] A pusher mechanism may be provided to push the carton blanks 1211 in the magazine from the bottom of the stack, through the slot 1231, and onto the infeed conveyor 1204 in response to signals from the PLC 132 of the carton forming system 1100. The pusher mechanism may be any suitable type of device, including, for example, a plurality of lugs 1217 spaced between the continuous belts 1213. The lugs 1217 may be driven in a cyclical path by a crank mechanism (not shown) of the conventional type including a conventional pneumatic or hydraulic cylinder having a piston controlled by the PLC 132 by actuating appropriate valves to appropriately control the flow of pressurized air / hydraulic fluid to the cylinder. The cylinder may include a piston arm attached to a longitudinal rod mounted for rotation. The crank mechanism may be configured to provide a path for lug 1217 to start at a position behind the bottom carton blank in the stack and then engage the trailing edge of the bottom carton blank, thereby providing a path for lug 1217 to move laterally across continuous belt 1213 while pushing the bottom carton blank through slot 1231. When the crank mechanism reaches the end of its stroke, lug 1271 is shown lowering below the stack of carton blanks and moving laterally in the opposite direction back to the starting position, while simultaneously not engaging the next bottom carton blank on the stack and passing under the stack. This path returns lug 1217 to the starting position, and the action is repeated when PLC 132 signals to load another carton blank onto infeed conveyor 1204.

[0258] In summary, PLC 132 can control the magazine conveyor servo motors 1219, and therefore the movement of each conveyor 1203, and consequently the movement of lugs 1271. Thus, PLC 132 can selectively move one carton blank at a time from any one of magazines M1-M16 and transport it onto in-feed conveyor 1204.

[0259] Thus, unlike system 100, in which a stack of carton blanks is fed to alignment conveyor 206 by infeed conveyor 204, in order fulfillment system 1000, separate individual carton blanks may be fed serially and longitudinally by infeed conveyor 1204 to alignment conveyor 1206. The particular sequence / order of carton blanks placed on infeed conveyor 1204 of each carton forming system 1100 may be determined and selected by PLC 132 so that the carton blanks arrive at alignment conveyor 1206 in a manner that is desired to process the carton blanks, at least within carton forming system 1100.

[0260] Additionally, each PLC 132 may maintain in its memory a record of the carton blanks placed on the infeed conveyor 1204 for formation. Each record may include information the PLC 132 receives from the order fulfillment processor 1300 (e.g., via a fulfillment order data structure) about the particular carton blank to be formed. For example, this information may include the type / size / configuration of the carton blank. A new record may be added each time a request for a new carton is received from the order fulfillment processor 1300, and, optionally, a record may be deleted once the carton is formed. Such records may thus be maintained in sequential order in the memory of the PLC 132 using conventional shift registering techniques. In this manner, a record of the next carton blank scheduled to arrive on the alignment conveyor 1206 may be provided at the output of the shift register as the next carton blank arrives. Furthermore, the type / configuration / size of the next carton blank may be determined from the provided output.

[0261] Once a given carton blank has been transferred from the infeed conveyor 1204 to the alignment conveyor 1206, the alignment conveyor 1206, under the control of the PLC 132, may move the given carton blank to a pick-up position. The pick-up position may be determined, in part, by the leading edge of each carton blank striking the surfaces of a pair of spaced vertical plates 1218 (see FIG. 63) as it is moved longitudinally downstream by the alignment conveyor 1206.

[0262] The in-feed conveyor 1204 may be configured to include a pair of spaced apart in-feed conveyor belts 214 that may be driven by a suitable motor, such as a DC motor or a variable frequency drive motor, in a manner substantially similar to the structure of the in-feed conveyor 204 of Figure 7. If the motor is a DC motor, the motor may be controlled by the PLC 132 via a DC motor drive (such as, for example, a model AXH-5100-KC-30, all manufactured by Oriental).

[0263] The in-feed conveyor belt 214 can have an upper belt portion supported on rollers (not shown). The PLC 132 can move the upper portion of the in-feed conveyor belt 214 longitudinally downstream toward the alignment conveyor 1206 as needed. In this manner, the in-feed conveyor belt 214 can move a series of spaced carton blanks longitudinally downstream. The PLC 132 can control the motor that drives the in-feed conveyor 1204 via a motor drive, such that the in-feed conveyor 1204 can be operated to move and transfer a series of carton blanks obtained from a plurality of magazines, magazines M1 through M16, toward and to the alignment conveyor 1206.

[0264] The alignment conveyor 1206 may include a series of laterally oriented rollers 1208 that may be mounted for free rotational movement on the bottom of the magazine frame 202, similar to the alignment conveyor 206 of FIG. 7. The alignment conveyor belt 1216 may be driven by a motor with a corresponding motor drive. This motor and motor drive for the alignment conveyor 1206 may also be controlled by the PLC 132. The alignment conveyor belt 1216 may include an upper belt portion supported on the rollers 1208, upon which one or more carton blanks may be supported. The alignment conveyor belt 1216 may be operated to further longitudinally move each carton blank in turn until the front surface of the carton blank abuts against the generally planar, vertically and laterally oriented, inwardly facing surfaces of the upright, spaced-apart plates 1218, thereby placing each carton blank in turn at a pickup position.

[0265] The infeed conveyor belt 1214 of the infeed conveyor 1204 and the alignment conveyor belt 1216 of the alignment conveyor 1206 may be made from any suitable material, such as, for example, ropanyl.

[0266] A sensor (not shown), such as an Allen-Bradley Electronic Eye Model 42KL-D1LB-F4, may be positioned in the horizontal gap between the infeed conveyor belt 1214 and the alignment conveyor belt 1216. The sensor may be positioned and operable to detect the presence of the leading edge of each blank as it begins to move across the gap between the infeed conveyor belt 1214 and the alignment conveyor belt 1216 in sequence. Upon detecting the leading edge, the sensor may send a digital signal to the PLC 132 indicating that a particular carton blank (of a size / configuration / type recognized by the PLC 132) has moved to a position where the conveyor 1206 can begin movement. The PLC 132 may then activate the motor of the conveyor 1206 so that the top of the alignment conveyor belt 1216 begins to move the carton blank downstream. In this manner, a "handoff" of each carton blank from the infeed conveyor 1204 to the alignment conveyor 1206 may occur.

[0267] As the trailing edge of each carton blank passes the sensor, a signal is sent to PLC 132, which in turn may respond by sending a signal to stop the motor driving infeed conveyor belt 1214 of infeed conveyor 1204. Infeed conveyor 1204 then goes into a state to await a further signal to feed the next carton blank in the series of carton blanks on infeed conveyor 1204 to alignment conveyor 1206. Meanwhile, alignment conveyor 1206 may be operated to move the carton blank placed thereon to a pick-up position.

[0268] The presence of a carton blank on the alignment conveyor 1206 at the pick-up position may be detected by another sensor, which may be the same type of sensor as the presence sensor 240 and gap sensor 242 of Figure 7. This sensor may detect the presence of the leading edge of the blank at the pick-up position and may send a digital signal to the PLC 132 indicating that the carton blank is at the pick-up position. At the pick-up position, the carton blank may also be centered longitudinally by a pair of movable longitudinal sidewall guides 1201, 1202.

[0269] Each carton blank may be suitably positioned and oriented longitudinally and laterally at the pickup location for proper engagement by one of the erector heads, such as erector heads 120a, 120b, of system 100. Side guide walls 1201, 1202 may be attached to the lower part of the lower frame on the track, and both side guide walls 1201, 1202 may be oriented generally vertically and extend longitudinally for substantially the entire length of alignment conveyor 1206. Side guide walls 1201, 1202 may be attached in a manner similar to left side guide wall 200 and right side guide wall 201 in system 100.

[0270] A drive mechanism can be provided to drive each of the side walls 1201, 1202 on its respective track. One or more drive mechanisms can be provided for the side walls 1201, 1202 in electronic communication with the PLC 132. As an example, a geared servo motor 258 (see FIG. 1B) can be provided and in electronic communication with the PLC 132 through a servo drive. An example that can be used is the Allen-Bradley servo motor MPL-B1530U-VJ42AA in combination with the Allen-Bradley servo drive 2094-BC01-MP5-S and the Apex gear head AE050-010FOR MPL-A1520.

[0271] Similar to carton forming system 100, in carton forming system 1100, a lead screw rod may be interconnected to a servo motor / gearhead. The lead screw rod may pass through a nut fixedly secured to a plate. The plate may be interconnected to spaced apart, generally vertically oriented bar members. The bar members may be interconnected to a support frame (not shown) that forms part of the sidewalls. By operating the servo motor / gearhead, rotation of the servo motor can rotate the screw rod. As the rod passes through the nut, the nut can move laterally either inward or outward, causing sidewalls 1201, 1202 to slide on the track inward or outward, depending on the direction of rotation of the screw rod. Encoders are provided within or associated with the servo drive motors, and the encoders can rotate in association with the rotation of the respective drive shafts of the servo drives. The encoders communicate with the servo drives and provide signals to the servo drives, which can pass the information to PLC 132. Thus, the PLC 132 can determine the longitudinal position of the screw rods in real time, and consequently the lateral position of the side walls 1201, 1202. In response, the PLC 132 can operate the servo drives to adjust the position of the side walls 1201, 1202. Certain types of encoders that can be used are known as "absolute" encoders. Thus, once the encoders are calibrated and the position of each screw rod is "zero," the encoders can maintain that zero position calibration even if power to the order fulfillment system 1000 is lost.By having the lateral alignment features of the side guide walls 1201, 1202 approximately coincide with the left and right side edges of the carton blank, the guide walls can ensure that when the carton blank is flattened, the datum lines are properly aligned laterally so that it can be labeled by the labeling device 1281 (shown only in FIG. 63), picked up by the erector head 120 of the carton forming system 1100, and moved through the folding and sealing device 130 as described above to achieve proper folding and sealing of the carton blank.

[0272] Optionally, PLC 132 may verify that the type / size / configuration of the carton blank at the pickup location matches the expected type / size / configuration of the carton blank. For example, the top surface of each carton blank may include a barcode identifying its type / size / configuration, which may be read at the pickup location by an appropriately positioned barcode reader. The type / size / configuration of the carton blank read from the barcode may be compared to the expected type / size / configuration of the carton blank, which may be determined from the record of the next scheduled carton blank stored in PLC 132's memory, as described above. If there is a match, the verification is successful. If there is no match, PLC 132 may issue a signal requesting manual operator intervention.

[0273] As indicated above, each carton blank in each magazine may generally be initially formed and provided in a flattened, tubular configuration, as illustrated in FIGS. 10A-10E. Each carton blank has a height dimension "H," a length dimension "L," and a major panel length "Q" (see FIG. 10B). The PLC 132 of each carton forming system 1100 can maintain in memory each of these three dimensions for the carton blanks processed by the carton forming system 1100, and using these stored dimensions, the PLC 132 can determine the required positions and / or movements of at least some of the components of the carton forming system 1100, including the path of movement of the erector heads 120a, 120b as they move through the processing sequence.

[0274] In this regard, for each carton blank in magazines M1-M16, PLC 132 may have the information necessary to properly process each selected carton blank.

[0275] As indicated above, with respect to a representative carton blank such as that shown in FIG. 11 , each carton blank in each magazine may be assigned a first datum line "Wl" that passes through the midpoint of the fold line between panel D and flap K and passes through the midpoint of the fold line between panel B and flap J. This first datum line Wl may be determined by PLC 132 for the carton blank being processed based on the blank's dimensions H, L, and Q stored by or retrieved by PLC 132. The carton blank may be assigned a second datum line "W2," which may be determined by PLC 132 and that passes along and is generally parallel to the fold line between panel A and flap F. PLC 132 may also determine the relative position of the bottom of the upright carton for the carton blank in each magazine, as it aligns with a vertical datum plane that passes through the first datum line Wl and the second datum line W2. The alignment of the second datum line W2 and the datum plane with other components within the carton forming system 1100 may be shown to verify that the carton is properly positioned during processing. The vertical distance R between the first datum line Wl and the second datum line W2 may also be calculated by the PLC 132. This allows the PLC 132 to know with certainty where the erector head needs to be positioned so that the top plate A and, accordingly, the first datum line Wl are properly positioned throughout the processing of the carton blank by the carton forming system 1100.

[0276] It may be shown that carton forming system 1100 can track and correct the position of each carton blank as it is processed, and in particular, the vertical position of the first reference line W1 of the carton blank as it moves longitudinally through carton forming system 1100 and as various components of carton forming system 1100 engage the carton blank during its movement. This may be shown to ensure that the carton blank being processed is properly positioned relative to the system components and that the system components engage the carton blank at the correct location on the carton blank during its processing. Carton blanks of different configurations than carton blank 111 may require appropriate adjustments to the dimensions and datums maintained by PLC 132 to enable carton forming system 1100 to process a particular size / configuration / type of carton blank.

[0277] Once the carton blanks are formed, sealed, and partially sealed to form erect cartons, which may be configured as shown in FIG. 16, the erect cartons may be delivered from a discharge conveyor 117 (see, e.g., FIG. 8) or placed on an accumulation conveyor that may be part of a respective carton loader, such as a particular one of the AMRs 1400 that may be associated with the particular carton forming system 1100 that formed the erect carton. Indeed, in embodiments of the present invention, in response to the arrival of a particular AMR 1400 at a particular carton forming system 1100, a robotic arm (not shown) may be controlled to pick the erect carton from the discharge conveyor 117 and place the erect carton on the particular AMR 1400.

[0278] The order retrieval process can be considered to begin when an empty, stand-up carton is removed from a loading conveyor and placed on an AMR 1400 that can move autonomously around the warehouse where the products to be handled by the system 1100 are located. The AMR 1400 can be controlled to visit one or more loading stations within the product guidance area 5208.

[0279] Once an order (or partial order for a particular carton) is obtained within a stand-up carton transported by the AMR 1400 and all products have been loaded into the stand-up carton, the AMR can transport the stand-up carton to one of the final carton sealing devices 1500. For example, the AMR 1400 can transport the stand-up carton, with all products loaded therein, onto a predetermined Random Top Carton Seal (RTCS) infeed conveyor, which feeds the stand-up carton into the appropriate top sealing device. The RTCS is adapted to receive information provided by the order fulfillment processor 1300, and the RTCS can automatically adjust the sealing components of the device so that it can close and seal the tops of the stand-up and loaded cartons. The sealed cartons can then be transported to the route distribution and accumulation area 5212 for further sorting and processing. One example of a type of suitable RTCS device that may be employed as part of the order fulfillment system 1000 is a Random Carton Sealer manufactured by Marq Packaging Systems.

[0280] In operation of the order fulfillment system 1000, each of a plurality of customers may use a customer ordering device, such as the order fulfillment processor 1200, possibly including access to a call center 1250. Through operation of appropriate software on the order fulfillment processor 1200, the order fulfillment processor 1200 may communicate directly or indirectly with the order fulfillment processor 1300 such that a plurality of orders may be placed by the customers with the order fulfillment processor 1300.

[0281] The order fulfillment processor 1300 may process customer orders received directly or indirectly from the customer ordering device 1200. The order fulfillment processor 1300 may utilize a database containing information that may be stored for each order, the database including: (a) details of all products that may be ordered by a customer through the order fulfillment system 1000, including the actual physical dimensions of each product (such as the dimensions of the product package in which the product is packaged), optionally the weight of each product, and optionally a product code associated with each product; (b) details of each of multiple types / sizes / configurations of carton blanks that may be used by the order fulfillment system 1000 to package one or more products ordered by the customer, including the dimensions of each carton / carton blank; (c) details of each carton forming system (e.g., carton forming systems 1100A, 1100B); , 1100C), including details of each carton forming system, including the types of stand-up cartons that each carton forming system can form, and optionally, if the carton forming system includes multiple magazines, the types of carton blanks provided in each of those magazines and the corresponding types of stand-up cartons that can be formed from each carton blank type, and optionally the quantity of carton blanks provided in each of those magazines; (d) information related to each customer, including the name and shipping address of the company to which orders fulfilled by order fulfillment system 1000 will be shipped; and (e) information related to the location of each product within a warehouse building that houses the products that may be ordered.

[0282] The order fulfillment processor 1300 may also use the product packaging utilities to identify, for each order, an appropriate carton, possibly an optimal carton (e.g., having a particular type / size / configuration), from a packaging suite of a limited, predetermined number of carton types / sizes / configurations. Thus, as each order for a particular product is entered into the order fulfillment processor 1300, the product packaging utilities may determine the optimal carton or cartons that can be used to package the products for each order (e.g., determine the minimum number of cases and / or the smallest size case required to package all products in a customer order).

[0283] The order fulfillment processor 1300 may then generate for each order a fulfillment order data structure that may be communicated over a communication link to the PLC 132 of one of the carton forming systems 1100. The order fulfillment processor 1300 may determine which of the carton forming systems 1100 to send each fulfillment order data structure to randomly or based on availability and / or suitability for processing the carton type / size / configuration determined for the particular customer order. The fulfillment order data structure can include information including: (i) the type / size / configuration of the stand-up carton determined by the product packaging utility that is required to be formed by the carton forming system 1100; (ii) the specific magazine of the carton forming system that contains carton blanks for forming the requested carton type / size / configuration; (iii) a list of the specific product(s) from the customer order being fulfilled that is required to be loaded into the requested stand-up carton once formed, optionally arranged in the order in which the products should be loaded into the carton once formed; (iv) optionally, a diagram showing the desired optimal physical placement of the products to be loaded into the stand-up carton; (v) optionally, the location within the warehouse building of each specific product from the customer order being fulfilled; and (vi) customer shipping information for that carton, indicating the name and address of the recipient for that carton.

[0284] Each fill order data structure may then be received and processed by PLC 132 of the carton forming system to which the data structure was sent. In particular, PLC 132 of the carton forming system processes the fill order data structure to identify the required erect carton type / size / configuration, the specific carton forming system magazines containing carton blanks for forming each required erect carton type / size / configuration, and the contents of the label(s) to be applied. Once the required carton blank type / size / configuration and the specific magazines containing carton blanks for forming the required carton blank type / size / configuration have been identified, PLC 132 of the carton forming system can cause the carton blanks to be formed from the identified magazines, generally as described above.

[0285] In particular, PLC 132 activates the appropriate one of magazine conveyors 1203(1)-1203(16) corresponding to the identified magazine, if necessary, to move a stack of carton blanks of the identified type adjacent to infeed conveyor 1204. A transfer device, under the control of PLC 132, can then transfer the desired carton blank from the identified magazine to infeed conveyor 1204. Infeed conveyor 1204, under the control of PLC 132, may then be indicated to move that carton blank longitudinally and then transfer that carton blank to alignment conveyor 1206 when signaled to do so by PLC 132.

[0286] An alignment conveyor 1206, also under the control of PLC 132, then moves the carton blank to a pickup position, which may then laterally align the carton blank against side walls 1201, 1202 so that the carton blank is in the correct pickup position. PLC 132 may then cause the carton forming components of the carton forming system, including the erector head 120, to move via a movement subsystem to pick up the carton blank 111 from the pickup position and erect and partially seal the carton erected from the carton blank 111. PLC 132 may continually cause adjustments of the components of the folding and sealing apparatus 130 to accommodate each carton blank 111 as multiple carton blanks 111 are processed as each carton blank is processed.

[0287] Once a stand-up carton has been formed for a particular customer product order, the stand-up carton can then be physically transported to the AMR 1400. The AMR 1400 is then controlled to visit stations within the product guidance area 5208.

[0288] As briefly described herein, the stations in product guidance area 5208 may be associated with providing products stored in tower storage area 5204. Also, as briefly described herein, in some embodiments, although no towers are specifically illustrated in tower storage area 5204 in FIG. 52, multiple towers may be located in tower storage area 5204 that may be used to store products.

[0289] FIG. 75 is a perspective view of a tower 7510 of multiple towers that may be used to store products, according to an exemplary embodiment of the present invention. As shown, the tower 7510 may have compartments 7512 for storing individual products within the compartments 7512. Some compartments, such as a first compartment 7512A of the tower 7510, may be filled with individual products corresponding to the same stockkeeping unit (SKU). Other compartments, such as a second compartment 7512B of the tower 7510, may be filled with individual products corresponding to at least two different SKUs. Each compartment 7512 may have one or more openings, such as a first opening 7514 or a second opening 7516, through which individual products can be stored in and removed from the tower 7510.

[0290] Storing products in the multiple towers 7510 may generally include the following steps: When products arrive at the order fulfillment location 5200, they are often organized on pallets, and the packaging surrounding the products is first removed to provide access to the individual product items. In some embodiments, the individual product items may also be checked for obvious defects. Assuming no defects are found, a human may pick up the individual product items and store them in a compartment 7512 of the multiple towers 7510. Once a particular product item is stored in a particular compartment 7512, the human may scan the barcode of the particular product item and / or a barcode located on the tower 7510 (e.g., a barcode associated with the particular compartment 7512 in which the particular product item is stored) so that the order fulfillment processor 1300 knows the location of the particular product item. This process may also be performed automatically. For example, there may be one or more robots for removing packaging, one or more robots for picking up and storing individual product items in compartments 7512 of multiple towers 7510, and one or more robots for making information regarding each location of the stored individual product items (e.g., a particular component 7512 of a particular tower 7510) known to the order fulfillment processor 1300.

[0291] Each opening, such as the first opening 7514 or the second opening 7516 of the compartment 7512, may be covered by one or more flexible strips 7520, which may prevent individual products stored within the compartment 7512 from falling out of the respective compartment 7512, for example, during transport of the tower 7510 by the tower transport AMR 7518.

[0292] In operation, the tower transport AMR 7518 may engage the tower 7510 and transport the tower 7510 to the product storage guidance area 5202, where, as previously described herein, a human and / or robot 5999 may unload the products delivered to the order fulfillment system 5200 (e.g., by transport trailer, which products may be on pallets) and store the products in the tower 7510. Once the tower 7510 is sufficiently filled with product, the tower transport AMR 7518 may transport the tower 7510 to an available location within the tower storage area 5204.

[0293] When one or more products stored in the tower 7510 are needed to fulfill an order, the order fulfillment processor 1300 may command the tower transport AMR 7518 to transport the tower 7510 between a first location intermediate the tower storage area 5204 and a second location in the product guiding area 5208. The tower transport AMR 7518 may be a device manufactured by Amazon Robotics, Inc. (formerly Kiva Systems, Inc.) of North Reading, Massachusetts. The tower transport AMR 7518 may navigate around the tower storage area 5204. When the tower transport AMR 7518 reaches the first location, the tower transport AMR 7518 may slide under the tower 7510 and lift the tower 7510 off the ground, for example, with a corkscrew motion. The tower transport AMR 7518 may then transport the tower 7510 to a second location within the product guiding area 5208.

[0294] Conventional AMRs are known to navigate in a variety of ways. A conventional AMR may include an upward-facing camera used to read a barcode on the underside of the tower 7510. Additionally, a conventional AMR may include a downward-facing camera used to read a barcode on the floor of the tower storage area 5204. The barcode may be understood to enable the AMR to determine its instantaneous location and navigate accordingly. The location information may be combined with readings from other navigation sensors, such as encoders, accelerometers, and rate gyroscopes. Conventional AMRs are also known to include collision detection systems, sometimes implemented as infrared sensors or touch-sensitive bumpers, that act to stop the AMR in response to a person or object that gets in the way of the AMR's navigation.

[0295] In some embodiments, a tower 7510 in tower storage area 5204 may be identified, for example, by order fulfillment processor 1300, as storing one or more products for fulfilling an order. A tower 7510 storing one or more products for fulfilling an order, or simply a tower 7510 storing one or more products, may be transported from tower storage area 5204 to a particular station in product guiding area 5208. This transport may be manual or automatic. For example, multiple tower transport AMRs 7518 (not shown) may generally be designated to transport towers 7510 between tower storage area 5204 and product guiding area 5208. A fulfillment order data structure generated by order fulfillment processor 1300 includes tower transport AMR instructions for one of the multiple tower transport AMRs 7518 to engage with the tower 7510 and transport the tower 7510 to a particular station in product guiding area 5208, where an upright carton will receive one or more products for fulfilling the order. Indeed, loading of one or more products into installed cartons can be performed manually or robotically. A station in the product guidance area 5208 where loading of one or more products into standing cartons is performed manually may be referred to as a "manual product guidance station." A station in the product guidance area 5208 where loading of one or more products into standing cartons is performed robotically may be referred to as a "robotic product guidance station" or a "product transfer device." For example, a loading robot (not shown) may be positioned near and / or assigned to a robotic product guidance station in the shipping container guidance area 5208. When a tower (e.g., see tower 7510 in FIG. 75 ) storing one or more products for order fulfillment is transported to the robotic product guidance station, the loading robot may be instructed by the order fulfillment processor 1300 to retrieve the one or more products from one or more compartments of the tower 7510 and load them into the appropriate cases or cartons.For example, a loading robot may include an extendable arm that can reach a particular product in one or more compartments of the tower 7510 and load the particular product into a case. The product guiding area 5208 may include one or more loading robots for loading products from the tower 7510 into cases, e.g., one loading robot may service one robotic product guiding station or multiple robotic product guiding stations in the product guiding area 5208. In this manner, the AMR 1400 supporting the standing cartons can travel to one or more stations in the product guiding area 5208 and, at each station, receive one or more products for order fulfillment from a respective tower 7510, which is transported from a first location in the tower storage area 5204 to its respective station by a respective tower transport AMR 7518 that received a tower transport AMR command by the order fulfillment processor 1300.

[0296] Once the AMR 1400 obtains an order (or a partial order for a particular carton) for loading all products into a stand-up carton at either a manual or robotic product induction station, the AMR 1400 can transport the loaded carton to one of the final carton sealing devices 1500A, 1500B, 1500C. For example, the AMR 1400 can transport the stand-up carton with all products loaded therein through a predetermined random top carton seal (RTCS) infeed conveyor, which can feed the stand-up carton to the appropriate top sealing device. The RTCS is adapted to receive information provided by the order fulfillment processor 1300, and the RTCS can automatically adjust the sealing components of the device to close and seal the top of the stand-up loaded carton. The completed cartons may then be transported to a central carton distribution system for further sorting and processing.

[0297] Further sorting and processing may include labeling the completed cartons. The labeling device 1281 illustrated in FIG. 63 may be thought of as being configured to label the carton blanks 111 before they are formed by the carton forming system 1100. Alternatively, a labeling device (not shown) may be employed to label the completed cartons at the output end of the final carton sealing devices 1500A, 1500B, 1500C.

[0298] If the erected cartons are to be labeled while they are under the control of the carton forming system 1100, the labeling device 1281 may be mounted to the frame of the carton forming system 1100 near the alignment conveyor 1206. For example (although not depicted as such in FIG. 63 for simplicity), the labeling device 1281 may be mounted to a portion of the frame of the carton forming system 1100 generally above where the carton blank 111 is located when it is in the pickup position. The labeling device 1281 may be operable to print and apply one or more labels to one or more panels, preferably the upward-facing panels, of the carton blank 111 located at the pickup location. The labeling device 1281 may be any suitable device, such as a PLS-500 label application system manufactured by Paragon Labeling Systems, Inc., of White Bear Lake, Minnesota, in combination with an integrated print engine, such as an Lt408 print engine or an S84 series print engine (e.g., model numbers S8408, S8412, or S8424) manufactured by SATO America, Inc., of Charlotte, North Carolina. In some embodiments, the labeling device is capable of applying a physically separate label to the finished carton or carton blank 111, while in other embodiments, the labeling device is capable of applying printing to the finished carton or carton blank 111 without providing printing on a physically separate label.

[0299] As described above, the label or labels applied by the labeling device 1281 to the upward-facing panel of each carton blank 111 may be specially configured for that particular carton blank 111 and may include various types of information related to the order for the products to be filled into the erect carton formed from that particular carton blank 111. The label or labels may include information providing specific order information, including the types of products to be loaded into the erect carton formed from that blank, optionally including product codes for those products, the customer to whom the case is being shipped, and the customer's address. The label may also include a unique carton identifier. Some or all of the information may be provided in bar code format.

[0300] In this embodiment, the label is printed and applied to the carton blank 111 while the carton blank 111 is in a flattened configuration at the pick-up location and before the carton blank 111 is erected and bottom sealed, making the labeling step more reliable and providing the carton blank 111 with unique identification information.

[0301] A first exemplary label 1283a that may be applied by the labeling device 1281 is shown in Figure 65. A second exemplary label 1283b that may be applied by the labeling device 1281 is shown in Figure 66.

[0302] Various modifications are possible in some embodiments. As one example, instead of providing magazine conveyors 1203(1)-1203(N) for magazines M1-M(N), it is possible to provide a robotic system that can extract carton blanks from any one of the stacks of carton blanks in each magazine as requested by PLC 132. The robotic system can place the particular carton blank required on an infeed conveyor. In other embodiments, the infeed conveyor can be eliminated, and the robotic system can place each carton blank required at a pick-up location.

[0303] Other fulfillment systems are contemplated. For example, FIG. 69 shows a schematic floor plan of an order fulfillment center 6900. The order fulfillment center 6900 may share similarities with the order fulfillment center 5200 described in detail above. In this exemplary embodiment, the order fulfillment center 6900 includes a product storage guidance area 6902, a product storage area 6904, a shipping container guidance area 6906, an order verification and sealing area 6910, and a route distribution accumulation area 6912. Depending on the size of the order fulfillment center 6900, the order fulfillment center 6900 may include one or more multiples of the areas illustrated in FIG. 69, or in some cases, may omit one or more areas.

[0304] Similar to shipping container guiding area 5206 described above, shipping container guiding area 6906 of FIG. 69 may be populated with a plurality of receptacle forming systems, which may also be referred to as shipping container delivery systems, with one or more of such systems possibly following the design of carton forming system 100 described previously herein. In some embodiments, one or more of the plurality of receptacle forming / delivery systems may only be capable of producing / delivering a single size / configuration / type of receptacle to an AMR.

[0305] According to aspects of the present invention, as described in further detail below, multiple AMRs (e.g., AMRs 5300 and / or 5800) may be deployed for movement within a warehouse between the various illustrated areas. For example, an AMR may be controlled to visit shipping container guidance area 6906 to retrieve a shipping case (or other receptacle), and then, with the shipping container secured thereon, to visit product storage area 6904 to receive one or more products in the shipping container for order fulfillment.

[0306] In the product storage guidance area 6902, various products may be shown arriving at the order fulfillment center 6900, for example, in multiple transport trailers. Multiple units of a single SKU may be grouped into a container, and multiple containers may be grouped into a pallet. The term "pallet" may also refer to a stacked arrangement of containers on a pallet base for handling using machinery such as a forklift 6999. The term "pallet" may also refer to a pallet base. In some embodiments, multiple pallets may arrive as a single unit, and the units may have to be separated into individual pallets by humans and / or machines. For example, multiple pallets may be bundled or wrapped together and then unbundled or unwrapped before being stored.

[0307] The pallets may be transported to specific corresponding locations in product storage area 6904. Such transportation may be accomplished using a forklift 6999, which may be manually operated by an operator or, in other examples, automatically operated. In a preferred embodiment, forklift 6999 may be implemented as an automated guided vehicle (AGV).

[0308] Product storage area 6904 may be comprised of multiple product storage racks 7100. In product storage area 6904, pallets may be placed in corresponding storage locations. For example, for a particular pallet, forklift 6999 may receive, for example, coordinates or a set of instructions related to a particular storage rack located in product storage area 6904 and a particular area within the particular storage rack where the particular pallet should be stored. In this manner, pallets corresponding to various products can be placed in each product storage rack 7100.

[0309] FIG. 70 is a perspective view illustrating a portion of a product unloading system for an order fulfillment center in accordance with an exemplary embodiment of the present invention. The product unloading system portion of FIG. 70 is illustrated as including a product storage rack from the plurality of product storage racks 7100 of FIG. 69 and an AMR elevator 7110. The product storage rack 7100 may include multiple storage levels 7102 for storing pallets, such as first pallet 7120, containing products. As previously described, each pallet may contain individual products of a particular SKU. In some embodiments, each pallet may include a structured set of identical containers, such as container 7122, each containing one or more of a particular SKU (e.g., a container may be a box containing one or more sets of three books sold as a unit). In some embodiments, one or more pallets may contain a variety of different products as opposed to one particular SKU.

[0310] The product storage rack 7100 may further include a plurality of elevation platforms 7104, each of which is positioned proximate a respective one of the plurality of storage levels 7102. Each of the elevation platforms 7104 may be configured for the AMR5800 to travel thereon.

[0311] The product storage rack 7100 may further include one or more product retrieval robots, such as a robotic picker arm 7106. In some embodiments, a robotic picker arm 7106 may be associated with one respective storage level 7102 of the product storage rack 7100, as shown. In some embodiments, a robotic picker arm 7106 may correspond to multiple storage levels 7102 of the product storage rack 7100. Each robotic picker arm 7106 may be configured to retrieve individual products from a pallet and load the products into appropriate shipping containers carried by the AMR5800.

[0312] Specifically, each robotic picker arm 7106 may be equipped with an end effector suitable for selectively removing individual items from containers within a pallet and releasing the items into an appropriate shipping container to be carried by the AMR5800. The configuration of the end effector of the robotic picker arm 7106 may depend on the characteristics of the items being moved. For example, flat surfaces and relatively low weight items may be effectively engaged using an end effector having one or more vacuum cups. Other items, such as items with curved or irregular surfaces or relatively heavy weight items, may be grasped using claws or clamping devices of corresponding size and shape.

[0313] In some embodiments, multiple interchangeable end effectors may be available. For example, one or more of the robotic picker arms 7106 may include a releasable linkage configured to engage or disengage a selected one of multiple end effectors. For example, FIG. 77 shows an exemplary robotic picker arm 7106 having a connector 7710 that can be used to engage multiple end effectors. The connector 7710 may include a physical linkage, such as a quick connect for electrical and pneumatic connections. Available end effectors (not shown) may be located at one or more resting positions accessible by the robotic picker arm 7106. As needed, the robotic picker arm 7106 can move, via the connector 7710, to engage the appropriate end effector and use the end effector to perform a particular task. After the task is performed, or when a different end effector is needed, the robotic picker arm 7106 can return to the resting position and release the connector 7710 to return the end effector.

[0314] The robotic picker arm 7106 may further be configured to perform depalletizing operations. For example, the robotic picker arm 7106 may be configured to remove packaging material from a pallet, such as straps 7702, or to open or disassemble containers within a pallet to access individual items held within the containers. The robotic picker arm 7106 may further be configured to dispose of the removed packaging material. For example, the robotic picker arm 7106 may grasp the packaging material and transport the packaging material to a disposal location, such as a chute (not shown).

[0315] To accomplish the depalletizing operation, the robotic picker arm 7106 may engage an end effector configured for use in depalletizing operations. In some embodiments, such an end effector may be a destrapper-debander.

[0316] For example, FIGS. 78A and 78B show a de-strapper-debander 7800. The de-strapper-debander 7800 can include one or more of a motor 7804, a roller (not shown), scissors 7807, and a clamp including an upper clamp 7806 and a lower clamp 7805. In operation, a cycle begins when the robotic picker arm 7106 brings the de-strapper-debander 7800 into proximity with a strap 7702. The clamp components 7805 / 7806 can hold the strap 7702 in place using a clamping mechanism. Once the strap 7702 is held in place, the scissors 7807 can cut the strap 7702. Because the clamp components 7805 / 7806 hold the strap 7702 in place, the strap 7702 can maintain its position while tension is released, thereby avoiding undesirable and unpredictable movement. Once the strap 7702 is cut, the motor 7804 can rotate the de-strapper-debander 7800 to wrap the strap 7702 around the de-strapper-debander 7800. A roller (not shown) can be a spring-loaded roller employed to maintain the position of the strap 7702 on the de-strapper-debander 7800 as the strap 7702 forms a reel wound around the de-strapper-debander 7800.

[0317] Once the strap 7702 is fully reeled, the robotic picker arm 7106 may position the strap 7702 at a dunnage drop zone or chute (not shown). Specifically, the robotic picker arm 7106 may move the de-strapper-debander 7800 to position it above the dunnage drop zone or chute. There, the clamping components 7805 / 7806 are released from holding the strap 7702, thereby allowing the wound reel of strap 7702 to fall down the chute. Alternatively, there may be a mechanism (not shown) that pushes the wound reel of strap 7702 away from the de-strapper-debander 7800 so that it falls down the chute. This cycle can be repeated as necessary to remove the strap from the pallet 7120.

[0318] The robotic picker arm 7106 may be mounted on a rail (not shown) above the associated storage level 7102. Such a configuration provides efficient access to items through the top of the cases. However, other mounting arrangements are possible. For example, the robotic picker arm 7106 may be mounted below the associated storage level 7102 or may be suspended from a side frame. Alternatively, the robotic picker arm 7106 may be an element of a free-standing autonomous robot that can move along the storage level 7102 and / or lift platform 7104, possibly utilizing an AMR elevator 7110 to travel to another lift platform 7104 or to ground level of the order fulfillment center 6900.

[0319] As shown in FIG. 70, the robotic picker arm 7106 may be able to move on rails (not shown) in multiple axes, e.g., X, Y, and Z, and thus may be able to reach any product stored in the associated storage level 7102.

[0320] The AMR elevator 7110 may be configured to transport the AMR5800 between the ground and the elevated platform 7104 of one of the product storage racks 7100. The AMR elevator 7110 may include a receiving dock 7112 disposed between vertical rails 7114. The receiving dock 7112 may be configured to move vertically along the vertical rails 7114 using an actuator 7016. In some embodiments, the AMR elevator 7110 may further include wheels or other means for configuring the AMR elevator 7110 to move along the X-axis and the Y-axis. In some embodiments, one AMR elevator 7110 may accommodate one product storage rack 7100. Alternatively, one AMR elevator 7110 may accommodate multiple product storage racks 7100.

[0321] In operation, the AMR elevator 7110 may be controlled to receive an AMR having a shipping container or other receptacle secured thereon, such as the AMR 5800 illustrated in FIG. 70, at a loading dock 7112 and transport the AMR 5800 from ground level to one of the elevated platforms 7104. Once the AMR 5800 reaches its destination platform 7104, the AMR 5800 may exit the loading dock 7112 onto the elevated platform 7104 and travel along the elevated platform 7104 until the AMR 5800 reaches the commanded location to receive the particular product needed to fulfill an order. The robotic picker arm 7106 engages a container in a corresponding pallet, such as container 7122 in the first pallet 7120, to retrieve the required product and load the required product into a shipping container, after which the AMR 5800 returns toward the AMR elevator 7110 and moves onto the loading dock 7112, after which the AMR 5800 is transported to ground level. If a particular product storage rack 7100 has multiple items required to fulfill an order, the AMR elevator 7110 may be controlled to transport the AMR 5800 up to all necessary elevated platforms 7104 of the product storage rack 7100 to receive the various items. This process may be repeated with one or more product storage racks 7100 until the shipping container has received all the products required to fulfill the order. The AMR 5800 may then be controlled to move to another location for further processing.

[0322] In some embodiments, a product retrieval robot, such as the robotic picker arm 7106, may include sensors to detect products to be retrieved for a shipping case. For example, the sensors may include a camera, and the robotic picker arm 7106 may be configured to use computer vision to detect products to be retrieved. The robotic picker arm 7106 may be configured with one or more grippers, such as suction cups or any other suitable gripper, to retrieve products. In some embodiments, the product unloading system may be organized such that at least a portion of the storage level 7102 has pallets or containers of similar shape and / or size and / or containing similar packaging positioned in close proximity to one another. The corresponding robotic picker arm 7106 servicing that section may be equipped with grippers that can more easily interact with products of that shape and / or size and / or packaging.

[0323] In embodiments in which one or more pallets contain a structured set of identical containers, each container containing one or more of a particular SKU, the dimensions of each container and the manner in which the containers are organized may be known to the product picking robot. For example, the embodiment shown in FIG. 70 shows a first pallet 7120 containing a structured set of identical containers 7122. In such embodiments, instead of or in addition to using computer vision, the product picking robot may be numerically guided to pick one of the containers and load the picked container into a shipping case.

[0324] In some embodiments, each product pick robot may be configured to load products into one type of shipping case (e.g., one robot may be configured to load products into open-top regular slotted cases, while another robot may be configured to load products into open-sided envelopes). In some embodiments, one or more product pick robots may be configured to load products into one or more types of shipping cases, and may be able to determine, for example, using cameras and computer vision, which type of shipping case a particular product should be loaded into, so that the product pick robot can accurately load the product into the shipping case.

[0325] FIG. 71 illustrates an example conceptual embodiment of a fulfillment center 6900 utilizing AMR devices such as AMR 5300 of FIG. 53 and / or AMR 5800 of FIG. 58, as described herein. In a manner similar to that described above in connection with FIG. 56A, AMRs such as AMR 5300 or AMR 5800 in the system can be programmed to move from station to station along an example path 7210 and process orders as follows:

[0326] When the shipping container delivery system (e.g., a case erector as previously described herein) has produced the appropriate size shipping case for a particular customer order, the AMR 5300 / 5800 moves to one of multiple case guide stations 7204. The case guide station 7204 may be part of a shipping container guide area 5206 (FIG. 52), 6906 (FIG. 69). The case erector transfers the shipping case onto the AMR 5300 / 5800, which secures the shipping case to itself according to one of the methods previously described.

[0327] The AMR 5300 / 5800 moves to the product storage area 6904, and shipping cases secured on the AMR 5300 / 5800 receive one or more products from one or more product storage racks 7100 necessary to fulfill the customer order in accordance with the method described above in connection with FIG. 70 .

[0328] The AMR 5300 / 5800 then travels to one of multiple order verification stations 7630 so that the contents of the shipping case can be verified to correspond to the products in the customer order.

[0329] The AMR 5300 / 5800 can then move to a case sealer 7220 of multiple case sealers 7220 and then to a case labeler 7224 to sequentially seal and label the shipping case. For example, if the shipping case is a regular slotted case with a bottom seal, the top of the case can be sealed by the case sealer 7220 and labeled, for example, with a label containing information useful for shipping the sealed shipping case to a customer. In some embodiments, order verification, case sealing, and / or case labeling may be accomplished at the same station, as described below in connection with FIG. 73.

[0330] The AMR 5300 / 5800 then moves to a case discharge station 7225 where the sealed shipping cases are unloaded from the AMR 5300 / 5800 onto a discharge conveyor 7226 and can then be loaded into a delivery vehicle by a human and / or robot 6998.

[0331] The AMR5300 / 5800 can then move to the charging station 7202 or return to the case induction station 7204 to pick up the appropriate size shipping container for a different customer order and repeat the cycle.

[0332] 72-74 provide a more detailed description of steps 1, 3, 4, and 5 of the exemplary process 7210.

[0333] FIG. 72 is a perspective view of multiple case guide stations 7204 of the order fulfillment center of FIG. 69. Each case guide station 7204 is positioned at the end of a carton forming system, such as a case erector or carton forming system 100, located within shipping container guide area 6906. Each case guide station 7204 may include a case discharge system 7240 including a discharge conveyor 7226. As shown, shipping cases, such as case 7250, may be assembled by a case assembler and loaded onto discharge conveyor 7226. An AMR may be instructed to move to discharge conveyor 7226. The AMR may then be instructed to wait to receive the case (AMR 5300 is shown, but may alternatively be AMR 5800 or another shipping container AMR). For example, a first AMR 5300-1 is shown moving to a first case guide station 7204 and waiting to receive a first case 7250, a second AMR 5300-2 is shown moving to a second case guide station 7204 and receiving a second case 7252, and a third AMR 5300-3 is shown moving to a third case guide station 7204 and waiting to receive a third case.

[0334] In some embodiments, each case erector may be configured to build and deliver one type of shipping case (e.g., regular slotted cases) or only one particular size of case. In some embodiments, one or more case erectors may be configured to build two or more types of shipping cases (e.g., regular slotted cases and open-sided envelopes). In such embodiments, one or more case erectors may be configured to build one or more sizes of cases. Regardless of the capabilities of any one particular case erector, multiple case erectors in the shipping container guidance area 6906 can build different types of shipping cases of different sizes so that the right size and type of container is built for the customer order. For example, as shown in FIG. 72, a first case 7250 may be larger than a second case 7252 because the first case 7250 may have been built for a customer order with more products or larger sizes of products than the second case 7252.

[0335] Once the AMR 5300 receives the case, the AMR 5300 may be instructed to move the case to the product storage area 6904 to fill the case with one or more products needed to fulfill the customer's order.

[0336] FIG. 73 is a perspective view of an order verification case sealing station 7620 located in the order verification sealing area 6910. Advantageously, each order verification and case sealing station 7620 can be configured so that the first case 7250 containing the customer's requested product does not have to be unloaded from and reloaded onto the AMR 5300 along which it travels. Instead, the first case 7250 remains fixed to the AMR 5300, and the AMR 5300 and first case 7250 move together through the case sealing station 7620. The case sealing station 7620 can be configured with means (not shown) for verifying that the one or more products in the first case 7250 are accurate and complete, and means for sealing the container. In some embodiments, each order verification and case sealing station 7620 may be configured to interact with only one type of shipping case (e.g., a top-opening regular slotted case versus a side-opening envelope). In some embodiments, one or more validation and case sealing stations 7620 may be configured to interact with more than one type of shipping case. Regardless of the capabilities of any one validation sealing station 7620, multiple stations 7620 in the order validation and sealing area 6910 may perform validation and sealing services for different shipping case types and for different size types.

[0337] In some embodiments, one or more of the order verification and case sealing stations 7620 may be further configured to label the case after verification and sealing with a label (not shown) containing information necessary for proper delivery (e.g., sender's name and address, recipient's name and address, weight, tracking barcode, etc.) In some embodiments, case labeling may occur at a different location, e.g., at a different station.

[0338] FIG. 74 is a perspective view of multiple case discharge stations 7225 of the order fulfillment center of FIG. 69. As shown, each case discharge station 7225 includes a discharge conveyor 7226 having a receiving end for receiving verified, sealed, and labeled shipping cases from the AMR 5300 and a discharge end, at which the cases may be loaded into a shipping container (e.g., a storage space in a delivery transport trailer) for delivery to the respective customer. In a preferred embodiment, the AMR 5300 can have means (e.g., as described elsewhere with respect to the AMR 5800) for automatically unloading its shipping cases onto the discharge conveyor 7226. In some embodiments, an automated vehicle or person may assist in unloading the shipping cases from each AMR 5300. The loading of cases from the discharge end of the discharge conveyor 7226 into a delivery vehicle may be accomplished by one or more people or an automated robot 7998, as shown in FIG. 74. Alternatively, loading of cases from the discharge end of the discharge conveyor 7226 onto a delivery vehicle may be accomplished by an automated vehicle.

[0339] FIG. 76 shows in a schematic plan view an order fulfillment location 7600, which can be considered a hybrid of the order fulfillment center 5200 of FIG. 52 and the order fulfillment center 6900 of FIG. 69. The order fulfillment location 7600 can be considered to be physically organized in a logical manner into areas or zones associated with various functions. The order fulfillment location 7600 includes a product storage guidance area 7603, a tower storage area 7604T, a product rack storage area 7604P, a shipping container guidance area 7606, a product guidance area 7608, an autonomous mobile robot movement area 7610 where multiple AMRs (e.g., AMR 5300 and / or AMR 5800) are located, and a route distribution and accumulation area 7612. In practice, depending on the size of the order fulfillment location 7600, the order fulfillment location 7600 may include multiple areas illustrated in FIG. 76 or, in some cases, omit one or more areas. The product guidance area 7608 may be surrounded by multiple walls and a roof.

[0340] A tower storage area 7604T may be populated with multiple towers 7510 (see FIG. 75). In some embodiments, the multiple towers 7510 in a tower storage area 7604T may store higher margin, lower volume products. Examples of such products may include electronics, clothing, toys, and health and beauty products. In some embodiments, the number of different individual products (SKUs) stored by the multiple towers 7510 may be on the order of hundreds of thousands, or even a million or more different products (e.g., a vast variety of different books or DVDs).

[0341] The product rack storage area 7604P may be populated with multiple product storage racks 7100, as well as multiple AMR elevators 7110 (see FIG. 70 ). In some embodiments, the multiple product storage racks 7100 in the product rack storage area 7604P may store lower-margin, higher-volume products. For example, the multiple product storage racks 7100 may store food products. In some embodiments, as described in more detail below, the product rack storage area 7604P may be subdivided into various sub-areas maintained at different conditions, e.g., different temperatures. In this manner, the product rack storage area 7604P may be able to simultaneously store refrigerated and frozen food products in addition to food products that may be maintained at ambient / normal room temperature. In some embodiments, the number of different types (SKUs) of product stored by the multiple product storage racks 7100 in the product rack storage area 7604P may be on the order of thousands, although many multiple units of the same SKU / type of product (e.g., multiple individual oranges, multiple cartons of milk, etc.) may be stored.

[0342] Operationally, in product storage guidance area 7603, various products may be shown arriving at order fulfillment center 7600, for example, in multiple transport trailers.

[0343] Portions of the arriving product may be stored in compartments of multiple towers, often organized on pallets, which are ultimately placed in tower storage area 7604T.

[0344] Humans and / or robots 7999 may unload products delivered to the order fulfillment system 7600 (e.g., by transport trailer, and which products may be delivered on pallets). Individual products organized on pallets may be recovered through a depalletizing and disassembly process. The unloaded individual products may then be placed in a predetermined tower 7510 of the towers 7510 by humans and / or robots 7999, as described previously herein. Once filled with products, the predetermined tower may then be moved by the tower transport AMR 7518 so that the predetermined tower 7510 is located within the tower storage area 7604T. Information regarding the location where each individual product is stored (e.g., the particular tower 7510 and the particular tower compartment 7512) may be stored in an appropriate memory of the order fulfillment processor 1300.

[0345] Portions of the arriving products are often organized onto pallets and may be transported on each pallet to a specific corresponding location within the product rack storage area 7604P, which is arranged with a plurality of product storage racks 7100 on which the pallets may be stored. Such transport may be performed using a forklift 7997. The forklift 7997 may be manually operated by an operator or may be autonomously operated. In a preferred embodiment, the forklift 7997 may be an automated guided vehicle (AGV).

[0346] In some embodiments, products stored in the product rack storage area 7604P may arrive at the order fulfillment location 7600 / 7600A or order fulfillment center 6900 in standardized storage cases that are palletized onto standardized pallet bases. In other words, a supplier may place products stored in the product rack storage area 7604P and used to fulfill an order into standardized storage cases and palletize multiple such cases onto standardized pallet bases, as described below.

[0347] Referring briefly to FIGS. 79 and 80, FIG. 79 illustrates an exemplary standardized storage case 7910. The standardized storage case 7910 may be one type of standardized storage case. The standardized storage case 7910 may be manufactured from plastic and may be designed to be durable and reusable. Each type of standardized storage case within a plurality of standardized storage cases may be manufactured with precisely standardized dimensions. For example, the standardized storage case 7910 may be manufactured to have a length L of 24 inches, a width W of 20 inches, and a height of 22 inches. The standardized storage case 7910 may generally conform to the shape of an open-top case having two parallel sides 7912 along the length of the standardized storage case 7910 and two parallel sides 7914 along the width of the standardized storage case 7910. The standardized storage case 7910 may further include a handle 7912 and a plurality of holes 7916 on each of the sides 7912 and 7914. The handle 7912 allows an individual (such as a supplier employee) to easily lift the standardized storage case 7910, and the multiple holes 7916 allow a person to more easily discern what is contained in the standardized storage case 7910.

[0348] The type of standardized storage case selected may be based on the type of product. For example, the standardized storage case 7910 may be a type of standardized storage case selected for specific or all bakery products because the dimensions, materials, and other characteristics of the standardized storage case 7910 may be ideal for such products. Other types of standardized storage cases may be suitable for other types of food products, such as dairy products, meat and poultry, fruits and vegetables, frozen goods, etc. Thus, the dimensions, materials, and characteristics of one type of standardized storage case may differ from other types. Regardless of the number of different types, in some embodiments, all standardized storage cases delivered to the order fulfillment location 7600 / 7600A or order fulfillment center 6900 and stored in the product rack storage area 7604P may be known to the order fulfillment system and, therefore, to a robot configured to be used for depalletizing operations, such as the robotic picker arm 7106. Individual suppliers may be responsible for the maintenance and refurbishment of standardized storage cases, ensuring that standardized storage cases, such as standardized storage case 7910, arriving at an order fulfillment location or center are free of defects.

[0349] Some products may not be packaged in standard storage cases, such as standard storage case 7910. These products may be pre-packaged and sold in units, such as cases of consumer beverages. These products may be palletized on a pallet base without being packaged in standardized storage cases or other containers. In some embodiments, these products may be packaged with straps that can be removed by an end effector of a robotic picker arm, such as destrapper-debander 7800. Alternatively, these products may arrive at the order fulfillment location in standardized storage cases, such as standardized storage case 7910.

[0350] As discussed above, in some embodiments, many, most, or all of the products stored in the product rack storage area 7604P may arrive palletized on standardized pallet bases. FIG. 80 shows a pallet 8010 containing products to be stored in the product rack storage area 7604P. The pallet 8010 includes a plurality of standardized storage cases 7910 palletized on a standardized pallet base 8002. In the illustrated embodiment, eight standardized storage cases 7910 are shown in the pallet 8010, organized into two layers of four standardized storage cases 7910 each, but this is for illustrative purposes only. In some embodiments, the number of layers may be increased. In some embodiments, the number of standardized storage cases per layer may be increased, for example, for standardized storage cases with smaller dimensions than the standardized storage case 7910. Similar to steps described elsewhere, the pallet 8010 may be wrapped with straps that can be removed by an end effector of the robotic picker arm, such as the destrapper-debander 7800 of the robotic picker arm 7106.

[0351] The standardized pallet base 8002 may be manufactured from wood or plastic and designed to be durable and reusable. The standardized pallet base 8002 may be manufactured to precisely standardized dimensions. In some embodiments, these dimensions include a length L of 48 inches (1219.2 mm) and a width W of 40 inches (1016 mm). This standard size of the standardized pallet base 8002 ensures compatibility and ease of use across various industries and supply chain networks. The standardized pallet base 8002 may have a "stringer" design, which includes three parallel wooden or plastic beams running the length of the pallet, with deck boards placed across them. This design can provide good load-bearing capacity and stability. Additionally, the standardized pallet base 8002 may have block supports at the corners, which allow forklift tines to easily engage and move on the standardized pallet base 8002, thereby enabling efficient handling during loading and unloading. The standardized pallet base 8002 may be a "four-way entry" pallet base. As such, a forklift or pallet jack can engage the pallet from either side. Individual suppliers may be responsible for maintaining and refurbishing the standardized pallet base 8002, thereby ensuring that the standardized pallet base 8002 that arrives at the order fulfillment location is defect-free.

[0352] Returning to FIG. 76 , product rack storage area 7604P may be comprised of multiple product storage racks 7100. In product rack storage area 7604P, pallets, which may include standardized pallet base 8002 and standardized storage cases, such as standardized storage case 7910, may be placed in their corresponding storage locations. For example, for a particular pallet, a forklift or pallet jack may receive, for example, coordinates or a set of instructions, associated with a particular storage rack located within product rack storage area 7604P and a particular area within the particular storage rack 7100 where the particular pallet should be stored. In this manner, pallets corresponding to various products may be placed in each product storage rack 7100.

[0353] In some embodiments, the product rack storage area 7604P may be divided into multiple partitions, each of which may be maintained at different conditions.

[0354] For example, FIG. 76A shows an order fulfillment location 7600A in which a product rack storage area 7604P is divided into three partitions 7605-1, 7605-2, and 7605-3. Each of the three partitions 7605-1, 7605-2, and 7605-3 may include one or more product storage racks 7100 on which pallets corresponding to various products may be placed.

[0355] Partitions 7605-1, 7605-2, and 7605-3 may be maintained at different conditions. For example, a first partition 7605-1 may maintain products at a moderate temperature, such as room or ambient temperature, a second partition 7605-2 may maintain products at a reduced temperature relative to the temperature of the first partition 7605-1, such as refrigerated temperature, and a third partition 7605-3 may maintain products at a temperature below freezing. In this manner, partitions 7605-1, 7605-2, and 7605-3 can provide three different storage conditions for storing different products. For example, as previously described, product rack storage area 7604P may store food products. Items that are safe to store at room temperature, such as non-perishable foods, may be stored in a first partition 7605-1, perishable foods such as fresh produce and meat may be stored in a second partition 7605-2, and frozen foods may be stored in a third partition 7605-3.

[0356] In some embodiments, air curtains or air doors may be provided for the product storage racks 7100 located within the second partition 7605-2 and / or the third partition 7605-3. An air curtain may be a device configured to blow a consistent, controlled stream of high-velocity air to create an air seal and separate two environments from one another. Specifically, the air curtain may separate a portion of the product storage racks 7100 that stores products at refrigerated or freezer temperatures from the average warehouse temperature, which may be ambient.

[0357] 70 , for a product storage rack 7100 located within the second partition 7605-2 or the third partition 7605-3, an air curtain (not shown) may be positioned above the product storage rack 7100 and configured to blow a high-velocity air stream in a substantially vertical direction between the multiple storage levels 7102 and the multiple elevated platforms 7104. The air curtain may thus enable a first environment including the multiple storage levels 7102 and products stored on the multiple storage levels 7102 to be maintained at different conditions than a second environment including the multiple elevated platforms 7104, one or more robotic picking arms 7106, AMR elevators 7110, AMR5800, and any forklifts or automated guided vehicles traveling at ground level. For example, for product storage racks 7100 located within the second partition 7605-2, a first environment may be maintained at a refrigerated temperature and a second environment may be maintained at an ambient temperature, while for product storage racks 7100 located within the third partition 7605-3, a first environment may be maintained at a sub-zero temperature and a second environment may be maintained at an ambient temperature. In this manner, within the second partition 7605-2 and the third partition 7605-3, the AMR5800, the AMR elevator 7110, and other equipment or materials located within the second partition 7605-2 and the third partition 7605-3 may be protected from damage that may be caused by refrigerated or freezing temperatures. One or more robotic picker arms 7106 may be configured to enter and exit the first environment to retrieve products stored in the multiple storage levels 7102 and release them into one or more shipping containers carried by the AMR5800. In a stationary position, one or more robotic picker arms 7106 may be positioned in a second environment to minimize damage from prolonged exposure to refrigerated or sub-freezing temperatures. In some embodiments, the product storage rack 7100 may be provided with multiple air curtains to form an air seal around all of the products stored in the multiple storage levels 7102.In other words, air curtains may be provided to form air seals on the left, right, and rear sides of the multiple storage levels 7102, as opposed to forming an air seal only on the front side of the multiple storage levels 7102. In some embodiments, air curtains or other means for maintaining various areas or environments of the second partition 7605-2 and / or the third partition 7605-3 at different temperatures may not be implemented. Instead, the second partition 7605-2, including the entirety of the product storage racks 7100 and AMR elevator 7110, may generally be maintained at a refrigerated temperature such that the AMR 5800 and vehicles traveling at ground level are exposed to the maintained refrigerated temperature when they enter the second partition 7605-2. Similarly, the third partition 7605-3, which contains the product storage racks 7100 and the AMR elevator 7110, may generally be maintained at a sub-zero temperature such that when any AMR5800 and vehicles traveling at ground level enter the third partition 7605-3, the third partition 7605-3 is exposed to a maintained refrigerated temperature.

[0358] 76 or 76A, the shipping container induction area 7606 may be populated with multiple carton forming systems, which may also be referred to as shipping container distribution systems, possibly in accordance with the design of the carton forming system 100 disclosed herein. In embodiments in which the product rack storage area 7604P is divided into three partitions 7605-1, 7605-2, and 7605-3 that maintain products at different temperatures and conditions, one or more of the multiple carton forming systems may be configured to form shipping containers that can safely transport one or more items stored in the second partition 7605-2 or the third partition 7605-3 to a destination. For example, one or more of the multiple carton forming systems may be configured to form shipping containers with an inner insulating lining or made entirely of insulating material to preven...

Claims

1. 1. A processor, comprising: Generate carton forming instructions; Generate autonomous mobile robot (AMR) instructions; a processor operable to:

1. A carton forming system comprising: receiving the carton formation instructions from the processor; selecting a carton blank from a plurality of available carton blanks in accordance with said carton formation instructions; forming the carton blank into a stand-up carton; a carton forming system configured as follows: AMR, receiving the AMR instruction from the processor; moving to the carton forming system in accordance with the AMR command and receiving the erected carton from the carton forming system; In accordance with the AMR command, the carton is moved to a station in a product guiding area while holding the upright carton. receiving the product into the stand-up carton at said station; moving the stand-up carton with the product therein to a location for further processing in accordance with the AMR order, while retaining the stand-up carton; An AMR configured as follows: A fulfillment system comprising:

2. 2. The fulfillment system of claim 1, wherein the carton formation instructions are generated by the processor based on a customer order received by the processor, and the AMR instructions are generated by the processor based on the customer order received by the processor.

3. 3. The fulfillment system of claim 1 or 2, wherein the product induction area includes a product tower, the product tower including a plurality of compartments for storing products, at least one of the plurality of compartments including one or more products, the one or more products corresponding to at least one stockkeeping unit.

4. 4. The fulfillment system of claim 1, further comprising a scale, wherein the further processing includes verifying that a weight of the stand-up carton and the product combination measured using the scale is close to an expected weight of the stand-up carton and the product combination.

5. 5. The fulfillment system of claim 1, further comprising a carton sealing device, wherein said further processing comprises sealing said upstanding carton with said carton sealing device.

6. 6. The fulfillment system of claim 1, further comprising a carton labeling device, wherein the further processing comprises labeling the upstanding cartons using the carton labeling device.

7. a path distribution accumulation region, wherein the further processing comprises: determining a destination for the product; transporting the upright cartons to stations within the route distribution and accumulation area; Equipped with The fulfillment system of claim 1 , wherein the stations within the route distribution collection area correspond to the destinations.

8. The unloading locations within the route distribution storage area correspond to a delivery route representing an ordered sequence of destinations, and generating the AMR command. determining a position in an ordered sequence of destinations for the destination of the product; arranging the timing of arrival of the AMR at the unloading location within the route distribution storage area so that the timing of arrival corresponds to the location in the ordered sequence of the destinations; The fulfillment system of claim 7 , comprising:

9. 9. The fulfillment system of claim 1, wherein the further processing comprises holding the upright carton with suction cups.

10. 10. The order fulfillment system of claim 1, wherein the further processing comprises holding the upright cartons with lugs attached to independently controlled belts.

11. 11. The order fulfillment system of claim 1 or 10, wherein the product guidance area is adjacent to a storage area.

12. 12. The order fulfillment system of claim 11, wherein the storage area includes a plurality of towers that store products in compartments, the towers being configured to be transported to the product guidance area by a tower-transporting autonomous mobile robot.

13. 12. The order fulfillment system of claim 11, wherein the storage area includes a plurality of product storage racks that store products on pallets.

14. 14. The order fulfillment system of claim 1, wherein the plurality of available carton blanks is stored in a plurality of magazines.

15. 15. The order fulfillment system of claim 1, wherein the stations in the product guidance area include a robotic product loading station, and the AMR is configured to receive the product from the product pick robot into the standing carton at the robotic product loading station.

16. 15. The order fulfillment system of claim 1, wherein the stations within the product guidance area include a manual product loading station, and the AMR is configured to receive the product from a manual product removal operator into the standing carton at the manual product loading station.

17. 1. A processor, comprising: Generate a shipping container selection instruction; Generate autonomous mobile robot (AMR) instructions; a processor operable to:

1. A shipping container delivery system comprising: receiving the shipping container selection instruction from the processor; selecting a selected shipping container from the plurality of shipping containers in accordance with the shipping container selection instructions; a shipping container delivery system configured as follows: AMR, receiving the AMR instruction from the processor; traveling to the shipping container delivery system in accordance with the AMR command and receiving a selected shipping container from the shipping container delivery system; Moving to a station in a product guidance area while holding the selected shipping container in accordance with the AMR command; receiving the product into the selected shipping container at the station; and moving the selected shipping container with the product therein to a location for further processing in accordance with the AMR command. An AMR configured as follows: A fulfillment system comprising:

18. 20. The fulfillment system of claim 17, wherein the shipping container selection instructions are generated by the processor based on a customer order received by the processor, and the AMR instructions are generated by the processor based on the customer order received by the processor.

19. 19. The fulfillment system of claim 17 or 18, wherein the product guidance area has a product tower, the product tower including a plurality of compartments for storing products, at least one of the plurality of compartments including one or more products, the one or more products corresponding to at least one stockkeeping unit.

20. The product is a first product, and the AMR is In accordance with the instructions of the AMR, while holding the selected shipping container, move to a predetermined product storage rack within a storage area including a plurality of product storage racks storing products on pallets; receiving a second product into the selected shipping container at the predetermined product storage rack; and moving the selected shipping container with the first product and the second product therein to another location for further processing in accordance with instructions from the AMR.

20. The fulfillment system of any one of claims 17 to 19, further configured to:

21. 21. The fulfillment system of any one of claims 17 to 20, wherein the AMR is further configured to move, in accordance with the AMR command, while holding the selected shipping container to a location within a second product guiding area, the second product guiding area having a crate holding structure, the crate holding structure holding a plurality of crates for storing products, at least one of the plurality of crates containing one or more products, the one or more products corresponding to a single stockkeeping unit.

22. 22. The fulfillment system of claim 21, wherein the AMR is a shipping container AMR, the system further comprising a crate-holding AMR, the processor operable to generate a crate-holding AMR instruction, the crate-holding AMR instruction instructing the crate-holding AMR to transport the crate-holding structure to the second product guidance area to meet the shipping container AMR.

23. 23. The fulfillment system of any one of claims 17 to 22, further comprising a sealing device operable to seal an open flap of the selected shipping container.

24. 24. The fulfillment system of claim 23, wherein the sealing device seals an open flap of the selected shipping container while the AMR moves through the sealing device.

25. 25. The fulfillment system of claim 24, wherein the AMR further comprises a drive mechanism operable to drive movement of the AMR, the AMR being driven through the sealing device by the drive mechanism.

26. 26. The fulfillment system of claim 25, further comprising first and second laterally spaced, longitudinally extending guide belts operable to guide the selected shipping container during longitudinal movement of the AMR with the selected shipping container thereon.

27. 27. The order fulfillment system of claim 26, wherein the order fulfillment system is operable to provide information to the processor indicative of the movement of the guide belt through the sealing device of the AMR and the shipping container.

28. 28. The fulfillment system of any one of claims 17 to 27, wherein the stations in the product guidance area include a robotic product loading station, and the AMR is configured to receive the product from the product removal robot into the shipping container at the robotic product loading station.

29. 28. The fulfillment system of any one of claims 17 to 27, wherein the stations within the product guidance area include a manual product loading station, and the AMR is configured to receive the product into the shipping container from a manual product removal operator at the manual product loading station.

30. an autonomous mobile robot (AMR); a processor operable to generate an AMR instruction; a shipping container delivery system configured and operable to deliver a shipping container to the AMR; a sealing device operable to seal the shipping container as the AMR moves through the sealing device with the shipping container thereon; Equipped with The AMR is receiving the AMR instruction from the processor; traveling to and through the sealing device in accordance with the AMR command to seal the shipping container; 1. A carton closure and sealing system constructed and operable to:

31. 31. The system of claim 30, wherein the AMR further includes a drive mechanism operable to drive the movement of the AMR, the AMR with the shipping container thereon being driven through the sealing device by the drive mechanism.

32. 32. The system of claim 30 or 31, further comprising first and second laterally spaced, longitudinally extending guide belts operable to guide the shipping container during longitudinal movement of the AMR with the shipping container secured thereto through the sealing device.

33. 33. The system of claim 32, wherein the guide belts contact opposite sides of the shipping container during longitudinal movement of the AMR through the sealing device with the shipping container secured thereon.

34. 34. The system of claim 32 or 33, wherein the lateral spacing of the guide belts is adjustable by the processor to correspond to the width of the shipping container.

35. 35. The system of any one of claims 32 to 34, wherein the system is operable such that movement of the longitudinal guide belt provides information to a processor indicative of movement of the AMR and shipping container through the sealing device.

36. 36. The system of any one of claims 30-35, wherein the sealing device includes a folding rail system operable to close at least one of a top leading flap and first and second opposing side flaps of the shipping container during movement of the AMR and the shipping container through the sealing device.

37. 37. The system of claim 36, wherein the sealing device further comprises a flap kicking mechanism operable to close a rear flap of the shipping container while the AMR and the shipping container move through the sealing device.

38. 38. The system of any one of claims 30 to 37, further comprising a labeling device operable to label the shipping container as the AMR moves through the labeling device with the shipping container thereon.

39. 39. The system of claim 38, wherein the AMR moves through the sealing device and the labeling device to seal and label the shipping container in accordance with the AMR commands.

40. An autonomous mobile robot (AMR) for transporting a receptacle, comprising: A mobile cart and a control system for controlling operation of the AMR; a first belt having an upper surface; a first lug secured to the top surface of the first belt; a second belt having an upper surface; a second lug secured to the upper surface of the second belt; Equipped with the control system is operable to control and adjust the position of the first lug with respect to the second lug moving between a first position and a second position; the first position is a position where a spacing between the first lug and the second lug is suitable for allowing a receptacle to be placed between the first lug and the second lug and removed from between the first lug and the second lug; the second position is a position where a spacing between the first lug and the second lug allows the first lug and the second lug to engage with a side surface of the receptacle to secure the receptacle between the first lug and the second lug. AMR.

41. 41. The AMR of claim 40, wherein the upper surface of the first belt and the upper surface of the second belt are configured to support the receptacle thereon, and when the shipping container is secured between the first lug and the second lug, the receptacle is supported on the upper surface of the first belt and the upper surface of the second belt.

42. An autonomous mobile robot (AMR) for transporting a receptacle, comprising: A mobile cart and a control system for controlling the operation of the autonomous mobile robot; a receptacle securing mechanism operable to releasably secure a shipping container to the mobile cart during transport within the warehouse when the receptacle is carrying at least one product of a product order and when the receptacle is empty of any product; Equipped with the control system is operable to control and regulate the operation of the receptacle between a first state and a second state; the first state is a state in which the receptacle is secured to the mobile cart and moved within the warehouse when the receptacle is carrying at least one product of a product order and when the receptacle is empty of any product; The second state is a state in which the receptacle is removed from the mobile cart, AMR.

43. 43. The AMR of claim 42, wherein in the second state, the receptacle is received on the mobile cart.

44. A product rack for storing products, a plurality of storage levels for storing the products thereon, the storage levels being spaced apart from one another and vertically disposed within the product rack; a plurality of elevation platforms configured for movement of an autonomous mobile robot (AMR), each of the plurality of elevation platforms positioned proximate a respective one of the plurality of storage levels; a product rack having an elevator system including a lifting platform for lifting the AMR between ground level and a plurality of lifting platforms; a product picking robot for picking a product from one of the plurality of storage levels and unloading the product onto a receptacle held by the AMR of a corresponding one of the plurality of storage levels; A product unloading system comprising:

45. 45. The system of claim 44, wherein the product picking robot has an end of arm tool (EOAT) for engaging the product being picked.

46. 46. ​​The system of claim 44 or 45, wherein the product picking robot has a sensor to detect the product for picking.

47. 47. The system of claim 46, wherein the sensor is a camera.

48. 48. The system of any one of claims 45 to 47, further comprising a pallet positioned on one of the plurality of storage levels, the pallet including a plurality of containers, each of the containers including an item having dimensions known to the product picking robot, and wherein engaging the product during picking includes engaging the item.

49. 49. The system of claim 48, wherein the plurality of containers are reusable containers.

50. 1. A processor, comprising: Generate carton forming instructions; Generate product pick-up instructions; Generate Autonomous Mobile Robot (AMR) instructions a processor operable to:

1. A carton forming system comprising: receiving the carton formation instructions from the processor; selecting a carton blank from a magazine in accordance with said carton forming instructions; forming the carton blank into an upright carton; a carton forming system configured as follows: A product pick-up robot, receiving the product removal instruction from the processor; Following the product removal command, remove the product from the product rack in the product storage area. A product take-out robot configured as above, AMR, receiving the AMR instruction from the processor; moving to the carton forming system in accordance with the AMR command and receiving the erected carton from the carton forming system; In accordance with the AMR command, move to the product rack while holding the upright carton; A product rack receives the product from the product pick-up robot into the upright carton; moving the stand-up carton with the product therein to a location for further processing in accordance with the AMR command; AMR configured as follows: A fulfillment system comprising:

51. 51. The system of claim 50, wherein the carton formation instructions are generated by the processor based on a customer order received by the processor, the product removal instructions are generated by the processor based on the customer order received by the processor, and the AMR instructions are generated by the processor based on the customer order received by the processor.

52. The product rack comprises: a plurality of storage levels for storing products thereon, the storage levels being spaced apart from one another and vertically disposed within the product rack; a plurality of elevation platforms upon which the AMR is configured to travel, each of the plurality of elevation platforms being positioned proximate a respective one of the plurality of storage levels; 52. The system of claim 50 or 51, comprising:

53. and an elevator system configured to receive from the processor lift commands for lifting the AMR between ground level and one of a plurality of lift platforms, the AMR comprising: the product rack is transported by the elevator system to one of the plurality of elevated platforms; moving along one of the plurality of elevated platforms in accordance with the AMR command; receiving the product from the product pick-up robot into the upright carton; 53. The system of claim 52, configured to:

54. a pallet disposed in one of the plurality of storage levels, the pallet including a plurality of reusable containers, each of the plurality of reusable containers including a plurality of products; In response to the AMR receiving a last product of the plurality of products in any one of the reusable containers, the empty AMR: receiving from the processor an empty AMR instruction generated by the processor; Move to the product rack according to the empty AMR command; receiving the reusable container from the product pick robot at the product rack; and moving the reusable container to a location for further processing while retaining the container in accordance with the empty AMR order.

54. The system according to claim 52 or 53, configured so as to

55. 55. The system of claim 54, wherein further processing of the reusable container includes unloading the reusable container onto an additional pallet.

56. 1. A processor, comprising: Generate a receptacle delivery instruction; Generate autonomous mobile robot (AMR) instructions; a processor operable to:

1. A carton delivery system comprising: receiving the receptacle delivery instruction from the processor; selecting selected receptacles for delivery from a selection of receptacles in accordance with said receptacle delivery instructions; a carton delivery system configured as follows: AMR, receiving the AMR instruction from the processor; moving to a receptacle delivery system in accordance with the AMR command and receiving a selected receptacle from the receptacle delivery system; In accordance with an AMR command, while holding the selected receptacle, move to a station within a product guidance area; receiving the product into the selected receptacle at the station; moving the selected receptacle with the product therein to a location for further processing in accordance with the AMR command; An AMR configured as follows: A fulfillment system comprising:

57. The receptacle delivery system includes a carton forming system, the carton forming system comprising: receiving receptacle delivery instructions from the processor, the receptacle delivery instructions including carton formation instructions; selecting carton blanks from a plurality of magazines in accordance with said carton forming instructions, thereby establishing the selected carton blanks; forming the selected carton blanks into stand-up cartons; 57. The fulfillment system of claim 56, configured to:

58. 58. The fulfillment system of claim 56 or 57, wherein the stations in the product guidance area include a robotic product loading station, and the AMR is configured to receive product from a product pick robot into a selected receptacle.

59. 58. The fulfillment system of claim 56 or 57, wherein the stations within the product guidance area include a manual product loading station, and the AMR is configured to receive the product from a manual product picker into the selected receptacle.

60. 1. A processor, comprising: Generate a shipping container selection instruction; Generate autonomous mobile robot (AMR) instructions; a processor operable to:

1. A shipping container delivery system comprising: receiving the shipping container selection instruction from the processor; selecting a selected shipping container from the plurality of shipping containers in accordance with the shipping container selection instructions; a shipping container delivery system configured as follows: AMR, receiving the AMR instruction from the processor; traveling to the shipping container delivery system in accordance with the AMR command and receiving the selected shipping container from the shipping container delivery system; moving, in accordance with instructions from the AMR, while holding the selected shipping container, to a station within a product guidance area, the product guidance area including a product tower, the product tower including a plurality of compartments for storing products, at least one of the plurality of compartments containing one or more products, the one or more products corresponding to at least one stockkeeping unit; receiving a first product into the selected shipping container at the station; In accordance with the AMR command, moving the selected shipping container to a predetermined product storage rack within a storage area, the storage area including a plurality of product storage racks for storing products on pallets; receiving a second product into the selected shipping container at the predetermined product storage rack; moving the selected shipping container with the first product and the second product therein to a location for further processing in accordance with the AMR command; An AMR configured as follows: A fulfillment system comprising:

61. 61. The fulfillment system of claim 60, wherein the shipping container selection instructions are generated by the processor based on a customer order received by the processor, and the AMR instructions are generated by the processor based on the customer order received by the processor.

62. 62. The fulfillment system of claim 60 or 61, further comprising a sealing device operable to seal an open flap of the selected shipping container.

63. 63. The fulfillment system of claim 62, wherein the sealing device seals the open flap of the selected shipping container while the AMR moves through the sealing device.

64. 64. The implementation system of claim 63, wherein the AMR further comprises a drive mechanism operable to drive movement of the AMR, the AMR being driven through the sealing device by the drive mechanism.

65. 65. The fulfillment system of claim 64, further comprising first and second laterally spaced, longitudinally extending guide belts operable to guide the selected shipping container during longitudinal movement of the AMR through the sealing device with the selected shipping container thereon.

66. 61. The fulfillment system of claim 60, wherein the processor is further operable to generate instructions for a tower relocation AMR to relocate the product tower to the station within the product guidance area.

67. The processor instructs a product picking robot associated with a given product storage rack to: picking the second product; 61. The fulfillment system of claim 60, further operable to generate instructions to place the second product within the selected shipping container.

68. 61. The fulfillment system of claim 60, wherein the AMR is further configured to move, in accordance with instructions from the AMR, while holding the selected shipping container to a location within a second product guiding area, the second product guiding area including a crate holding structure, the crate holding structure holding a plurality of crates for storing products, at least one of the plurality of crates containing one or more products, the one or more products corresponding to a single stockkeeping unit.

69. 69. The fulfillment system of claim 68, wherein the AMR is a shipping container AMR, the system further comprises a crate-holding AMR, and the processor is further operable to generate a crate-holding AMR instruction, the crate-holding AMR instruction instructing the crate-holding AMR to transport the crate-holding structure to the second product guidance area to meet the shipping container AMR.

70. 61. The fulfillment system of claim 60, wherein the storage area comprises a plurality of zones.

71. 71. The fulfillment system of claim 70, wherein the plurality of zones includes a zone in which the product is maintained at a sub-freezing temperature.

72. 71. The fulfillment system of claim 70, wherein the plurality of zones includes a zone in which the product is maintained at ambient temperature.

73. 71. The fulfillment system of claim 70, wherein the plurality of zones includes a zone in which the product is maintained at a temperature above freezing and below ambient temperature.

74. 61. The fulfillment system of claim 60, wherein said product tower stores product representing approximately 50 stockkeeping units.

75. 75. The fulfillment system of claim 74, further comprising a tower storage area configured to store a plurality of product towers.

76. 76. The fulfillment system of claim 75, wherein said tower storage area stores products representing greater than 500,000 stockkeeping units.

77. 61. The fulfillment system of claim 60, wherein each pallet in said storage area stores products representing a single stockkeeping unit.

78. 78. The fulfillment system of claim 77, wherein the storage area stores products representing less than 10,000 stockkeeping units.

79. 79. The fulfillment system of claim 78, wherein the products stored in the storage area include grocery items.

80. 1. A processor, comprising: Generate carton forming instructions; Generate product pick-up instructions; Generate autonomous mobile robot (AMR) instructions; a processor operable to:

1. A carton forming system comprising: receiving the carton formation instructions from the processor; selecting a carton blank from a plurality of available carton blanks in accordance with said carton formation instructions; forming the carton blank into a stand-up carton; a carton forming system configured as follows: A product pick-up robot, receiving a product removal command from the processor; Following the product removal command, remove the product from the product storage area. A product take-out robot configured as above, a reusable container containing a plurality of products to be used to fulfill a plurality of orders, the reusable container becoming an empty reusable container once the plurality of products have been removed from the reusable container to fulfill the plurality of orders; AMR, receiving the AMR instruction from the processor; moving to the carton forming system in accordance with the AMR command and receiving the erected carton from the carton forming system; moving the upstanding cartons, while retaining the product therein, to a location for further processing in accordance with the AMR instructions, the further processing of the upstanding cartons including removing the upstanding cartons from the AMR; thereafter, removing and removing the empty reusable container in accordance with the AMR command; and moving the empty reusable container to a location for further processing while retaining the empty reusable container in accordance with the AMR command. AMR configured as follows. A fulfillment system comprising:

81. 81. The system of claim 80, wherein the plurality of available carton blanks is stored in a plurality of magazines.

82. 81. The system of claim 80, wherein the carton formation instructions are generated by the processor based on a customer order received by the processor, the product removal instructions are generated by the processor based on the customer order received by the processor, and the AMR instructions are generated by the processor based in part on the customer order received by the processor.

83. 81. The system of claim 80, wherein the product loading station comprises a robotic product loading station, and the AMR is configured to receive the product from the product pick robot into the stand-up carton.

84. 81. The system of claim 80, wherein the product loading station comprises a manual product loading station, and the AMR is configured to receive the product from a manual product picker into the stand-up carton.

85. 1. A processor, comprising: Generate shipping container delivery instructions; Generate product pick-up instructions; Generate autonomous mobile robot (AMR) instructions; a processor operable to:

1. A shipping container delivery system comprising: receiving the shipping container delivery instructions from the processor; selecting a shipping container from a plurality of available shipping containers in accordance with said shipping container delivery instructions; a shipping container delivery system configured as follows: A product pick-up robot, receiving the product removal instruction from the processor; retrieving the product within the product storage location in accordance with said product retrieval command; A product take-out robot configured as above, a reusable container containing a plurality of products to be used to fulfill a plurality of orders, the reusable container becoming an empty reusable container once the plurality of products have been removed from the reusable container to fulfill the plurality of orders; AMR, receiving the AMR instruction from the processor; traveling to the shipping container delivery system and receiving the shipping container in accordance with the AMR order; moving to the product loading station while holding the shipping container in accordance with the AMR command; receiving the product into the shipping container at the product loading station; In accordance with the AMR command, moving the shipping container with the product therein to a location for further processing, the further processing of the shipping container including removing the shipping container from the AMR; Thereafter, in accordance with the instructions of the AMR, the vehicle moves on the AMR and receives an empty reusable container; and moving the empty reusable container to a location for further processing while retaining the empty reusable container in accordance with the AMR command. AMR configured as follows: A fulfillment system comprising:

86. 86. The system of claim 85, wherein the product loading station comprises a robotic product loading station, and the AMR is configured to receive the product into the shipping container from the product removal robot.

87. 86. The system of claim 85, wherein the product loading station comprises a manual product loading station, and the AMR is configured to receive the product into the shipping container from a manual product removal operator.

88. 86. The system of claim 85, wherein the shipping container delivery instructions are generated by the processor based on a customer order received by the processor, the product retrieval instructions are generated by the processor based on the customer order received by the processor, and the AMR instructions are generated by the processor based in part on the customer order received by the processor.

89. 1. A method of receiving products into a fulfillment center, comprising: sending a command to a first autonomous mobile robot (AMR), the command causing the first AMR to: Navigating to a crate holding structure within the first transport trailer, the crate holding structure holding a crate containing a plurality of products; transporting the crate support structure to a product guide area where individual products of the plurality of products are removed from the crates; And, sending an instruction to a second AMR, the instruction causing the second AMR to: navigating the crate that no longer stores the product to the crate holding structure within the product guidance area; transporting the crate support structure to a second transport trailer; and navigating away from the second transport trailer without the crate retention structure. And, A method for providing

90. 90. The method of claim 89, wherein the origin of the first transport trailer includes a supplier of the product.

91. 91. The method of claim 90, wherein the destination of the second transport trailer comprises a supplier of the product.

92. 91. The method of claim 90, wherein the destination of the second transport trailer comprises a supplier of another product.

93. 90. The method of claim 89, further comprising configuring the first transport trailer to facilitate navigation within the first transport trailer by the first AMR.

94. 94. The method of claim 93, wherein configuring the first transport trailer includes using a configuration that matches a configuration of the fulfillment center that facilitates navigation within the fulfillment center by the first AMR.

95. 1. An autonomous mobile robot for transporting shipping containers, comprising: A mobile cart and a control system for controlling the operation of the autonomous mobile robot; an outer case mounted on the cart, a vacuum reservoir defining a plurality of apertures; a vacuum pump pneumatically coupled to the vacuum reservoir, the vacuum pump configured to create a negative pressure within the vacuum reservoir in response to commands received from the control system; a plurality of suction cups mounted on the outer case, the suction cups corresponding to the plurality of apertures; an outer case having An autonomous mobile robot comprising:

96. 96. The autonomous mobile robot of claim 95, wherein each suction cup of the plurality of suction cups is fluidly coupled to a valve to provide a plurality of valve and suction cup combinations, each valve having a corresponding suction cup.

97. 97. The autonomous mobile robot of claim 96, wherein each valve is configured to open in response to detecting that a corresponding suction cup is covered by at least a portion of the shipping container.

98. 97. The autonomous mobile robot of claim 96, further comprising a side plate sandwiched between each combination of the plurality of combinations and the vacuum reservoir, the side plate having a plurality of openings corresponding to the plurality of apertures in the vacuum reservoir and the combinations.

99. 96. The autonomous mobile robot of claim 95, further comprising a side plate sandwiched between each of the plurality of suction cups and the vacuum reservoir, the side plate having a plurality of openings corresponding to a plurality of apertures in the vacuum reservoir and the plurality of suction cups.

100. 96. The autonomous mobile robot of claim 95, further comprising a side plate sandwiched between said outer case and said vacuum reservoir, said side plate having a plurality of openings corresponding to said plurality of apertures in said vacuum reservoir.

101. an electric actuator responsive to receiving activation from the control system to move the side plate between a first position and a second position; the first position is where the opening in the side plate is aligned with the opening in the vacuum reservoir; the second position is where the opening in the side plate is not aligned with the aperture in the vacuum reservoir; 101. An autonomous mobile robot according to any one of claims 98 to 100.

102. 101. The autonomous mobile robot of any one of claims 95 to 100, wherein the mobile cart has drive wheels.

103. 103. The autonomous mobile robot of claim 102, wherein the control system is configured to control the drive wheels to steer the autonomous mobile robot to a station within a fulfillment center.

104. 104. An autonomous mobile robot as described in any one of claims 95 to 103, wherein at least some of the plurality of suction cups are oriented generally vertically upward.

105. 1. An outer case for mounting on a mobile cart of an autonomous mobile robot (AMR) for transporting shipping containers, the AMR including a control system for controlling operation of the AMR, the outer case comprising: a vacuum reservoir defining a plurality of apertures; a vacuum pump pneumatically coupled to the vacuum reservoir, the vacuum pump responsive to commands received from the control system to create a negative pressure within the vacuum reservoir; a plurality of suction cups mounted on the outer case, the suction cups corresponding to the plurality of apertures; Equipped with an outer case.

106. 106. The outer case of claim 105, wherein each suction cup of the plurality of suction cups is fluidly coupled to a valve to provide a plurality of valve and suction cup combinations, each valve having a corresponding suction cup.

107. 107. The outer case of claim 106, wherein each valve is configured to open in response to detecting that the corresponding suction cup is covered by at least a portion of the shipping container.

108. 107. The outer case of claim 106, further comprising a side plate sandwiched between each combination of the plurality of combinations and the vacuum reservoir, the side plate having a plurality of openings corresponding to the plurality of apertures in the vacuum reservoir and the plurality of combinations.

109. 106. The outer case of claim 105, further comprising a side plate sandwiched between each of the plurality of suction cups and the vacuum reservoir, the side plate having a plurality of openings corresponding to the plurality of apertures in the vacuum reservoir and the plurality of suction cups.

110. 106. The outer case of claim 105, further comprising a side plate sandwiched between the outer case and the vacuum reservoir, the side plate having a plurality of openings corresponding to the plurality of apertures in the vacuum reservoir.

111. an electric actuator responsive to receiving activation from the control system to move the side plate between a first position and a second position; the first position is a position where the opening in the side plate is aligned with the opening in the vacuum reservoir; the second position is a position where the opening in the side plate is not aligned with the aperture in the vacuum reservoir.

111. An outer case according to any one of claims 108 to 110.

112. 112. The outer case of any one of claims 105 to 111, wherein at least some of the suction cups face in a generally vertically upward direction.

113. 1. An autonomous mobile robot for transporting shipping containers, comprising: Bass and at least three wheels configured to support the base, at least one of the wheels being a drive wheel, the drive wheel being operatively coupled to a drive motor; a control system for controlling operation of the drive motor, which corresponds to movement of the base and controls movement of the drive wheel; a vacuum reservoir interconnected to the base, the vacuum reservoir defining a plurality of openings; a vacuum pump pneumatically coupled to the vacuum reservoir, the vacuum pump responsive to commands received from the control system to create a negative pressure within the vacuum reservoir; a plurality of suction cups corresponding to the plurality of openings and interconnected to the base; An autonomous mobile robot comprising:

114. 1. A method of fulfilling an order, comprising: moving an autonomous mobile robot according to any one of claims 95 to 104 to a shipping container loading station; receiving an empty shipping container on the autonomous mobile robot; generating a suction force with each suction cup of at least some of the plurality of suction cups to hold the empty shipping container on the autonomous mobile robot; moving the autonomous mobile robot to an item loading station while the suction force is being generated by each suction cup of at least some of the plurality of suction cups to hold the shipping container on the autonomous mobile robot; A method for providing

115. 115. The method of claim 114, further comprising receiving one or more items at the item loading station in the empty shipping container.

116. 116. The method of claim 115, further comprising moving the autonomous mobile robot to a closing station while the suction force is being generated by each suction cup of at least some of the plurality of suction cups to hold the shipping container on the autonomous mobile robot.

117. 117. The method of claim 116, further comprising closing the shipping container with the one or more items held within the shipping container at the closing station.

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