A warehouse system for storing and retrieving goods from containers.

Abstract

An autonomous transport vehicle for transporting merchandise units for filling shipping totes or containers, the autonomous transport vehicle comprising: a frame configured to move as a unit over at least one of transport decks and ramps; a controller connected to the frame and configured to cause the movement of the autonomous transport vehicle over at least one of the transport decks and ramps so that the autonomous transport vehicle moves freely via autonomous navigation from a first position to a different second position, the first position being a supply position for merchandise units and the second position being a tote filling position based on an order; and a payload connected to the frame for holding merchandise units loaded onto the autonomous transport vehicle, the payload having an end effector positioned to extend and unload merchandise units from the payload.

Description

Technical Field

[0001] [Cross - Reference to Related Applications] This application is a non - provisional application of U.S. Provisional Patent Application No. 63 / 452,735, filed on March 17, 2023, the entire disclosure of which is incorporated herein by reference and for which priority is claimed.

[0002] [Technical Field] The disclosed embodiments generally relate to material handling systems, and more specifically, to the conveyance and storage of articles within a material handling system.

Background Art

[0003] Brief Description of Related Developments It is well - recognized that the integration of automated storage and retrieval systems into the logistics chain, particularly goods - to - man systems, is highly advantageous across the efficiency and cost of the logistics chain. Conventional systems generally operate by storing product (e.g., supply) containers, where a supply container contains cases, packs, etc. that include common types of merchandise (also called products). The product containers can arrive on a pallet (e.g., a common supply container) or as truck cargo, are depalletized or unloaded from the truck, stored in a logistics facility, and distributed throughout the storage volume of the logistics facility (e.g., in a three - dimensional array of storage racks) by an automated storage and retrieval system.

[0004] In particular, when combined product containers are desired (for example, here, any given order container may have combined / different products or product types held in a common container in cases such as direct to consumer fulfillment, or in cases of indirect fulfillment to consumers via a retail order collection point, the combination of ordered products in the order container is generated at least partially at the logistics facility before being shipped out of the logistics facility), order fulfillment from the logistics facility, conventionally, the creation of combined product containers is done by goods-to-person (goods to) automated storage and retrieval systems. Using a person-to-person configuration, the automated storage and retrieval system is brought from the storage location of the entire three-dimensional array of storage racks to the workstation by unloading product / supply containers (each containing articles of one or more products of a common product type, i.e., the articles of each product in the product container are the same or substantially similar), and manually or automatically, according to a given performance (or filling) order, goods are picked and retrieved from the various product / supply containers supplied to the given workstation by the automated storage and retrieval system, and the various picked goods (combined or common if the given order is filled in that way) are placed into the order container. Such workstations may be called breakpack stations, where product containers are "unpacked" and their contents, in whole or in part, may be placed in order containers or in what are called breakpack storage containers (e.g., tote bags), for example, where the product containers are not suitable for continuously holding the remaining product items after the breakpack operation, and such remaining products (i.e., the remaining products in the "unpacked" product containers) should be returned to their storage location in a three-dimensional array of storage racks by an automated storage and retrieval system. Products placed in order containers are not ideally packaged in order containers because they are loosely placed into the containers by automation.For example, conventionally, products are placed in order containers by a conveyor belt / roller system or an inclined / dumping system, where, in such transfers, products tend to be placed in the area of ​​the order container closest to the belt / roller conveyor or inclined / dumping system, and the products are not evenly distributed within or throughout the order container.

[0005] It is desirable to have a system that distributes products approximately equally within the order container. It is also desirable to be able to verify the distribution of products within the order container. [Overview of the Initiative]

[0006] The aforementioned aspects and other features of the disclosed embodiments are described in the following description made in relation to the accompanying drawings. [Brief explanation of the drawing]

[0007] [Figure 1] This is a schematic diagram of an automated storage and retrieval system according to an embodiment of the disclosed model. [Figure 2A] Figure 1 is a schematic diagram of the product bot of the automated storage and retrieval system according to an embodiment of the disclosed embodiment. [Figure 2B] Figure 1 is a schematic diagram of the product bot of the automated storage and retrieval system according to an embodiment of the disclosed embodiment. [Figure 3A] Figures 2A and 2B are schematic "exploded" views of a portion of the product bot according to an embodiment of the disclosed model. [Figure 3B] Figures 2A and 2B are schematic plan views of the end effector drive system of the product bot according to an embodiment of the disclosed model. [Figure 4A] Figures 2A and 2B are illustrative schematic diagrams of the payload portion and end effector of the product bot according to an embodiment of the disclosed features. [Figure 4B] Figures 2A and 2B are illustrative schematic diagrams of the payload portion and end effector of the product bot according to an embodiment of the disclosed features. [Figure 5A] Figures 2A and 2B are illustrative schematic diagrams of the payload portion and end effector of the product bot according to an embodiment of the disclosed features. [Figure 5B] Figures 2A and 2B are illustrative schematic diagrams of the payload portion and end effector of the product bot according to an embodiment of the disclosed features. [Figure 5C] Figures 2A and 2B are illustrative schematic diagrams of the payload portion and end effector of the product bot according to an embodiment of the disclosed features. [Figure 6A] Figures 2A and 2B are illustrative schematic diagrams of the payload portion and end effector of the product bot according to an embodiment of the disclosed features. [Figure 6B] Figures 2A and 2B are illustrative schematic diagrams of the payload portion and end effector of the product bot according to an embodiment of the disclosed features. [Figure 7A] This is an exemplary perspective view of part of the automated storage and retrieval system of Figure 1 according to an embodiment of the disclosed features. [Figure 7B] This is an exemplary perspective view of part of the automated storage and retrieval system of Figure 1 according to an embodiment of the disclosed features. [Figure 8] These are illustrative schematic diagrams of parts of the product bot shown in Figures 2A and 2B according to an embodiment of the disclosed features. [Figure 9A] This is an illustrative schematic diagram of the product bot shown in Figure 8, interfaced with a product container according to an embodiment of the disclosed embodiment. [Figure 9B] This is an illustrative schematic diagram of the product bot shown in Figure 8, interfaced with a product container according to an embodiment of the disclosed embodiment. [Figure 10A] This is an illustrative schematic diagram of the product bot shown in Figure 8 according to an embodiment of the disclosed features. [Figure 10B] This is an illustrative schematic diagram of the product bot shown in Figure 8 according to an embodiment of the disclosed features. [Figure 11A]An exemplary image generated using sensor data of the product bottles of FIGS. 2A and 2B according to aspects of the disclosed embodiments. [Figure 11B] An exemplary image generated using sensor data of the product bottles of FIGS. 2A and 2B according to aspects of the disclosed embodiments. [Figure 12A] A schematic diagram of product transfer brought about by the product bottles of FIGS. 4A - 4B according to aspects of the disclosed embodiments. [Figure 12B] A schematic diagram of product transfer brought about by the product bottles of FIGS. 6A - 6B according to aspects of the disclosed embodiments. [Figure 12C] A schematic diagram of product transfer brought about by the product bottles of FIGS. 6A - 6B according to aspects of the disclosed embodiments. [Figure 12D] A schematic diagram of product transfer brought about by the product bottles of FIGS. 6A - 6B according to aspects of the disclosed embodiments. [Figure 13] A schematic diagram of product transfer brought about by the product bottles of FIGS. 5A - 5C according to aspects of the disclosed embodiments. [Figure 14] An exemplary diagram of a product bottle passing through a product deck according to aspects of the disclosed embodiments. [Figure 15] An exemplary diagram of a product bottle passing through a product deck according to aspects of the disclosed embodiments. [Figure 16] An exemplary flowchart of a method according to aspects of the disclosed embodiments. [Figure 17] An exemplary flowchart of a method according to aspects of the disclosed embodiments. [Figure 18] An exemplary flowchart of a method according to aspects of the disclosed embodiments. [Figure 19] An exemplary flowchart of a method according to aspects of the disclosed embodiments. [Figure 20] An exemplary flowchart of a method according to aspects of the disclosed embodiments.

DETAILED DESCRIPTION OF THE INVENTION

[0008] Figure 1 is a schematic diagram of an automated storage and retrieval system (also referred to herein as a warehouse system or product order fulfillment system) 100 according to an aspect of the disclosed embodiment. While aspects of the disclosed embodiment will be described with reference to the drawings, it should be understood that aspects of the disclosed embodiment can be embodied in many forms. Furthermore, elements or materials of any suitable size, shape, or type may be used.

[0009] In some aspects of the disclosed embodiments, the automated storage and retrieval system 100 may operate within a retail distribution center or warehouse to fulfill orders received from retailers for case units, such as those described in U.S. Patent No. 10,822,168, issued November 3, 2020, the entire disclosure of which is incorporated herein by reference. For example, a case unit is a case or unit of goods that is not stored (e.g., not included) on a tray, on a tote, or on a pallet. In other examples, a case unit is a case or unit of goods that is included in any suitable way on a tray, on a tote, in a container (such as a container for leftover goods after break-packing where the broken-down case unit structure is not suitable for transporting leftover goods as a unit), on a pallet, etc. In yet another example, a case unit is a combination of included and not included items. It should be noted that a case unit may include, for example, a unit of goods in a case (e.g., a case of soup cans, a box of cereal, etc.) or individual goods that are adapted to be retrieved from or placed on a pallet. According to aspects of the disclosed embodiments, a transport case for a case unit (e.g., a carton, barrel, box, crate, jug, or any other suitable device for holding a case unit) may have a variable size, be used to hold a case unit during transport, and be configured to be palletized for transport. For example, when a bundle or pallet of case units arrives at a storage and retrieval system, the contents of each pallet may be uniform (e.g., each pallet holds a predetermined number of the same items; i.e., one pallet holds soup and another holds cereal), and when the pallet leaves the storage and retrieval system, the pallet may contain any suitable number and combination of various case units (e.g., a mixed pallet where each mixed pallet holds different types of case units; i.e., a pallet holds a combination of soup and cereal), and it should be noted that these are provided to a palletizer in a sorted arrangement for forming a mixed pallet, for example.In aspects of the disclosed embodiments, the storage and retrieval system 100 described herein may be applied to any environment in which the units are stored and retrieved.

[0010] According to aspects of the disclosed embodiments, orders for filled goods (e.g., pallets, cases, containers, product packages, individual (unpacked) goods, etc.) may be probabilistic (e.g., the goods to be ordered and the time at which the order is received may be substantially random) and may be fulfilled by the automated storage and retrieval system 100 in accordance with time (e.g., sorting of ordered goods at a predetermined scheduled time prior to the time when the order is shipped / fulfilled or sorting of goods just in time). These probabilistic orders determine the picking order of sorted goods, such as for building pallet loads or pallet PALs (see, for example, U.S. Patent No. 8,965,559, issued February 24, 2015, titled “Pallet Building System,” the entire disclosure of which is incorporated herein by reference). Pallet PALs may include mixed cases, mixed totes, mixed packs, mixed units (or individual units) per tote, etc., where sorted goods are picked from a common storage array (e.g., a storage array formed by storage spaces 130S of a storage structure 130).The automated storage and retrieval system 100 brings a given order from a common storage array, regardless of the order type (e.g., pallet order, case order, pack order, mixed order, etc.), order order order, and order time, by utilizing or otherwise processing the order to the required classification level via one or more orthogonal classification echelons (e.g., those described in U.S. Patent Application No. 17 / 358,383, filed June 25, 2021, “Warehousing System for Storing and Retrieving Goods in Containers”), thereby bringing the goods to the maximum throughput for each order (e.g., received for processing by the automated storage and retrieval system 100) (e.g., the controller 120 drills down / drives down the orthogonal classification echelons to bring the desired level of classification required for a given order, i.e., case-level classification, pack-level classification, unit / individual-level classification, or a combination thereof).

[0011] According to aspects of the disclosed embodiments, the automated storage and retrieval system 100 includes one or more breakpack modules 266. The breakpack modules 266 are configured to break down product containers or case units CU into breakpack product containers 264 (also referred to herein as product containers or totes for product shipment) for order fulfillment. Here, the products are loaded into the breakpack product containers 264 by automation (such as a product bot 262 as described herein) so that they can be loosely placed. As described herein, the product bot 262 includes a payload (also referred to herein as a payload bay or tray) 310 for holding (one or more) product units (also referred to herein as (one or more) breakpack products) BPG loaded onto the product bot (also referred to herein as an autonomous transport vehicle) 262, wherein the payload bay 310 has an end effector 262E which extends and is positioned to unload the breakpack products BPG from the payload bay 310. The end effector 262E forms a fill placement regulator 262FPR (see, for example, Figures 2A and 2B), which adjusts the placement of break pack goods BPGs unloaded when filling totes or goods containers 264 so that each goods container 264 is repeatedly filled by tote filling to a predetermined fill level 1222 (see Figures 12A-12D and 13) at each goods container filling position (see, for example, Figure 7A). The predetermined fill level 1222 may be approximately 80% filled, or any other appropriate amount which may be more or less than 80% filled. The end effector 262E may distribute the goods substantially evenly within the break pack goods containers 264.

[0012] In some embodiments, the automated storage and retrieval system 100 may include (in addition to or instead of) one or more picking modules substantially similar to those described in U.S. Patent No. 9,037,286 issued on May 19, 2015 (the entire disclosure is incorporated herein by reference), wherein the breakpack goods containers 264 are filled by a human or robotic operator and unloaded for transport by a container bot 110 for storage placement or for transfer to an output station 160UT.

[0013] To make it clear, the controller 120 of the automated storage and retrieval system 100 is configured to bring about the operation of container bots 110 and product bots 262 for assembling orders of breakpack goods BPG from supply containers 265 (e.g., case unit CU) to breakpack goods containers 264, and the unloading of breakpack goods containers 264 via container unloading station TS. For example, the controller 120 is configured to bring about the operation of (one or more) container bots 110 between container storage position 130S, breakpack operation station 140 (of breakpack module 266), and breakpack goods transport deck 130DG (see also Figures 7A and 7B). As another example, the controller 120 is configured to cause the operation of (one or more) product bots 262 to sort the breakpack product BPGs into corresponding breakpack product containers 264 (see also Figure 7A) (for example, by transporting the breakpack product BPGs by the product bots 262 traveling on the product transport deck 130DG, for example, by unit / individual level classification. As yet another example, the controller 120 is configured to cause the operation of (one or more) container bots 110 (for example, traveling along the container transport deck 130DC) to transport the breakpack product containers 264 on the product transport deck 130DG to at least one of the corresponding container storage positions 130SB in the storage space 130S at the corresponding level 130L of the container unloading / transportation station TS and the multi-level storage array (i.e., storage structure 130) by traveling along the container transport deck 130DC.

[0014] For example, it should be noted that when incoming bundles or pallets (also called pallet loads) IPALs (e.g., from a manufacturer or supplier of case units) arrive at the automated storage and retrieval system 100 for replenishment, the contents of each pallet IPAL may be uniform (e.g., each pallet holds a predetermined number of the same items, i.e., one pallet holds soup and another pallet holds cereal). As can be understood, the cases in such pallet IPALs may be substantially similar, or in other words, homogeneous cases (e.g., similar dimensions) and may have the same SKUs (otherwise, as mentioned above, the pallet may be a “rainbow” pallet with layers formed of homogeneous cases). When the pallet PAL leaves the storage and retrieval system 100, with the cases fulfilling customer replenishment orders, the pallet PAL may contain any appropriate number and combination of various case units CU (e.g., each pallet may hold different types of case units, i.e., the pallet holds combinations of canned soup, cereal, beverage packs, cosmetics, and household detergents). Cases assembled on a single pallet may have various dimensions and / or various SKUs. In one aspect of the disclosed embodiment, the storage and retrieval system 100 may generally be configured to include an incoming section, a storage and sorting section (wherein one aspect, storage of goods is optional), and an outgoing section. As can be understood, in one aspect of the disclosed embodiment, for example, operating as a retail distribution center, the storage and retrieval system 100 may be responsible for receiving a uniform pallet load of cases (IPAL), unpacking the pallet goods, or separating the cases from the uniform pallet load (e.g., at an incoming station 160IN) into independent case units CU that are handled individually by the system 100, taking out the various case CUs required by each order, sorting them into corresponding groups, and transporting the corresponding groups of cases (e.g., at an outgoing station 160UT) to assemble into what is called a mixed case pallet load (see pallet load PAL above).As can also be understood, in one aspect of the disclosed embodiments, System 100, operating as, for example, a retail distribution center, may play a role in receiving a uniform pallet load of cases (IPAL), unpacking the pallet goods, or (for example, at receiving station 160IN) separating the cases from the uniform pallet load into independent case units CU that are handled individually by the system, taking out the various cases required by each order, sorting them into corresponding groups, and transporting and ordering the corresponding groups of cases in the manner described in U.S. Patent No. 9,856,083 issued January 2, 2018, the entire disclosure of which is incorporated herein by reference.

[0015] The storage and sorting section includes a multilevel automated storage system having an automated transport system that sequentially receives individual case units CUs and supplies them to a multilevel storage array for storage in a storage area (such as storage space 130S of storage structure 130), as will be described in more detail below. The storage and sorting section also defines the outbound transport of case units from the multilevel storage array so that desired case units are individually retrieved according to commands generated according to orders entered into a warehouse management system, such as a warehouse management system 2500, for transport to the outbound section. In other embodiments, the storage and sorting section receives individual cases, sorts the individual cases (for example, utilizing buffer stations and interface stations as described herein), sorts them, for example, by case-level classification, and transports the individual cases to the outbound section according to orders entered into the warehouse management system. The sorting and grouping of cases according to orders (e.g., order-out sequences) may be carried out entirely or partially by either the storage and retrieval section or the outbound section, or both, the boundaries being for illustrative purposes only, and the sorting and grouping may be carried out in any number of ways. The intended result is that the loading section assembles appropriate groups of ordered cases, which may differ in SKU, dimensions, etc., into mixed case pallet loads in the manner described, for example, in U.S. Patent No. 8,965,559, issued February 24, 2015, entitled “Pallet Building System,” which is incorporated herein by reference in its entirety.

[0016] In the disclosed embodiments, the unloading section generates a pallet load with what may be called a structured architecture of mixed case stacks. The structured architecture of the pallet load described herein is representative, and in other embodiments, the pallet load may have any other suitable configuration. For example, the structured architecture may be any suitable predetermined configuration such as a truck bay load or other suitable container or load container envelope that holds structural loads. The structured architecture of the pallet load may be characterized by having several flat case layers, as described in U.S. Patent No. 9,856,083, the entire disclosure of which is incorporated herein by reference.

[0017] According to aspects of the disclosed embodiments, still referring to Figure 1, the automated storage and retrieval system 100 includes a storage array (e.g., a storage structure 130 having storage space 130S) having at least one elevated storage level 130L (where more than one elevated storage level forms a storage rack of stacked storage levels). Mixed product units are brought into the storage array in case CUs of product units of a common type for each case CU and distributed (each case brought into the system 100 holds a stock keeping unit (SKU) of a common type). For example, the automated storage and retrieval system 100 includes a receiving station 160IN (including a depalletizer 160PA and / or conveyor 160CA for transporting articles (e.g., receiving supply containers) to a lift module (or lift) 150A for placing them into storage level 130L of the storage structure 130).

[0018] As described herein, the automated storage and retrieval system 100 includes an automated transport system (e.g., bots, breakpack stations, and other suitable level transport devices described herein) with at least one asynchronous transport system for transporting cases / products at a given storage structure level 130L (e.g., level transport). The storage and retrieval system 100 includes non-deterministic container bots 110 that travel along one or more physical paths of the storage and retrieval system (e.g., one or more of the picking passage 130A and the container transport deck 130DC) to provide at least one level of asynchronous transport. The container bots 110 may be any suitable independently operating autonomous transport vehicles that transport and transfer case units along the X and Y throughput axes throughout the storage and retrieval system 100. In one embodiment, the container bots 110 are automated, independent (e.g., free-riding) autonomous transport vehicles. Appropriate examples of bots are, for illustrative purposes only, U.S. Patent No. 10,822,168 issued on 3 November 2020, U.S. Patent No. 8,425,173 issued on 23 April 2013, U.S. Patent No. 9,561,905 issued on 7 February 2017, U.S. Patent No. 8,965,619 issued on 24 February 2015, and U.S. Patent No. 8, issued on 15 April 2014, which are included herein by reference in their entirety. This can be seen in U.S. Patent No. 696,010, U.S. Patent No. 9,187,244 issued on November 17, 2015, U.S. Patent No. 11,078,017 issued on August 3, 2021, U.S. Patent No. 9,499,338 issued on November 22, 2016, U.S. Patent No. 10,894,663 issued on January 19, 2021, and U.S. Patent No. 9,850,079 issued on December 26, 2017. The container bot 110 may be configured to place case units such as the above-mentioned retail goods into a picking stock at one or more levels of the storage structure 130, and then selectively retrieve the ordered case units.

[0019] For example, at least another level of asynchronous operation is provided (as described herein) such that the number of positions holding cases / products is greater than the number of bots transporting cases / products. At least one lift module (or lift) 150B is provided for transporting cases / products between storage levels 130L (e.g., between level transport devices). At least one lift 150B is connected to the storage array (e.g., formed by the storage spaces 130S of (one or more) storage levels 130L) so as to automatically retrieve and unload product units distributed to case CUs in a common area of ​​at least one elevated storage level 130L of the storage array (e.g., storage position 130S of each storage level 130L). Unloaded product units are one or more mixed and unified product units in mixed and packed groups and in mixed cases. As an example, the automated storage and retrieval system 100 includes unloading stations 160UT and 160EC (including a palletizer 160PB, operator station 160EP and / or conveyor 160CB) for transporting goods (e.g., outbound supply containers and filled breakpack goods (order) containers) from the lift module 150B for retrieval (e.g., to a palletizer (for palletizer loads) or to a truck (for truck loads). Here, unloading station 160EC is an individual fulfillment (or e-commerce) unloading station, where, for example, filled breakpack goods (order) containers containing single goods and / or small bundles of goods are transported to fulfill individual fulfillment orders (such as orders placed by consumers over the internet). Unloading station 160UT is generally a commercial unloading station where a large number of goods are provided on pallets to fulfill orders from commercial entities (e.g., a retail store, warehouse club, restaurant, etc.).As can be understood, the automated storage and retrieval system 100 includes both a commercial retrieval station 160UT and an individual performance retrieval station 160EC, while in other embodiments it includes one or more of the commercial retrieval station 160UT and the individual performance retrieval station 160EC.

[0020] The automated storage and retrieval system 100 also includes an inbound vertical lift module 150A and an outbound vertical lift module 150B (generally referred to as the lift module 150; although an inbound lift module and an outbound lift module are shown, it should be noted that a single lift module may be used to bring in and retrieve case units from the storage structure), a storage structure 130 (which may have at least one elevated storage level as described above and, in some embodiments, form a multi-level storage array), and at least one autonomous container transport vehicle 110 (referred to herein as a “container bot” or “autonomous guided vehicle” and forming at least part of an asynchronous transport system for level transport), which may be constrained to each of the storage levels of the storage structure 130 and are separate from the transport deck 130DC on which they move. It should be noted that the depalletizer 160PA may be configured to remove case units from pallets so that the inbound station 160IN can transport the articles to the lift module 150 for loading into the storage structure 130. The palletizer 160PB may be configured to place articles removed from the storage structure 130 onto a pallet PAL for transport. As used herein, the lift module 150, the storage structure 130, and the container bot 110 may together be referred herein to the above-described multi-level automated storage system (storage and sorting section), in which each throughput axis has essential "on-the-fly" sorting (e.g., sorting of case units while they are being transported) so that sorting and throughput of case units are performed substantially simultaneously without a dedicated sorting machine, such as the one described herein by U.S. Patent No. 9,856,083, which is entirely incorporated herein by reference.

[0021] Referring to Figures 1 and 7A, the storage structure 130 may include (one or more) container autonomous transport travel loops 233 positioned at each level of the storage structure 130 (e.g., formed on and along the container transport deck 130DC). The container bot 110 travels along the (one or more) container autonomous transport travel loops 233 to transport supply containers 265 to a breakpack module 266 and to retrieve breakpack goods containers 264 from the breakpack module 266, in a manner similar to that described in U.S. Patent Application No. 17 / 358,383 filed on 25 June 2021 (titled "Warehousing System for Storing and Retrieving Goods in Containers") and No. 17 / 657,705 filed on 1 April 2022 (titled "Warehousing System for Storing and Retrieving Goods in Containers"), the entire disclosure of which is incorporated herein by reference.

[0022] It should be noted that the lifts 150 are connected to the container transfer deck 130DC via transfer stations TS (also referred to herein as the container receiving station when the lift 150 is the receiving lift 150A or the container unloading station when the lift 150 is the outgoing lift 150B), and each lift is configured to lift one or both of the supply containers 265 (empty or filled) and the break-pack goods containers 264 (empty or filled) to and from at least one elevated storage level 130L of the storage structure 130. The container storage locations (or spaces) 130S are arranged circumferentially along the container transfer deck 130DC and / or picking passages 130A, as described in U.S. Patent No. 9,856,083, which is incorporated herein by reference in its entirety, and U.S. Patent No. 10,822,168, issued on November 3, 2020, which is also incorporated herein by reference in its entirety.

[0023] The container transfer deck 130DC is substantially open and configured for the non-deterministic passage of container bots 110 along multiple travel lanes across and along the container transfer deck 130DC. As described in U.S. Patent No. 10,556,743, issued on 11 February 2020 and U.S. Patent Application No. 15 / 671,591 (the entire disclosure is incorporated herein by reference), the multiple travel lanes may be configured to provide multiple access routes or paths to each storage location 130S (e.g., pick faces, case units, containers, or other articles stored on storage shelves) so that container bots 110 can reach each storage location using a secondary route, for example, if the primary route to the storage location is blocked. As can be understood, one or more container transfer decks 130DC at each storage level 130L communicate with each of the picking passages 130A at their respective storage levels 130L.

[0024] Still referring to Figure 1, each storage level 130L may also include a charging station 130C for charging the onboard power supply of the container bot 110 in that storage level 130L, such as those described in U.S. Patent Application No. 14 / 209,086 filed March 13, 2014 and U.S. Patent No. 9,082,112 issued July 14, 2015, the entire disclosure of which is incorporated herein by reference.

[0025] Referring again to Figures 1, 7A, and 7B, one or more break pack modules 266 may be located in (one or more) picking passages 130A or accessible from container transfer decks 130DC, as described in U.S. Patent Application No. 17 / 358,383 filed on 25 June 2021 (titled “Warehousing System for Storing and Retrieving Goods in Containers”) and No. 17 / 657,705 filed on 1 April 2022 (titled “Warehousing System for Storing and Retrieving Goods in Containers”), which have been previously disclosed in their entirety incorporated herein by reference.

[0026] Each of one or more breakpack modules 266 has a container bot loading surface 266RS that forms a portion 130DCP of the container transport deck 130DC, where the loading surface 266RS is substantially similar to a portion of the container transport deck 130DC (e.g., open and non-deterministic), but in other embodiments, the container bot loading surface 266RS may be substantially similar to a portion of the picking passage 130A (e.g., rail-guided). For simplicity of explanation, embodiments of the disclosed embodiments refer to the container bot loading surface 266RS in a breakpack module 266 as part of the container transport deck 130DC. It should be noted that in embodiments where the bot loading surface 266RS is formed by (or an extension of) a portion of the container transport deck 130DC, the transport loop of the breakpack module 266 may be a multi-lane transport loop.

[0027] Each Break Pack module 266 includes a Break Pack autonomous transport travel loop 234 (formed, for example, on and along the product deck or product transfer deck 130DG), at least one Break Pack operating station 140 (configured so that one or more Break Pack products BPGs are unpacked from (one or more) supply containers 265, manually or automatically, and loaded onto product bots 262 at the Break Pack operating station 140), and a Break Pack product interface 263 located between the product transfer deck 130DG and the container transfer deck 130DC, interface them together. As shown in Figure 7A, the container bot travel surface 266RS of the Break Pack module 266 forms a travel loop 233 around which the container bot 110 travels, along the travel loop 233 of the container bot travel surface 266RS, transporting supply containers (e.g., case units, pick faces, remaining containers, etc.) between storage position 130S and Break Pack operating station 140 (and / or vice versa), and Break Pack product containers (also called Break Pack product containers) 264 between Break Pack product interface 263 and Break Pack product container storage position 130SB or lift 150B (and / or vice versa). The travel loop 233 provides the container bot 110 with random access to any and each Break Pack product interface position 263L along the bot travel surface 266RS, where Break Pack product interface positions 263L form an asynchronous product distribution system.

[0028] The product transfer deck 130DG forms a product autonomous transport travel loop 234 located at storage level 130L. The product transfer deck 130DG is separate from the travel loop 233 formed by the container bot travel surface 266RS and has a breakpack product interface 263 that connects the respective edges of the container autonomous transport travel loop 233 of the container transfer deck 130DC and the breakpack product autonomous transport travel loop 234 of the product transfer deck 130DG. The autonomous product transport travel loops 234 formed by the product transport deck 130DG are located on the deck surface 130DGS of the deck (e.g., product transport deck 130DG) at each storage level 130L, and the (one or more) breakpack product autonomous transport travel loops 234 of the product transport deck 130DG are located on different deck surfaces 130DGS, separate from the deck surface of the container bot travel surface 266RS (formed by the rails of the container transport deck 130DC and / or picking passage 130A) where the container autonomous transport travel loops 233 are located. The breakpack product autonomous transport travel loops 234 formed by the product transport deck 130DG (and therefore the product transport deck 130DG) are located to constrain at least one autonomous breakpack product transport vehicle (also called a product bot or product transport vehicle) 262 to each storage level 130L. In one embodiment, as illustrated in Figures 7A and 7B, one or more breakpack modules 266 include two or more (i.e., multiple levels) of goods transfer decks 130DG1 to 130DG3 stacked vertically, the goods transfer decks 130DG1 to 130DG3 being connected to each other by one or more ramps 130DGR, the (one or more) ramps 130DGR may form part of one or more breakpack goods autonomous travel loops 234; however, in other embodiments, one or more breakpack modules may have a single level in which the elevated level of at least one breakpack module is connected to the container transfer deck level.The breakpack product interface 263 may be in the form of one or more racks and may include multi-level levels 130DGL1 to 130DGL3, each accessible from a common (level) container transfer deck 130DC.

[0029] At least one product bot 262 is positioned or otherwise configured to transport one or more breakpack product BPGs (e.g., packs or units unpacked from supply containers in pack level classification / units unpacked from packs in individual level classification) between the breakpack operation station 140 and the breakpack product interface 263 along a breakpack product autonomous transport travel loop 234 formed by at least the product transport deck 130DG. One or more container bots 110 are also configured to autonomously pick and place breakpack product containers 264 at the breakpack product interface 263. The breakpack product interface 263 may substantially resemble one or more transport stations TS and buffer stations BS and may include a non-deterministic surface (similar to the non-deterministic surface of the rack storage space 130S) on which the breakpack product containers 264 are placed to form a non-deterministic interface between the product transport deck 130DG and the container transport deck 130DC.

[0030] Referring to Figures 2A, 2B, and 8, the product bot 262 may be any suitable type of autonomously guided bot or vehicle having a payload configured to hold breakpack product BPGs (e.g., received from the breakpack operation station 140) rather than product containers (e.g., case units, pick faces, etc.). The product bot 262 is configured to automatically retrieve one or more breakpack product BPGs (taken from the breakpack operation station 140) from the product bot 262 to the breakpack product container 264 via the breakpack product interface 263. The product bot 262 includes a frame 262F, a drive system 300 connected to the frame 262F, and a payload bay 310 connected to the frame 262F.

[0031] Frame 262F is configured such that the merchandise bot 262 travels as a unit over at least one of the transport decks (such as merchandise deck 130DG) and ramp 130DGR. Frame 262F includes one or more handles 277 that allow for the porting (carrying transport) of the merchandise bot 262 by a human operator or an automated handling device. Each handle 277 is shaped and sized so that a human operator can grasp the handle 277 and lift the merchandise bot 262. Each handle 277 can be attached to Frame 262F in any suitable way. For example, one or more handles 277 can be fixed to the frame using any suitable mechanical or chemical fasteners (e.g., welding, brazing, bolting, etc.). In other embodiments, one or more handles 277 may be detachably attached to Frame 277 so that they are attached to Frame 262F for transporting the merchandise bot 262 and detached from Frame 262F for the operation of the merchandise bot 262 within the storage and retrieval system 100. In other embodiments, the (one or more) handles 277 may be movably connected to the frame using a retractable connector 277CR so as to move from a stored configuration (folded relative to the frame 262F, such as on a hinged connector, or at least partially inserted into the frame 262F, such as on a sliding connector) to an deployed configuration (unfolded relative to the frame 262F, such as on a hinged connector, or at least partially pulled out from the frame 262F, such as on a sliding connector).

[0032] The frame may also include any suitable charging port 288 for bringing onboard charging of any suitable power supply 289 for the merchant bot 262 (see, for example, Figures 8 and 10B). The charging port may be configured as an inductive or contact port for connection with any suitable charger located at charging position 130DGC on the merchant deck 130DG. The (one or more) charging position 130DGC may be located at any suitable position on the merchant deck 130DG so that charging of the merchant bot 262 is performed during the transfer of breakpack goods to and from the merchant bot 262 (e.g., adjacent to the container 264 at interface 263 and / or at breakpack station 140), or at any other position on the merchant deck 130DG. The frame 262F may include any suitable electrostatic grounding structure 291 such as a rod, spring, etc. (see Figure 10B). Any suitable power switch (PWR) and emergency stop button (ESTP) can be mounted on the frame in any suitable position to supply and stop the power supply to the electronic equipment of product bot 262.

[0033] Controller 262C is connected to frame 262F and configured (via any suitable non-temporary computer-readable code, which may include, but is not limited to, a neural network) to cause the merchandise bot 262 to move freely from a first position to a different second position via autonomous navigation, where the first position is a supply position for the merchandise unit (e.g., break-pack station 140) and the second position is a tote-filling position based on an order (e.g., interface 263 - see Figures 7A, 9A, and 9B). For example, a pair of drive wheels 301A, 301B are connected to frame 262F adjacent to one end 262F1 of frame 262F and driven by a drive wheel drive unit 300D of drive system 300. The drive wheel drive unit 300D is operated under the control of any suitable controller 262C (see Figure 2A) of the commodity bot 262 to bring about the transport of the break-pack commodity BPG in the manner described herein. The drive wheel drive unit 300D may be any suitable drive unit, such as a direct drive motor coupled to each wheel 301A, 301B, or any other suitable drive unit (one or more) that utilizes any suitable transmission to give rotation to one or more of the wheels 301A, 301B (e.g., independent rotation of each wheel and / or differential rotation of the wheels). At least one caster wheel 302A, 302B is coupled to frame 262F adjacent to the other end of frame 262F2 opposite end 262F1 (in other embodiments, wheels 302A, 302B may be steerable wheels). The drive wheels 301A, 301B and at least one caster wheel 302A, 302B support the frame 262F for the passage of the merchandise bot 262 on and along the merchandise deck 130DG (see Figures 1, 7A, and 7B). The merchandise bot 262 may include any suitable cover to cover one or more components of the merchandise bot 262 (see, for example, Figures 2A, 2B, and 3A).

[0034] The payload bay or payload 310 is connected to frame 262F to hold the breakpack goods BPG loaded into the goods bot 262, where the payload bay 310 has an end effector 262E, which extends and is positioned to unload the breakpack goods BPG from the payload bay 310. The end effector 262E forms a fill placement regulator 262FPR, which adjusts the placement of breakpack goods BPG unloaded when filling the breakpack goods container 264 so that each breakpack goods container 264 is repeatedly filled by tote filling to a predetermined filling level 1222 (see Figures 12A-12D and 13) at each tote filling position (see interface 263 in Figure 7A). The fill placement regulator 262FPR adjusts each tote filling in a common breakpack goods container 264 substantially independent of the size, shape, and quantity of each goods unit BPG. Here, "independent" means, insofar as the packaging rules permit the breakpack goods BPGs to be packed together in a common breakpack goods container 264, it does not depend on the shape and size of each breakpack goods BPG, as well as the quantity and / or type of each breakpack goods BPG.

[0035] The payload bay 310 includes, and is formed by, a payload support 320 and an end effector 325. The payload support 320 is connected to the frame 262F in any suitable manner so as to be stationary with respect to the frame 262F. The payload support 320 is exemplified as having a planar structure, but may have any suitable configuration for supporting breakpack goods BPG within the payload bay 310. The payload support 320 may include any suitable pad 320P (see Figure 3A) on it, where the pad may have resilience and / or anti-friction properties to cushion and / or facilitate unloading of breakpack goods BPG transported by the goods bot 262. As described herein, the end effector 262E has at least one side wall 310W1 to 310W4 that accommodates the payload (e.g., one or more breakpack goods BPG) held by the goods bot 262. The end effector 262E extends from a closed position (as illustrated in Figures 2A, 2B, 4A, 5A, and 6A) to an open extended position (as illustrated in Figures 4B, 5C, 6B, 12B, and 13). The end effector 262E has a positioning mechanism (for example, at least the side wall 310W1, or the portion of the payload bay 310 forming the side wall 310W1) that contacts the break pack product BPG to offload the break pack product BPG (for example, by pushing or releasing it) and unloads the break pack product BPG from the payload bay 310. The end effector 262E may also have a position adjustment mechanism (for example, at least the side wall 310W4, or the portion of the payload bay 310 forming the side wall 310W4) which acts on the tote filling (for example, for the breakpack goods container 264 and any breakpack goods BPG therein) to adjust the tote filling of each breakpack goods container 264 to a substantially repeatable filling level 1222 (for example, as illustrated and described herein with respect to at least Figures 12A-12D and 13) and is arranged to bias the breakpack goods BPG of the tote filling during the extension or retraction of the end effector 262E.The end effector 262E's filling placement regulator 262FPR causes the end effector 262 to repeatedly retract to a closed position in each placement of the breakpack goods BPG, independently of interference by tote filling in each placement. In one or more embodiments, the end effector 262 has a movable wall 310W4 (see, for example, Figures 6A, 6B, 12C, and 12D) that moves with the retraction of the end effector to eliminate interference with each tote filling (for example, passively via contact with the breakpack goods BPG in the breakpack goods container 264), while in other embodiments, the movable wall 310W4 may be actively moved under the propulsion of any suitable actuator of the end effector configured to drive the movement of the movable wall 310W4, independently of the retraction of the end effector, to eliminate interference with each tote filling.

[0036] Referring to Figures 2A, 2B, 3A, and 3B, the end effector 325 forms the outer perimeter wall of the payload bay, extending from the payload support 320 at any appropriate distance or height H (Figure 2B) to substantially accommodate the breakpack goods within the payload bay 310. The end effector 325 includes a frame to which the end effector 325 is movably connected in any appropriate manner, such as on a slide, to the frame 262F (a portion of which is illustrated in Figure 3A). For example, one or more rails 311A, 311B are connected to the frame 262F to result in the extension and retraction of the end effector 262E in direction 399 along the rails 311A, 311B as described herein. In one embodiment, rails 311A ​​and 311B are positioned on frame 262F so as to straddle the payload support section 320, while in another embodiment, rails 311A ​​and 311B are positioned between the payload support section 320 and frame 262F, where the payload support section includes a slot through which frame 310F is movably connected to rails 311A ​​and 311B, while in yet another embodiment, the payload support section 320 is connected to frame 262F via spacers / post SD (see Figure 3A) so as to be spaced from the frame by any appropriate distance to allow connection and operation of sliders 312A and 312B to and along rails 311A ​​and 311B (extending traversely in direction 399 beyond the support tray for connection with posts 313A and 313B). Sliders 312A and 312B (as illustrated in the "exploded" view in Figure 3A) are movably connected to one of each of the rails 311A ​​and 311B so as to slide back and forth (for example, reciprocate) along the respective rails 311A ​​and 311B in direction 399.

[0037] The frame includes columns 313A and 313B connected to sliders 312A and 312B. For example, column 313A is connected to slider 312A so that column 313A and slider 312A move as a unit along rail 311A. Column 313B is connected to slider 312B so that column 313B and slider 312B move as a unit along rail 311B. As illustrated in Figure 3A, columns 313A and 313B are positioned at one end of frame 310F so that the end effector 262E is substantially cantilevered from columns 313A and 313B. For example, frame member 310F1 is connected to columns 313A and 313B, spans between columns 313A and 313B, and includes a product engagement surface 310S1 that forms the end wall 310W1 of the payload bay 310. Frame member 310F2 is connected to column 313B, cantilevered from column 313B, and extends in direction 399. Frame member 310F2 includes a product engagement surface 310S2 that forms the side wall 310W2 of the payload bay 310. Frame member 310F3 (similar to frame member 310F2) is connected to column 313A, cantilevered from column 313A, and extends in direction 399. Frame member 310F3 includes a product engagement surface 310S3 that forms the side wall 310W3 of the payload bay 310 on the opposite side of the side wall formed by the product engagement surface 310S2. A frame member 310F4, including the product engagement surface 310S4, spans between the side frame members 310F2 and 310F3 (as described herein) and is connected to them to form another end wall 310W4 of the payload bay 310 opposite to the end wall 310W1 formed by the frame member 310F1. With the end effector 262E in the retracted position (as illustrated in Figures 2A and 2B), the break-pack product BPG in the payload bay 310 is supported by the payload support 320 and accommodated by the product engagement surfaces 310S1 to 310S4, which form a dwelling boundary around the payload support 320.

[0038] The end effector 262E is driven by the end effector drive unit 300E between a retracted position (for example, as illustrated in Figures 2A, 2B, 4A, 5A, and 6A) and an extended position or a partially extended position (for example, as illustrated in Figures 4B, 5C, and 6B). Referring to Figures 3A and 3B, an exemplary end effector drive unit 300E is illustrated, but the end effector drive unit 300E may have any suitable configuration for driving the end effector in direction 399 between the retracted position and the extended position (including, for example, one or more of (one or more) piston drive units 300E1, (one or more) ball screw drive units 300E2, (one or more) chain and sprocket drive units 300E3, (one or more) belt and pulley drive units 300E4, magnetic actuator 300E5, and / or (one or more) electric actuator 300E6, etc.). In the example illustrated in Figures 3A and 3B, the end effector drive unit 300E includes a rotary motor 370 that drives a pulley 371 (for example, the pulley 371 is connected to the output of the rotary motor 370 in any suitable way). The pulley 371 in turn drives a meandering belt 372 which is wound around a plurality of idler pulleys 373. The idler pulleys 373 provide a belt transport path that includes two belt legs 372L1, 372L2 which move in the same direction when the rotary motor 370 is operated. For example, when the rotary motor 370 drives the pulley 371 counterclockwise, both belt legs 372L1, 372L2 move in the extension direction 399A. When the rotary motor 370 drives the pulley 372 clockwise, both belt legs 372L1, 372L2 move in the retraction direction 399B. Here, slider 312A is connected to belt leg 372L1 (by any suitable means such as clamp 366), and slider 312B is connected to belt leg 372L2 (by any suitable means such as clamp), so that both sliders (and the support columns 313A, 313B connected to them) are moved simultaneously in one of directions 399A, 399B to extend or retract the end effector 262E.The end effector drive unit 300E may include any suitable belt tensioner 379 to maintain any suitable predetermined belt tension of the meandering belt 372. The end effector drive unit 300E is operated under any suitable controller 262C (see Figure 2A) of the commodity bot 262 to bring about the transfer of the break pack commodity BPG in the manner described herein.

[0039] As described above, the frame member 310F4 straddles and connects to the side frame members 310F2 and 310F3, forming the end wall 310W4. Referring to Figures 4A to 6B, the frame member 310F4 may be connected to the side frame members 310F2 and 310F3 in any suitable way, but is not limited to this, the frame member 310F4 may be connected to the side frame members 310F2 and 310F3 in a fixed (e.g., stationary) relationship with the side frame members 310F2 and 310F3 (Figures 4A to 4B), or the frame member 310F4 may be connected to the side frame members 310F2 and 310F3 (with the end effector 262E retracted), (with the end effector 262E extended) The frame member 310F4 is connected to the side frame members 310F2 and 310F3 by one or more cammed connecting parts 501A and 501B, which are released from the side frame members 310F2 and 310F3 (in the state shown) (Figures 5A to 5C), and is also connected to the side frame members 310F2 and 310F3 by one or more hinges positioned adjacent to the upper part 310F4T of the frame member 310F4 (it should be noted that the term "upper part" is used herein for convenience, but any other spatial modifier may be used) (Figures 6A to 6B).

[0040] Referring to Figures 4A and 4B, the frame member 310F4 of the end effector 262E is connected to frame members 310F2 and 310F3 at ends 400A and 400B of frame member 310F4. Here, as the end effector 262E is moved in direction 399, any suitable fasteners (e.g., mechanical or chemical) are used to firmly secure ends 400A and 400B of frame member 310F4 to one of each of frame members 310F2 and 310F3 so that frame member 310F4 comes to rest and stays in place relative to frame members 310F2 and 310F3. Here, the frame member 310F4 can be used to "bulldoze" or otherwise push the breakpack goods BPG placed in the breakpack goods container 264, with the end effector 262E extended in direction 399A and / or retracted in direction 399B, thereby moving the breakpack goods BPG within the breakpack goods container 264 and distributing the breakpack goods substantially evenly within the breakpack goods container 264.

[0041] Referring to Figures 5A-5C, the frame member 310F4 is pivotably connected to one of the frame 262F and the payload support 320 in any suitable manner. In Figures 5A-5C, the frame member 310F4 is illustrated as being pivotably connected to the tray support 320 by a hinge 501 (e.g., a piano hinge or any other suitable hinge) so as to pivot in direction 599 about the axis of rotation of the hinge 501. Here, one or more ends 400A, 400B of the frame member 310F4 include cams 510A, 510B, and one or more of the frame members 310F2, 310F3 each include projections 511A, 511B (e.g., rollers, pins, or any other suitable projections that engage with the respective cams 510A, 510B). The protruding portion 511A and the cam 510A form a cammed connecting portion 501A, and the protruding portion 511B and the cam 510B form a cammed connecting portion 501B.

[0042] As illustrated in Figure 5A, with the end effector 262E in its fully retracted position, the (one or more) projections 511A, 511B engage with their respective cams 510A, 510B such that the frame member 310F4 is held substantially perpendicular to the payload support 320, and the ends 400A, 400B are closely connected (for example, substantially in contact along their entire length) to one of each of the frame members 310F2, 310F3 (and the walls 310W2, 310W3 formed thereby). When the end effector 262E is extended in direction 399A, the (one or more) projections 511A, 511B engage with the frame member 310F4, causing the frame member 310F4 to pivot in direction 599A. The pivotal motion of the frame member 310F4 in direction 599A (for example, due to the biasing of the hinge 500 rotating in direction 599A from gravity and / or an elastic member / torsion spring, etc.) is guided and limited by the engagement between (one or more) protrusions 511A, 511B and their respective cams 510A, 510B. Continued extension of the end effector 262E in direction 399A to the fully extended position of the end effector 262E results in the rotation of the frame member 310F4 to the fully extended position (see Figure 5C). In the fully extended position, the frame member 310F4 acts as a slide or chute through which the break pack goods BPG being ejected from the payload bay 310 by the end effector 262E passes. In its fully extended position, the frame member 310F4 can guide the breakpack goods BPG into a predetermined area of ​​the breakpack goods container 264 (for example, along or with the passage of goods bots 262 moving toward or away from the breakpack goods container 264 in which the breakpack goods are placed), thereby distributing the goods placed within the breakpack goods container 264 substantially evenly. The retraction of the end effector 262E in direction 399B results in the rotation of the frame member 310F4 in direction 599B and a close connection between the frame member 310F4 and the frame members 310F2 and 310F3, in a manner substantially opposite to that described above.

[0043] Referring to Figures 6A and 6B, frame member 310F4 is pivotally connected to (side) frame members 310F2 and 310F3 in any suitable manner. For example, as illustrated in Figures 6A and 6B, one end 400A of frame member 310F4 is pivotally connected to frame member 310F2 at pivot connection 601B. The other end 400B of frame member 310F4 is pivotally connected to frame member 310F3 at pivot connection 601A. In other embodiments, any suitable pivot connection may be used, where frame member 310F4 acts as a cross member connecting frame members 310F2 and 310F3, or where frame members 310F2 and 310F3 are connected to a cross member to which frame member 310F4 is connected (using a hinge 500A similar to hinge 500, for example), and where a cross member CCM (see Figure 10B) separate from frame member 310F4 is connected to a different payload bay frame, thereby so that both the cross member CCM and frame member 310F4 form the end wall 310W4 of the payload bay 310. The pivot connections 601A and 601B are positioned adjacent to the upper part 310F4T of frame member 310F4, such that the bottom part 310F4B of frame member 310F4 can freely pivot in direction 699 when the end effector is in an extended (e.g., not fully retracted) position. The pivot of frame member 310F4 can be restricted to direction 699A through contact between frame member 310F4 and one or more of frame members 310F2, 310F3 (and / or walls 310W2, 310W3) at their respective contact surfaces 655 (one or more of which are exemplified between frame members 310F4 and 310F3 in Figure 6A, and it should be noted that one or more similar contact surfaces may also be provided between frame member 310F4 and 310F2).

[0044] With the end effector 262E in a fully retracted position (as illustrated in Figure 6A), the frame member 310F4 is held in a closed position by one or more suitable releasable couplings 610 (as illustrated in Figure 6A, the frame 310F4 is in contact with one or more of the frame members 310F2, 310F3 at the contact surface 655 as described herein). One or more releasable couplings 610 may be any suitable magnetic coupling 615 (one or more), any suitable mechanical latch 616 (one or more), or a combination of a magnetic coupling and a mechanical latch. Examples of suitable mechanical latches 616 include, but are not limited to, electronically actuated bolt / pin / plunger latches, electronically actuated cam lock / latches, electronically actuated draw / toggle latches, and electronically actuated rotary latches. Examples of suitable magnetic couplings include, but are not limited to, permanent magnet couplings 615P and electromagnetic couplings 615E. For illustrative purposes, in this specification, one or more releasable couplings 610 are described in relation to one or more magnetic couplings 615, but it should be understood that a mechanical latch 616 may be used instead of or in combination with one or more magnetic couplings 615, and the mechanical latch is released to allow extension of the end effector 262E and is activated / coupled when the end effector 262E returns to its fully retracted position, maintaining the frame member 310F4 in a closed position (as illustrated in Figure 6A) while the merchant bot 262 is passing through the merchant deck 130DG.

[0045] If one or more magnetic couplings 615 include permanent magnets, one or more permanent magnets 611A, 611B are coupled to one or more of the frame 262F and payload support 310. One or more corresponding permanent magnets 610A, 610B are coupled adjacent to the bottom 310F4B of the frame member 310F4 so as to interact with the respective permanent magnets 611A, 611B of the frame 262F or payload support 310. The magnetic couplings formed between the permanent magnets 611A, 611B and the respective permanent magnets 610A, 610B can be sufficiently weak so that the force / torque generated by the end effector drive unit 300E as the end effector 262E extends is released above the magnetic couplings (for example, the attractive force of the magnetic couplings is less than the extension driving force of the end effector drive unit 300E). With the end effector in the fully retracted position, the magnetic coupling force holds the frame member 310F4 in the closed position, allowing the product bot 262 to move along the product deck 130DG. The permanent magnets 611A, 611B, 610A, and 610B are exemplified adjacent to the bottom 310F4B of the frame member 310F4, but in other embodiments, the permanent magnets 611A, 611B, 610A, and 610B may be located anywhere between the bottom 310F4B and the top 310F4T of the frame member 310F4 (such as where the magnets 611A and 611B are attached to / connected to the struts that straddle the end effector 262E and fixed to the frame 262F).

[0046] If the (one or more) magnetic couplings 615 include electromagnets, one or more electromagnets 613A, 613B are coupled to one or more of the frame 262F and payload support 310. One or more corresponding ferromagnetic elements 612A, 612B are coupled adjacent to the bottom 310F4B of the frame member 310F4 so as to interact with the respective electromagnets 613A, 613B of the frame 262F or payload support 310. The magnetic couplings formed between the electromagnets 613A, 613B and the respective ferromagnetic elements 612A, 612B can be released, resulting in extension of the end effector 262E, and can be activated when the end effector 262E is in a fully retracted position, holding the frame member 310F4 in a closed position as the merchandise bot 262 moves along the merchandise deck 130DG. The electromagnets 613A, 613B and ferromagnetic elements 612A, 612B are exemplified adjacent to the bottom 310F4B of the frame member 310F4, but in other embodiments, the electromagnets 613A, 613B and ferromagnetic elements 612A, 612B may be located anywhere between the bottom 310F4B and the top 310F4T of the frame member 310F4 (such as where the electromagnets 613A, 613B are attached / connected to the struts that straddle the end effector 262E and fixed to the frame 262F). The activation and deactivation of the electromagnets 613A, 613B can be brought about using any suitable controller 262C (see Figure 2A) of the commodity bot 262 for bringing about the transfer of break-pack commodity BPG in the manner described herein.

[0047] Referring to Figures 2B, 3A, 4B, 8, 9A, 9B, 10, 11, and 14, the product bot 262 uses an end effector 262E to bring about controllable filling of the breakpack product container 264 in the tote filling of breakpack product BPGs via a tote filling feedback device (also referred herein as a visual system, such as at least one of sensors PS1-PS4, PS8) that responds to at least one of the filling level and placement of the tote filling. The tote filling feedback device generates a feedback signal in response to at least one of the filling level and placement of the tote filling. The feedback signal is received by, for example, a controller 262C (see Figure 2A) and may cause the end effector 262E to extend and / or retract, as described above, to reposition the breakpack product BPGs to offload and / or bias within the breakpack product container 264. As described herein, the tote filling feedback device includes at least one camera (e.g., one or more of sensors PS2-PS4, PS8) that views the payload bay 310 and at least one camera (e.g., at least sensor PS1) that views the breakpack goods container 264 at the tote filling position (see interface 263 in Figure 7A).

[0048] The product bot 262 includes one or more sensors PS1-PS8 that, using the controller 262C, provide one or more of the product bot's positioning / navigation and object detection within the breakpack module 266. Sensors PS1-PS8 may include, but are not limited to, one or more suitable cameras. Object detection may be one or more of the following: detection of objects on the product deck 130DC (e.g., detection of other product bots and / or debris), detection of objects at interface 163 (e.g., product containers, breakpack product BPGs in product container 264), detection of objects in the payload bay 310 of the product bot 262 (e.g., breakpack products in payload bay 310), or detection of any other suitable objects onboard or offboard of the product bot 262. At least one sensor PS1-PS8 is connected to frame 262F and operably connected to controller 262C, where at least one sensor PS1-PS8 is positioned to image the payload loaded in payload bay 310, and controller 262C is configured to register images of the payload from at least one sensor PS1-PS8 and to detect the presence of breakpack goods BPG in the payload or to identify breakpack goods BPG from the images. Based on the detected presence or identification, controller 262C is configured to determine the suitability of the payload to predetermined load conditions based on the order and to initialize different transport commands based on the suitability (e.g., the correct goods for the order, goods properly ejected from payload bay 310, etc.) or non-suitability (e.g., the wrong goods for the order, goods not properly ejected from payload bay 310, etc.) determination. Controller 262C is configured to transmit a communication signal to an operator or management system (including controller 120) that represents or corresponds to the suitability or non-suitability determination.If a non-conformity is detected, the controller 262C may transport the Break Pack product BPG back to the Break Pack station 140 for correction or to another area, or may request the operator to make corrections if the Break Pack product BPG is not properly ejected from the payload bay 310.

[0049] Referring to Figures 2B, 8, 9A, 9B, 11A, and 14, the product bot 262 includes one or more sensors PS1 positioned on or adjacent to the end 262F2 (e.g., in front of the product bot 262 with respect to the direction of movement of the product bot 262). The sensors PS1 may be stereoscopic sensors (or other suitable ranging sensors) that provide object detection and localization for the product bot 262. Figure 14 illustrates an exemplary sensor image 1400 generated by controller 262C (or any other suitable controller such as controller 120) from sensor data (e.g., feedback signals) obtained by sensor PS1, where the sensor data is utilized (e.g., via any suitable image processing algorithm, including, but not limited to, a neural network) to provide a bot's passage along the product deck 130DG while maintaining a predetermined tracking distance behind another product bot 262.

[0050] As described herein, the sensor PS1 may also result in the detection of breakpack product BPGs within the breakpack product container 264 when the product bot 262 is interfaced with the breakpack product container 264 at interface 263. Figure 9B illustrates an exemplary sensor image 1400 generated by the controller 262C from sensor data (e.g., feedback signals) obtained by the sensor PS1 when the product bot 262 is interfaced with the product container 264 and the end effector 262E is in the retracted position (e.g., controller 262C, or other suitable controller such as controller 120, may include any suitable image processing algorithm, including a neural network for processing the sensor data and resulting in the detection of breakpack product BPGs). Figure 11A illustrates an exemplary sensor image 1400 generated by the controller 262C from sensor data (e.g., feedback signals) obtained by the sensor PS1 when the product bot 262 is interfaced with the product container 264 and the end effector 262E is in the extended position.With the product bot 262 interfaced with the product container 264 at interface 263, the sensor data obtained by the product bot 262's sensor PS1 is used to result in one or more of the following: detecting / verifying the presence of the product container 264 (to which the product bot 262 interfaced) at interface 263; if presence is not detected at a given interface location, the product bot 262 does not distribute breakpack product BPG and notifies the controller 120 that the breakpack product container 262 does not exist (where the controller 120 may instruct the placement of the breakpack product container at the given interface location or prevent other bots 262 from accessing the given interface location until the container 264 is delivered to that location); and the product container 264 that can be extended within the extension / retraction path of the end effector 262E, which the product bot 262 "bulldozes" through by extending the end effector as described herein. Detecting the breakpack product BPG within the product container; detecting the location of one or more breakpack product BPGs within the product container (for example, the products are loaded forward within the product container 264 toward a product bot 262 interfaced with the product container 264, or backward within the product container 264 toward a product bot 262 interfaced with the product container 264, or distributed substantially evenly within the product container 264 between the front and rear of the product container 264 toward a product bot 262 interfaced with the product container 264); verifying that the breakpack product BPGs in the payload bay 310 are located in the product container 264; verifying that the breakpack product container 264 at a given interface location is at or above a given fill level; if the container 264 is at or above a given fill level, the bot 262 does not distribute the product BPGs into the container 264.

[0051] As shown in Figures 5A-5C, if the product bot 262 is configured by hinge-connecting the frame member 310F4 to the payload support 320 (for example, by a hinge 500), then sensor data from sensor S1 (for example, a feedback signal) may be used by controller 262C to move product bot 262 in direction 399 to evenly distribute the breakpack product BPGs in the breakpack product container 264 (for example, as described herein), depending on whether the breakpack product BPGs in the breakpack product container 264 are loaded forward or backward. If the breakpack product BPGs are loaded forward in the breakpack product container 264, product bot 262 is positioned on the product deck 130DG to discharge the breakpack product carried by it to the rear of the breakpack product container 264 (for example, the portion of the product container 264 furthest from product bot 262 and product deck 130DG). If the Break Pack Goods BPG are loaded rearward within the Break Pack Goods Container 264, the Goods Bot 262 is positioned on the Goods Deck 130DG and discharges the Break Pack Goods it carries to the front of the Break Pack Goods Container 264 (for example, the portion of the Goods Container 264 closest to the Goods Bot 262 and Goods Deck 130DC). If the Break Pack Goods BPG are evenly distributed within the Break Pack Goods Container 264, the Goods Bot 262 may travel in direction 399 such that the Break Pack Goods BPG being discharged from it is placed substantially evenly on top of the Break Pack Goods BPG already present in the Break Pack Goods Container 264. In other embodiments, the Goods Bot 262 may discharge the Break Pack Goods BPG it carries into the Break Pack Goods Container 264 in any suitable manner.

[0052] The sensor data (e.g., feedback signals) obtained by sensor PS1 with respect to breakpack product BPGs within product container 264 may be referred to as product container filling feedback, which is communicated from product bot 262 to any appropriate controller, such as controller 120. Controller 120 may determine (by any appropriate method, such as any appropriate visual analysis) whether product container 264 is filled (e.g., whether it exceeds a predetermined filling level 1222, such as approximately 80% filling, or any other appropriate amount that may be more or less than 80% filling (see Figures 12A-12D and 13)). If product container 264 is not filled, controller 120 communicates with breakpack module 266 (where product container 264 is located) to instruct the placement of additional breakpack product BPGs into product container 264 (if additional breakpack product BPGs exist for the order to which the product container belongs). In this way, the filling amount of product container 264 is maximized, and the number of product containers for any given order is minimized. The product container filling feedback also results in a determination of the deployment (e.g., extension) of the end effector 262E, as described herein, which may "bulldoz" any breakpack product BPG that extends above the top 264T of the breakpack product container 264 (see Figures 12A-12B).

[0053] Referring to Figures 2B, 3A, 4B, 8, 10A, 10B, and 11B, the product bot 262 includes one or more payload bay sensors PS2, PS3, PS4, PS8 positioned on the product bot 262 to image a break-pack product BPG held within the payload bay 310. One or more payload bay sensors PS3, PS4, PS8 may be positioned above the payload bay 310 to "look down" into the payload bay 310, and / or one or more payload bay sensors PS2 may be positioned adjacent to a sensor window or opening 278 (see Figures 2B, 3A, and 4A-6B) in one or more of the frame members 310F1, 310F2, 310F3, 310F4 (the sensor opening 278 is illustrated in frame member 310F1 for illustrative purposes). The payload bay sensors PS2, PS3, PS4, and PS8 may be any suitable sensors, such as stereoscopic sensors, any suitable distance measuring sensors, and monocular sensors. The controller 262C (or any other suitable controller, such as the controller 120) includes any suitable image processing algorithm (including, but not limited to, neural networks) for processing data obtained by one or more payload bay sensors PS2, PS3, PS4, and PS8 for the detection of the break-packed product BPG.

[0054] Referring to Figure 10A, one or more payload bay sensors include sensors PS3, PS4 that form a pair of binocular cameras resulting in stereoscopic detection of break-packed goods BPGs within the payload bay 310. Here, sensors PS3, PS4 are positioned on pillars 1010, 1011 (or frame 262F or any other suitable mount extending from the payload support 310) adjacent to the opposing corners of the payload bay 310 (for example, toward the end 262F1 of the goods bot 262), but in other embodiments, sensors PS3, PS4 may be positioned anywhere on frame 262F (or payload support 320) to form a pair of stereoscopic or binocular cameras with a field of view covering the internal payload bay. An exemplary image 1099 obtained with sensor data (e.g., feedback signals) from sensors PS3, PS4 is illustrated in Figure 10A.

[0055] Referring to Figure 10B, one or more payload bay sensors include a sensor PS8, which may be a stereoscopic sensor substantially similar to sensor PS1. Sensor PS8 is positioned substantially in line with the longitudinal centerline of the payload bay 310 / product bot 262 (for example, extending between ends 262F1 and 262F2) toward the end 262F1 of the product bot 262. In other embodiments, sensor PS8 may be positioned anywhere on the frame 262F (or payload support 320) to have a field of view covering the internal payload bay. An exemplary image 1098 obtained from sensor data (e.g., feedback signals) from sensor PS8 is illustrated in Figure 10B.

[0056] Referring to Figures 2B, 3A, and 11B, one or more payload bay sensors include a sensor PS2. The sensor PS2 may be any suitable sensor that provides monocular or binocular / stereoscopic vision. The sensor PS2 is coupled to the payload support 320 (see, for example, Figure 4B) toward the end 262F1 of the product bot 262 in any suitable manner so as to be positioned to view the internal payload bay through the sensor aperture 278. In other embodiments, the sensor PS2 may be positioned anywhere on the frame 262F (or payload support 320) to have a field of view covering the internal payload bay. An exemplary image 1199 obtained with sensor data (e.g., feedback signals) from the sensor PS2 is illustrated in Figure 11B.

[0057] One or more sensors PS2, PS3, PS4, PS8 may be used individually or in any suitable combination to obtain one or more of the above images 1098, 1099, 1199. Controller 262C (or any other suitable controller such as Controller 120) includes any suitable image processing algorithm, including but not limited to a neural network, to bring the detection of breakpack goods BPG in the payload bay 310 with data from (one or more) sensors PS2, PS3, PS4, PS8. Controller 262C may utilize one or more sensors PS2, PS3, PS4, PS8 to verify the operator (manual or automatic) placement of breakpack goods BPG in the payload bay 310 at the breakpack station 140 and / or to verify the ejection of breakpack goods BPG from the payload bay 310 to the breakpack goods container 264 at interface 263.

[0058] Referring to Figures 2A, 2B, and 15, the product bot 262 may include lateral positioning sensors PS5, PS6 configured to detect any suitable structural feature of the storage and retrieval system 100 or any suitable indicator 1510 attached thereto, in order to determine the position of the product bot along the product deck 130DG using controller 262C (or any other suitable controller such as controller 120). An exemplary image 1500 obtained by one of the sensors PS5, PS6 is illustrated in Figure 15.

[0059] Referring to Figure 10A, the product bot 262 may include one or more sensors PS7 positioned on or adjacent to its end 262F1 (for example, in front of or behind the product bot 262 with respect to the direction of movement of the product bot 262). Sensor PS7 may be a stereoscopic sensor (or other suitable ranging sensor) that provides object detection and localization for the product bot 262 in the same manner as sensor PS1, as described above with respect to sensor PS1.

[0060] Referencing Figures 1, 7A, 7B, 9A, 12A, and 12B, exemplary operation of the end effector 262E (as illustrated in Figures 4A, 4B, 6A, and 6B) is described. The product bot 262 travels through the product deck 130DG to a predetermined breakpack product container 264 that is assigned to a predetermined order and located in a predetermined position on the interface 263 (Figure 17, block 1700). The product bot 262 positions itself on the product deck 130DG at the container interface location (as illustrated in Figure 9A) to bring about the transfer of breakpack product BPGs from the payload bay 310 of the product bot 262 to the breakpack product container 264. The tote filling feedback device may be used to determine one or more of the presence and status of breakpack product containers 264 at the container interface location (Figure 17, block 1710), and to determine the suitability (e.g., breakpack product containers 264 are present, not filled to a predetermined filling level, etc.) or unsuitability (e.g., breakpack product containers 264 are not present, filled to or above a predetermined filling level, etc.) of a given location on the interface 263. If the presence of breakpack product containers 264 is confirmed and the filling level of the breakpack product container is below a predetermined filling level, the product bot 262 results in the transfer of the breakpack product BPGs held by it to the breakpack product container 264 (Figure 17, block 1711).

[0061] If it is determined that a breakpack product container 264 is not present at the container interface location or is filled above a predetermined fill level, the product bot 262 will not transfer the breakpack product BPG held by it to the breakpack product container 264. The product bot 262 may notify the controller 120 that the breakpack product container 264 is not present or that a predetermined breakpack product container 264 is in a predetermined location for correction by the controller 120 (Figure 17, block 1713). The controller 120 may correct the absence of a breakpack product container by one or more of the following: transporting an empty breakpack product container 264 (using the container bot 110) to a container interface location where a product bot 262 can transfer goods there; assigning another (empty) breakpack product container 264 at another location on the interface 263 to a predetermined order and instructing the product bot 262 to place the breakpack product BPG held thereon into another breakpack product container 264 at another location; and preventing other product bots 262 from delivering breakpack product BPG to an empty container interface location. The controller 120 may modify a filled breakpack product container by one or more of the following: assigning another (empty) breakpack product container to a predetermined order; transporting the empty breakpack product container 264 (using the container bot 110) to another container interface location where the product bot 262 can transfer goods; assigning another (empty) breakpack product container 264 already located at another location on the interface 263 to a predetermined order; instructing the product bot 262 to place the breakpack product BPG held on it into another breakpack product container 264 at a different location; and preventing other product bots 262 from delivering breakpack product BPG to the filled breakpack product container 264.

[0062] As illustrated in Figure 12A, one or more breakpack items BPG1, BPG2 may extend above the top 264T of the breakpack item container 264 and reach within the extension path of the end effector 262E. A tote-filling feedback device may be used to detect these interfering breakpack items BPG1, BPG2 (Figure 17, block 1715), where the controller 262C receives a feedback signal from the tote-filling feedback device indicating the presence of interfering breakpack items BPG1, BPG2. Here, as described above, the end effector 262E is extended in direction 399A, and as it extends in direction 399A, the frame member 310F4 (e.g., wall 310W4) adjusts the tote filling and distributes the breakpack goods BPG1 and BPG2 in the breakpack goods container 264, "bulldozing" or otherwise pushing / clearing the breakpack goods BPG1 and BPG2 in the breakpack goods container 264 out of the end effector path, resulting in a repeatable filling level 1222 of the breakpack goods container 264 (Figure 17, block 1720). The breakpack goods BPG may be pushed under the extension path of the end effector 262E. As the end effector 262E extends in direction 399A, the frame member 310F1 (for example, wall 310W1) pushes the breakpack product BPG3 from the payload bay 310 into the breakpack product container 264 (see Figure 12B). As can be understood, the distance D1 between the side frame members 310F2, 310F3 may be approximately the same as the distance D2 between the side walls 264S1, 264S2 of the breakpack product container 264 (see Figure 9B), so that the side frame members 310F2, 310F3 guide (or reposition) the movement of the breakpack product BPG3 from the payload bay 310 into the breakpack product container 264. If the break pack products BPG1 and BPG2 already present in the break pack product container 264 do not obstruct the extension of the end effector 262E, the end effector 262E is extended in a manner similar to that described above, placing the break pack product BPG into the break pack product container 264 (Figure 17, block 1725).The tote filling feedback device may be used to determine whether all of the breakpack goods BPGs carried by the goods bot 262 have been placed in the breakpack goods container 264, where, if not all goods have been placed, the end effector is extended again (or continues to extend) (Figure 17, block 1715). If all goods have been placed, the end effector is retracted (Figure 17, block 1730).

[0063] With respect to the configuration of the end effector 262E in Figures 4A and 4B, as described herein, breakpack goods BPGs located in the back path of the end effector are either “pushed forward” from the back path or otherwise pushed out while the end effector 262E is moving in direction 399B, and are distributed into the breakpack goods container 264 in a manner similar to that described above for breakpack goods BPG1 and BPG2 (Figure 17, block 1730).

[0064] See also Figures 12C and 12D for further explanation of the configuration and operation of the end effector 262E in Figures 6A and 6B. Here, the breakpack goods BPG3 are placed in the breakpack goods container 264 from the payload bay 310 as described above, with one or more breakpack goods BPG3 extending into the retraction path of the end effector 262E. When the frame member 310F4 (e.g., wall 310W4) interacts with the breakpack goods BPG3 while the end effector 262E is moving (retracting) in direction 399B, the frame member 310F4 passively pivots in direction 699B around the pivot connections 601A, 601B, and rides on the breakpack goods BPG3 so that the end effector 262E can retract past (bypass) the breakpack goods BPG3 without interfering with the retraction movement of the end effector 262E (Figure 17, block 1735). In other embodiments, a frame member 310F4 (e.g., a wall 310W4) may be actively driven in direction 699B by any suitable actuator to lift the frame member 310F4 above the breakpack goods BPG in the breakpack goods container 264. With the end effector 262E in the fully retracted position, the goods bot 262 may travel along the goods deck 130DG to the breakpack station 140 for transporting various breakpack goods BPGs. Alternatively, a sensor on the goods bot 262 (such as those described herein) may be used to detect breakpack goods BPG3 extending above the top 264T of the breakpack goods container 264, and based on the sensor information, the end effector 262E may be extended in direction 399A to distribute the breakpack goods BPG3 within the breakpack goods container 264 (see Figure 12D).

[0065] Referencing Figures 1, 5A–5C, 9A, and 13, an exemplary operation of the end effector 262E (as illustrated in Figures 5A–5C) is described. The product bot 262 travels through the product deck 130DG to a predetermined breakpack product container 264 located at a predetermined position on the interface 263. The product bot 262 positions itself on the product deck 130DG at the container interface position (as illustrated in Figure 9A), resulting in the transfer of breakpack product BPG from the payload bay 310 of the product bot 262 to the breakpack product container 264. With the product bot 262 positioned adjacent to the breakpack product container 264, the end effector 262E is extended in direction 399A. With the end effector 262E extended, the protrusions 511A and 511B engage with the frame member 310F4 and the cams 510A and 510B to rotate the frame member 310F4 (for example, the wall 310W4) to a fully extended position in direction 599A in the manner described above. At this point, the rotation of the frame member 310F4 in direction 599A pushes the breakpack goods BPG in the breakpack goods container 264 down into the breakpack goods container 264, resulting in a repeatable filling level 1222 of the breakpack goods container 264. Also, with the end effector extended in direction 399A, the frame member 310F1 pushes the breakpack goods BPG from the payload bay 310 into the breakpack goods container 264. As described above, the distance D1 between the side frame members 310F2 and 310F3 can be approximately the same as the distance D2 between the side walls 264S1 and 264S2 of the breakpack product container 264, so that the side frame members 310F2 and 310F3 guide the movement of the breakpack product BPG from the payload bay 310 to the breakpack product container 264 (see Figure 9B).

[0066] As described above, with the frame member 310F4 in the fully extended position, the breakpack product BPG is pushed out of the payload bay 310 by the frame member 310F1 and slides along the frame member 310F4. The frame member 310F4 orients the breakpack product BPG toward the center of the breakpack product container 264, however, with the passage of the product bot 262 in direction 399A, the breakpack product sliding along the frame member 310F4 may be oriented beyond the center of the breakpack product container 264 (for example, toward the side of the container 264 farther from the product bot 262), and with the passage of the product bot 262 in direction 399B, the breakpack product sliding along the frame member 310F4 may be oriented forward of the center of the breakpack product container 264 (for example, toward the side of the container 264 closer to the product bot 262). Here, by moving product bot 262 toward and away from the breakpack product container 264, the breakpack product BPGs within the breakpack product container 264 are distributed approximately evenly.

[0067] Referring to Figures 1, 2A, 2B, 7A, 7B, 9A, 9B, 12A-12D, 13, and 16, an exemplary method for transporting merchandise units for filling shipping totes or containers is described. The method includes the step of providing a merchandise bot (e.g., an autonomous transport vehicle) 262 (Figure 16, block 1600), where the merchandise bot 262 has a frame 262F and a payload bay 310 connected to the frame 262F, the frame 262F being configured so that the merchandise bot 262, as a unit, travels over at least one of a transport deck (e.g., merchandise deck 130DG) and a ramp 130DGR, and the payload bay 310 holds the break-pack merchandise loaded into the merchandise bot 262.

[0068] The movement of the product bot 262 is brought over at least one of the product deck 130DG and ramp 130DGR (Figure 16, block 1610) so that the product bot 262 can move freely via autonomous navigation from a first position (such as the break pack station 140) to a different second position (such as the interface 263 - see Figures 7A, 9A, and 9B), using a controller 262C connected to frame 262F, where the first position is the supply position for break pack product BPG, and the second position is the tote filling position based on the order. One or more breakpack goods (e.g., one or more goods units) BPGs are unloaded from the payload bay 310 of the goods bot 262 using the end effector 262E of the payload bay 310 (Figure 16, block 1620), where the end effector 262E extends and is positioned to unload the breakpack goods BPGs from the payload bay 310, and the end effector 262E forms a fill placement regulator 262FPR, which adjusts the placement of breakpack goods BPGs that are unloaded when filling the breakpack goods container 264 so that each breakpack goods container 264 is repeatedly filled by tote filling to a predetermined filling level 1222 (see Figures 12A-12D and 13) at each tote filling position (e.g., at interface 263).

[0069] Referring to Figures 1, 2A, 2B, 7A, 7B, 9A, 9B, 12A-12D, 13, and 18, an exemplary method for transporting breakpack goods BPG for filling shipping totes or containers 264 is provided. The method includes the step (Figure 18, block 1800) of providing a goods bot (autonomous transport vehicle) 262 having a frame 262F and a payload bay 310 forming a tray connected to the frame 262F. The frame 262F is configured such that the goods bot 262 travels as a unit over at least one of the goods decks 130DG and ramps 130DGR, and the payload bay 310 holds the breakpack goods BPG loaded into the goods bot 262. The movement of the product bot 262 is brought over at least one of the product deck 130DG and ramp 130DGR (Figure 18, block 1810) so that the autonomous transport vehicle 262 can move freely via autonomous navigation from a first position (such as the breakpack station 140) to a different second position (such as the position of the breakpack product container 264 at interface 263), using a controller 262C connected to frame 262F, where the first position is the supply position of the product unit and the second position is the tote filling position based on the order. The end effector 262E formed by the tray opens the payload bay 310 (Figure 18, block 1820), engages with the payload bay 310, and moves it in a controllable manner, where the tray has sides 310W1 to 310W4 that are movably connected to the payload bay 310 so as to extend outward away from the frame 262F from a closed position that closes the payload bay 310 to an extended position that opens the payload bay 310, and the sides 310W1 to 310W4 of the tray form the end effector 262E.

[0070] Referring to Figures 1, 2A, 2B, 7A, 7B, 9A, 9B, 12A-12D, 13, and 19, an exemplary method for transporting breakpack goods BPG for filling shipping totes or containers is provided. The method includes the step (Figure 19, block 1900) of providing a goods bot (autonomous transport vehicle) 262 having a frame 262F and a payload bay 310 connected to the frame 262 for holding breakpack goods BPG loaded into the goods bot 262, wherein the frame 262F is configured so that the goods bot 262 travels as a unit over at least one of a goods deck (transport deck) 130DG and a ramp 130DGR, and the payload bay 310 holds the breakpack goods loaded into the goods bot 262. The movement of the product bot 262 is brought over at least one of the product deck 130DG and ramp 130DGR (Figure 19, block 1910) so that the product bot 262 can move freely via autonomous navigation from a first position (such as the break pack station 140) to a different second position (such as the position of the break pack product container 264 at interface 263), using a controller 262C connected to frame 262F, where the first position is the supply position of the break pack product BPG, and the second position is the tote filling position based on the order. The payload bay 310 is imaged using a vision system (at least one of sensors PS1 to PS8) having at least one camera (at least one of sensors PS1 to PS8) connected to frame 262F and operably connected to controller 262C (Figure 19, block 1920). The controller 262C registers images of the payload bay 310 from at least one camera (Figure 19, block 1930) and detects the presence of a breakpack product BPG in the payload bay 310 or identifies a breakpack product BPG from the images.

[0071] Referring to Figures 1, 2A, 2B, 7A, 7B, 9A, 9B, 12A-12D, 13, and 20, an exemplary method for transporting breakpack goods BPG for filling shipping totes or containers is provided. The method includes the step (Figure 20, block 2000) of providing a goods bot (autonomous transport vehicle) 262 having a frame 262F and a payload bay 310 connected to the frame 262 for holding breakpack goods BPG loaded into the goods bot 262, wherein the frame 262F is configured so that the goods bot 262 travels as a unit over at least one of a goods deck (transport deck) 130DG and a ramp 130DGR, and the payload bay 310 holds the breakpack goods loaded into the goods bot 262. The movement of the product bot is brought over at least one of the product deck 130DG and ramp 130DGR (Figure 20, block 2010) so that the product bot 262 can move freely via autonomous navigation from a first position (such as the break pack station 140) to a different second position (such as the position of the break pack product container 264 at interface 263), using a controller 262C connected to frame 262F, where the first position is the supply position of the break pack product BPG, and the second position is the tote filling position based on the order. The second position is imaged using at least one camera (at least one of sensors PS1-PS8) of the vision system (Figure 20, block 2020), where at least one camera (at least one of sensors PS1-PS8) is connected to the frame and operably connected to the controller 262C. Images from at least one camera (at least one of sensors PS1 to PS8) are registered using the controller 262C (Figure 20, block 2030), and the controller 262C detects the presence of the tote 264 at a second location from the images.

[0072] According to one or more aspects of the disclosed embodiments, an autonomous transport vehicle is provided for transporting merchandise units for filling shipping totes or containers. The autonomous transport vehicle includes a frame configured to travel as a unit over at least one of transport decks and ramps; a controller connected to the frame and configured to cause the movement of the autonomous transport vehicle over at least one of the transport decks and ramps so that the autonomous transport vehicle moves freely via autonomous navigation from a first position to a different second position, where the first position is a supply position for merchandise units and the second position is a tote filling position based on order; and a payload connected to the frame to hold merchandise units loaded onto the autonomous transport vehicle, wherein the payload has an end effector positioned to extend and unload merchandise units from the payload, the end effector forming a filling arrangement regulator, the filling arrangement regulator adjusting the arrangement of merchandise units to be unloaded when filling totes so that at each tote filling position, each tote is repeatedly filled to substantially a predetermined filling level by tote filling.

[0073] According to one or more embodiments of the disclosed embodiments, the filling arrangement regulator adjusts each tote filling in a common tote in a substantially independent manner of the size, shape, and quantity of each product unit.

[0074] According to one or more aspects of the disclosed embodiments, the end effector has at least one side wall for accommodating a payload, extends from a closed position to an open extended position, and has a position adjustment mechanism that contacts a product unit to offload the product unit and unloads the product unit from the payload.

[0075] According to one or more embodiments of the disclosed embodiments, the end effector has a position adjustment mechanism, which is configured to bias the product units of the tote filling during the extension or retraction of the end effector so as to adjust the tote filling of each tote to a substantially repeatable level.

[0076] According to one or more embodiments of the disclosed embodiments, an autonomous transport vehicle uses an end effector to bring about controllable filling of totes by tote filling of product units via a tote filling feedback device that responds to at least one of the filling level and arrangement of the tote filling.

[0077] According to one or more aspects of the disclosed embodiments, the autonomous transport vehicle further includes a tote filling feedback device that generates a feedback signal in response to at least one of the tote filling level and arrangement.

[0078] According to one or more embodiments of the disclosed embodiments, the tote filling feedback device is at least one of a camera that views the payload and a camera that views the tote at the tote filling position.

[0079] According to one or more aspects of the disclosed embodiments, the end effector filling placement regulator provides repeatable retraction of the end effector to a closed position in each placement of the product unit, independent of interference by tote filling in each placement.

[0080] According to one or more aspects of the disclosed embodiments, the end effector has a movable wall that moves with the retraction of the end effector to eliminate obstruction to each tote filling.

[0081] According to one or more embodiments of the disclosed embodiments, a method is provided for transporting merchandise units for filling shipping totes or containers. The method includes the steps of: providing an autonomous transport vehicle having a frame and a payload connected to the frame, wherein the frame is configured such that the autonomous transport vehicle, as a unit, travels over at least one of a transport deck and a ramp, and the payload holds a product unit loaded into the autonomous transport vehicle; using a controller connected to the frame, causing the autonomous transport vehicle to move over at least one of the transport deck and a ramp such that the autonomous transport vehicle moves freely via autonomous navigation from a first position to a different second position, where the first position is a product unit supply position and the second position is a tote filling position based on order; and unloading a product unit from a payload using an end effector of the payload, wherein the end effector extends and is positioned to unload the product unit from the payload, and the end effector forms a filling arrangement regulator, the filling arrangement regulator adjusting the arrangement of product units to be unloaded when filling totes such that at each tote filling position each tote is repeatedly filled to substantially a predetermined filling level by tote filling.

[0082] According to one or more embodiments of the disclosed embodiments, the method further includes the step of using a filling arrangement regulator to adjust each tote filling in a common tote in a manner substantially independent of the size, shape, and quantity of each product unit.

[0083] According to one or more aspects of the disclosed embodiments, the end effector has at least one side wall for accommodating a payload, and the method further includes the steps of extending the end effector from a closed position to an open extended position, and unloading the product unit from the payload using a position adjustment mechanism of the end effector that contacts the product unit to offload the product unit from the payload.

[0084] According to one or more embodiments of the disclosed embodiments, the method further includes the step of biasing the product units of the tote filling during the extension or retraction of the end effector to adjust the tote filling of each tote to a substantially repeatable level, using a position adjustment mechanism of the end effector positioned to act on the tote filling.

[0085] According to one or more embodiments of the disclosed embodiments, the method further includes a step of using an end effector of an autonomous transport vehicle to bring about controllable filling of totes by tote filling of a product unit via a tote filling feedback device that responds to at least one of the filling level and arrangement of the tote filling.

[0086] According to one or more embodiments of the disclosed embodiments, the method further includes the step of generating a feedback signal in response to at least one of the filling level and arrangement of the tote filling using a tote filling feedback device.

[0087] According to one or more embodiments of the disclosed embodiments, the tote filling feedback device is at least one of a camera that views the payload and a camera that views the tote at the tote filling position.

[0088] According to one or more aspects of the disclosed embodiments, the method further includes the step of using an end effector filling placement regulator to bring the end effector to a repeatable retraction to a closed position in each placement of the product unit, independent of interference by tote filling in each placement.

[0089] According to one or more aspects of the disclosed embodiments, the end effector has a movable wall that moves with the retraction of the end effector to eliminate obstruction to each tote filling.

[0090] According to one or more embodiments of the disclosed embodiments, an autonomous transport vehicle is provided for transporting merchandise units for filling shipping totes or containers. The autonomous transport vehicle includes a frame configured as a unit to travel over at least one transport deck and ramp; a controller connected to the frame and configured to cause the movement of the autonomous transport vehicle over at least one of the transport deck and ramp so that the autonomous transport vehicle moves freely via autonomous navigation from a first position to a different second position, the first position being a merchandise unit supply position and the second position being a tote filling position on order; and one or more handles connected to the frame, the one or more handles being shaped and sized for human transport of the autonomous transport vehicle.

[0091] According to one or more aspects of the disclosed embodiments, one or more handles are connected to the frame by retractable couplings.

[0092] According to one or more embodiments of the disclosed embodiments, the retractable connecting portion is one or more hinged connecting portions and sliding connecting portions.

[0093] According to one or more aspects of the disclosed embodiments, the autonomous transport vehicle further includes a payload connected to a frame for holding product units loaded into the autonomous transport vehicle, the payload having a fill placement regulator, the fill placement regulator adjusting the arrangement of product units to be unloaded when filling totes, such that at each tote filling position, each tote is repeatedly filled to substantially a predetermined filling level by tote filling.

[0094] According to one or more embodiments of the disclosed embodiments, the filling arrangement regulator adjusts each tote filling in a common tote in a substantially independent manner of the size, shape, and quantity of each product unit.

[0095] According to one or more aspects of the disclosed embodiments, the filling position regulator has at least one side wall for accommodating a payload, extends from a closed position to an open extended position, and has a position adjustment mechanism that contacts a product unit to offload the product unit and unloads the product unit from the payload.

[0096] According to one or more embodiments of the disclosed embodiments, the filling arrangement regulator has a position adjustment mechanism which acts on the tote filling to adjust the tote filling of each tote to a substantially repeatable filling level and is arranged to bias the product units of the tote filling during the extension or retraction of the filling arrangement regulator.

[0097] According to one or more embodiments of the disclosed embodiments, an autonomous transport vehicle uses a filling and placement regulator to bring about controllable filling of totes by tote filling of product units via a tote filling feedback device that responds to at least one of the filling level and placement of the tote filling.

[0098] According to one or more aspects of the disclosed embodiments, the autonomous transport vehicle further includes a tote filling feedback device that generates a feedback signal in response to at least one of the tote filling level and arrangement.

[0099] According to one or more embodiments of the disclosed embodiments, the tote filling feedback device is at least one of a camera that views the payload and a camera that views the tote at the tote filling position.

[0100] According to one or more aspects of the disclosed embodiments, the filling placement regulator provides for the repeated retraction of the end effector to a closed position in each placement of the product unit, regardless of interference by tote filling in each placement.

[0101] According to one or more embodiments of the disclosed embodiments, the filling arrangement regulator has a movable wall that moves with the retraction of the filling arrangement regulator to eliminate interference with each tote filling.

[0102] According to one or more aspects of the disclosed embodiments, a method is provided for transporting merchandise units for filling shipping totes or containers. The method includes the steps of: providing an autonomous transport vehicle having a frame and a payload connected to the frame, wherein the frame is configured such that the autonomous transport vehicle travels as a unit over at least one of transport decks and ramps, and the payload holds merchandise units loaded onto the autonomous transport vehicle; using a controller connected to the frame to cause the autonomous transport vehicle to move over at least one of the transport decks and ramps such that the autonomous transport vehicle moves freely via autonomous navigation from a first position to a different second position, where the first position is a merchandise unit supply position and the second position is a tote filling position on order; and transporting the autonomous transport vehicle using one or more handles connected to the frame, where the one or more handles are shaped and sized for human transport of the autonomous transport vehicle.

[0103] According to one or more aspects of the disclosed embodiments, one or more handles are connected to the frame by retractable couplings.

[0104] According to one or more embodiments of the disclosed embodiments, the retractable connecting portion is one or more hinged connecting portions and sliding connecting portions.

[0105] According to one or more embodiments of the disclosed embodiments, the method comprises the steps of using a filling arrangement regulator to adjust the arrangement of merchandise units to be unloaded when filling totes such that each tote at each tote filling position is repeatedly filled to substantially a predetermined filling level by tote filling, wherein the payload having the filling arrangement regulator is connected to a frame to hold the merchandise units loaded into an autonomous transport vehicle.

[0106] According to one or more embodiments of the disclosed embodiments, the filling arrangement regulator adjusts each tote filling in a common tote in a substantially independent manner of the size, shape, and quantity of each product unit.

[0107] According to one or more embodiments of the disclosed embodiments, the filling placement regulator has at least one side wall for accommodating a payload, and the method further includes the steps of extending the filling placement regulator from a closed position to an open extended position, and unloading the product unit from the payload using a position adjustment mechanism of the filling placement regulator that contacts the product unit to offload the product unit from the payload.

[0108] According to one or more embodiments of the disclosed embodiments, the method further includes the step of bringing a product unit of tote filling into the tote during the extension or retraction of the filling position regulator, using a position adjustment mechanism of the filling position regulator arranged to act on the tote filling, to adjust the tote filling of each tote to a substantially repeatable filling level.

[0109] According to one or more embodiments of the disclosed embodiments, the method further includes the step of using a filling and placement regulator of an autonomous transport vehicle to bring about controllable filling of totes by tote filling of a product unit via a tote filling feedback device that responds to at least one of the filling level and placement of the tote filling.

[0110] According to one or more embodiments of the disclosed embodiments, the method further includes the step of generating a feedback signal in response to at least one of the filling level and arrangement of the tote filling using a tote filling feedback device.

[0111] According to one or more embodiments of the disclosed embodiments, the tote filling feedback device is at least one of a camera that views the payload and a camera that views the tote at the tote filling position.

[0112] According to one or more embodiments of the disclosed embodiments, the method further includes the step of using a filling placement regulator to bring the end effector to a closed position in each placement of the product unit, independently of interference by tote filling in each placement.

[0113] According to one or more embodiments of the disclosed embodiments, the filling arrangement regulator has a movable wall that moves with the retraction of the filling arrangement regulator to eliminate interference with each tote filling.

[0114] According to one or more embodiments of the disclosed embodiments, an autonomous transport vehicle is provided for transporting product units for filling shipping totes or containers. The autonomous transport vehicle includes a frame configured as a unit to travel over at least one of transport decks and ramps, a controller connected to the frame and configured to cause the movement of the autonomous transport vehicle over at least one of the transport decks and ramps so that the autonomous transport vehicle can move freely via autonomous navigation from a first position to a different second position, the first position being a supply position for a product unit, and the second position being a tote-filling position based on an order, and a payload connected to the frame to hold a product unit loaded into the autonomous transport vehicle, the payload forming a tray having sides movably connected to the payload so as to extend outward away from the frame from a closed position that closes the payload to an extended position that opens the payload, the sides of the tray forming an end effector, the end effector opening and engaging with the payload as the tray extends to unload a product unit from the payload, thereby controlling the movement of the payload.

[0115] According to one or more embodiments of the disclosed embodiments, the sides of the tray are configured to extend and retract by sliding with at least one degree of freedom to open and close the payload.

[0116] According to one or more aspects of the disclosed embodiments, the side of the tray has a positioning edge that biases the tote filling to conform the tote filling to a substantially predetermined level.

[0117] According to one or more embodiments of the disclosed embodiments, a method is provided for transporting merchandise units for filling shipping totes or containers. The method provides an autonomous transport vehicle having a frame and a payload forming a tray connected to the frame, wherein the frame is configured such that the autonomous transport vehicle, as a unit, travels over at least one of a transport deck and a ramp, and the payload holds a product unit loaded into the autonomous transport vehicle; the method provides a method using a controller connected to the frame to cause the autonomous transport vehicle to move over at least one of the transport deck and a ramp such that the autonomous transport vehicle moves freely via autonomous navigation from a first position to a different second position, where the first position is a product unit supply position and the second position is a tote-filling position based on an order; and the method provides a method using an end effector formed by a tray to open and engage the payload and move the payload in a controllable manner, wherein the tray has sides that are movably connected to the payload such that it extends outward away from the frame from a closed position that closes the payload to an extended position that opens the payload, and the sides of the tray form an end effector.

[0118] According to one or more embodiments of the disclosed embodiments, the sides of the tray slide with at least one degree of freedom to extend and retract the sides of the tray to open and close the payload.

[0119] According to one or more embodiments of the disclosed embodiments, the method further includes the step of using a positioning edge on the side of the tray to bias the tote filling so that the tote filling conforms substantially to a predetermined level.

[0120] According to one or more aspects of the disclosed embodiments, an autonomous transport vehicle is provided for transporting merchandise units for filling shipping totes or containers. The autonomous transport vehicle includes a frame configured as a unit to travel over at least one transport deck and ramp; a controller connected to the frame and configured to cause the movement of the autonomous transport vehicle over at least one of the transport deck and ramp so that the autonomous transport vehicle moves freely via autonomous navigation from a first position to a different second position, the first position being a supply position for merchandise units and the second position being a tote filling position based on an order; a payload connected to the frame to hold merchandise units loaded into the autonomous transport vehicle; and a vision system connected to the frame and operably connected to the controller, the vision system having at least one camera, the at least one camera positioned to image the payload, and the controller configured to register images of the payload from the at least one camera and to detect the presence of merchandise units in the payload or to identify merchandise units from the images.

[0121] According to one or more aspects of the disclosed embodiments, the controller is configured to determine the suitability of the payload to predetermined load conditions based on the order, based on the detected presence or identification, and to initialize different transport commands based on the suitability or non-suitability determination.

[0122] According to one or more embodiments of the disclosed embodiments, the controller is configured to transmit a communication signal to an operator or management system that represents or corresponds to a conformance or nonconformance determination.

[0123] According to one or more embodiments of the disclosed embodiments, a method is provided for transporting merchandise units for filling shipping totes or containers. The method includes the steps of: providing an autonomous transport vehicle having a frame and a payload connected to the frame for holding merchandise units loaded onto the autonomous transport vehicle, wherein the frame is configured such that the autonomous transport vehicle travels as a unit over at least one of transport decks and ramps, and the payload holds merchandise units loaded onto the autonomous transport vehicle; using a controller connected to the frame to cause the autonomous transport vehicle to move over at least one of the transport decks and ramps such that the autonomous transport vehicle moves freely via autonomous navigation from a first position to a different second position, where the first position is a merchandise unit supply position and the second position is a tote filling position based on an order; imaging the payload using a vision system having at least one camera connected to the frame and operably connected to the controller; and using the controller to register an image of the payload from at least one camera and to detect the presence of merchandise units in the payload or to identify merchandise units from the image.

[0124] According to one or more embodiments of the disclosed embodiments, the method further includes using a controller to determine the suitability of a payload to predetermined load conditions based on an order, based on the detected presence or identification, and to initialize different transport commands based on the suitability or non-suitability determination.

[0125] According to one or more embodiments of the disclosed embodiments, the method further includes the step of using a controller to transmit a communication signal to an operator or a management system that represents a conformity or nonconformity determination, or that corresponds to a conformity or nonconformity determination.

[0126] According to one or more aspects of the disclosed embodiments, an autonomous transport vehicle is provided for transporting merchandise units for filling shipping totes or containers. The autonomous transport vehicle includes a frame configured as a unit to travel over at least one transport deck and ramp; a controller connected to the frame and configured to cause the autonomous transport vehicle to move over at least one of the transport deck and ramp so that the autonomous transport vehicle moves freely via autonomous navigation from a first position to a different second position, the first position being a supply position for merchandise units and the second position being a tote filling position based on an order; a payload connected to the frame to hold merchandise units loaded into the autonomous transport vehicle; and a vision system connected to the frame and operably connected to the controller, the vision system having at least one camera positioned to image a second position, and the controller configured to register images from the at least one camera and to detect the presence of totes at the second position from the images.

[0127] According to one or more aspects of the disclosed embodiments, the controller is configured to determine, based on the detected presence, whether the product unit at a second location is compatible with predetermined unloading conditions, and to select whether to unload or retain the product unit in the payload based on the compatibility or non-compliance determination.

[0128] According to one or more embodiments of the disclosed embodiments, the controller is configured to transmit a communication signal to an operator or management system that represents or corresponds to a conformance or nonconformance determination.

[0129] According to one or more embodiments of the disclosed embodiments, a method is provided for transporting merchandise units for filling shipping totes or containers. The method includes the steps of: providing an autonomous transport vehicle having a frame and a payload connected to the frame for holding merchandise units loaded onto the autonomous transport vehicle, wherein the frame is configured such that the autonomous transport vehicle travels as a unit over at least one of transport decks and ramps, and the payload holds merchandise units loaded onto the autonomous transport vehicle; using a controller connected to the frame to cause the autonomous transport vehicle to move over at least one of the transport decks and ramps such that the autonomous transport vehicle moves freely via autonomous navigation from a first position to a different second position, where the first position is a merchandise unit supply position and the second position is a tote filling position based on order; imaging the second position using at least one camera of a vision system, where at least one camera is connected to the frame and operably connected to a controller; and using the controller to register images from at least one camera and to detect the presence of totes at the second position from the images.

[0130] According to one or more aspects of the disclosed embodiments, the method further includes using a controller to determine, based on the detected presence, whether the product unit at a second location is suitable for a predetermined unload condition, and to select whether to unload or retain the product unit in the payload based on the suitability or unsuitability determination.

[0131] According to one or more embodiments of the disclosed embodiments, the method further includes the step of using a controller to transmit a communication signal to an operator or a management system that represents a conformity or nonconformity determination, or that corresponds to a conformity or nonconformity determination.

[0132] It should be understood that the foregoing description is merely illustrative of the aspects of the disclosed embodiments. Various substitutions and modifications can be attempted by those skilled in the art without departing from the aspects of the disclosed embodiments. Accordingly, the aspects of the disclosed embodiments are intended to encompass all such substitutions, modifications, and variations within the scope of any claims appended herein. Furthermore, the mere fact that different features are described in different dependent or independent claims does not imply that combinations of these features cannot be used to their advantage, or that such combinations remain within the scope of the disclosed embodiments.

Claims

1. An autonomous transport vehicle for transporting product units for filling shipping totes or containers, wherein the autonomous transport vehicle is The autonomous transport vehicle comprises a frame configured to travel over at least one of a transport deck and a ramp as a unit, A controller connected to the frame and configured to cause the autonomous transport vehicle to move on at least one of the transport deck and the ramp so that the autonomous transport vehicle can move freely from a first position to a different second position via autonomous navigation, wherein the first position is the supply position of the product unit and the second position is the tote filling position based on the order, A payload connected to the frame for holding the product units loaded onto the autonomous transport vehicle, wherein the payload has an end effector positioned to extend and unload the product units from the payload, the end effector forming a filling arrangement regulator, the filling arrangement regulator adjusting the arrangement of the product units to be unloaded when filling totes, such that at each tote filling position, each tote is repeatedly filled to substantially a predetermined filling level by tote filling, the payload and An autonomous transport vehicle equipped with [the following features].

2. The autonomous transport vehicle according to claim 1, wherein the filling arrangement regulator adjusts each tote filling in a common tote in a manner substantially independent of the size, shape, and quantity of each product unit.

3. The end effector has at least one side wall for accommodating the payload, The end effector extends from a closed position to an open extended position, The autonomous transport vehicle according to claim 1, wherein the end effector has a position adjustment mechanism that contacts the product unit to offload the product unit and unloads the product unit from the payload.

4. The autonomous transport vehicle according to claim 1, wherein the end effector has a position adjustment mechanism, the position adjustment mechanism acts on the tote filling to adjust the tote filling of each tote to a substantially repeatable level of filling, and is arranged to bias the product unit of the tote filling while the end effector is extended or retracted.

5. The autonomous transport vehicle according to claim 1, wherein the autonomous transport vehicle uses the end effector to bring about controllable filling of the tote by tote filling of product units via a tote filling feedback device that responds to at least one of the filling level and arrangement of the tote filling.

6. The autonomous transport vehicle according to claim 1, further comprising a tote filling feedback device that generates a feedback signal in response to at least one of the filling level and arrangement of the tote filling.

7. The autonomous transport vehicle according to claim 6, wherein the tote filling feedback device is at least one of a camera for viewing the payload and a camera for viewing the tote at the tote filling position.

8. The autonomous transport vehicle according to claim 1, wherein the filling placement regulator of the end effector causes the end effector to repeatedly retract to a closed position in each placement of the product unit, independently of interference by the tote filling in each placement.

9. The autonomous transport vehicle according to claim 1, wherein the end effector has a movable wall that moves with the retraction of the end effector to eliminate interference with the filling of each tote.

10. A method for transporting product units for filling shipping totes or containers, wherein the method is A step of providing an autonomous transport vehicle having a frame and a payload connected to the frame, wherein the frame is configured such that the autonomous transport vehicle, as a unit, travels over at least one of a transport deck and a ramp, and the payload holds a product unit loaded into the autonomous transport vehicle. A step of using a controller connected to the frame to cause the autonomous transport vehicle to move on at least one of the transport deck and the ramp so that the autonomous transport vehicle can move freely from a first position to a different second position via autonomous navigation, wherein the first position is the supply position of the product unit, and the second position is the tote filling position based on the order. A step of unloading the product units from the payload using the payload's end effector, wherein the end effector extends and is positioned to unload the product units from the payload, the end effector forms a filling arrangement regulator, and the filling arrangement regulator adjusts the arrangement of the product units to be unloaded when filling totes such that each tote is repeatedly filled to a substantially predetermined filling level by tote filling at each tote filling position. Methods that include...

11. The method according to claim 10, further comprising the step of using the filling arrangement regulator to adjust each tote filling in a common tote in a manner substantially independent of the size, shape, and quantity of each product unit.

12. The end effector has at least one side wall for accommodating the payload, and the method The process of extending the end effector from a closed position to an open extended position, A step of unloading the product unit from the payload using a position adjustment mechanism of the end effector that contacts the product unit so as to offload the product unit from the payload, The method according to claim 10, further comprising:

13. The method according to claim 10, further comprising the step of biasing the product unit of the tote filling while the end effector is extended or retracted, using a position adjustment mechanism of the end effector positioned to act on the tote filling, to adjust the tote filling of each tote to a substantially repeatable level.

14. The method according to claim 10, further comprising the step of using the end effector of the autonomous transport vehicle to bring about controllable filling of the tote by the tote filling of a product unit via a tote filling feedback device that responds to at least one of the filling level and arrangement of the tote filling.

15. The method according to claim 10, further comprising the step of generating a feedback signal in response to at least one of the filling level and arrangement of the tote filling using a tote filling feedback device.

16. The method according to claim 6, wherein the tote filling feedback device is at least one of a camera for viewing the payload and a camera for viewing the tote at the tote filling position.

17. The method according to claim 10, further comprising the step of using the filling placement regulator of the end effector to bring the end effector to a repeatable retraction to a closed position in each placement of the product unit, independently of interference by the tote filling in each placement.

18. The method according to claim 10, wherein the end effector has a movable wall that moves with the retraction of the end effector to eliminate interference with each tote filling.

19. An autonomous transport vehicle for transporting product units for filling shipping totes or containers, wherein the autonomous transport vehicle is The autonomous transport vehicle comprises a frame configured to travel over at least one of a transport deck and a ramp as a unit, A controller connected to the frame and configured to cause the autonomous transport vehicle to move on at least one of the transport deck and the ramp so that the autonomous transport vehicle can move freely from a first position to a different second position via autonomous navigation, wherein the first position is the supply position of the product unit and the second position is the tote filling position based on the order, One or more handles connected to the frame, wherein the one or more handles are shaped and sized for human transport of the autonomous transport vehicle, An autonomous transport vehicle equipped with [the following features].

20. The autonomous transport vehicle according to claim 19, wherein one or more handles are connected to the frame by a retractable connecting portion.

21. The autonomous transport vehicle according to claim 19, wherein the retractable connecting portion is one or more hinged connecting portions and sliding connecting portions.

22. The autonomous transport vehicle according to claim 19, further comprising a payload connected to the frame for holding the product units loaded into the autonomous transport vehicle, wherein the payload has a filling arrangement regulator, the filling arrangement regulator adjusts the arrangement of the product units to be unloaded when filling totes, such that at each tote filling position, each tote is repeatedly filled to substantially a predetermined filling level by tote filling.

23. The autonomous transport vehicle according to claim 22, wherein the filling arrangement regulator adjusts each tote filling in a common tote in a manner substantially independent of the size, shape, and quantity of each product unit.

24. The filling arrangement regulator has at least one side wall that accommodates the payload, The aforementioned packing arrangement regulator extends from a closed position to an open extended position. The autonomous transport vehicle according to claim 22, wherein the filling and positioning regulator has a position adjustment mechanism that contacts the product unit to offload the product unit and unloads the product unit from the payload.

25. The autonomous transport vehicle according to claim 22, wherein the filling arrangement regulator has a position adjustment mechanism, which acts on the tote filling to adjust the tote filling of each tote to a substantially repeatable filling level, and is arranged to bias the product unit of the tote filling while the filling arrangement regulator is extended or retracted.

26. The autonomous transport vehicle according to claim 22, wherein the autonomous transport vehicle uses the filling and placement regulator to bring about controllable filling of the tote by the tote filling of product units via a tote filling feedback device that responds to at least one of the filling level and placement of the tote filling.

27. The autonomous transport vehicle according to claim 22, further comprising a tote filling feedback device that generates a feedback signal in response to at least one of the filling level and arrangement of the tote filling.

28. The autonomous transport vehicle according to claim 27, wherein the tote filling feedback device is at least one of a camera for viewing the payload and a camera for viewing the tote at the tote filling position.

29. The autonomous transport vehicle according to claim 22, wherein the filling arrangement regulator causes the end effector to repeatedly retract to a closed position in each arrangement of the product unit, independently of interference by the tote filling in each arrangement.

30. The autonomous transport vehicle according to claim 22, wherein the filling arrangement regulator has a movable wall that moves with the retraction of the filling arrangement regulator to eliminate interference with the filling of each tote.

31. A method for transporting product units for filling shipping totes or containers, wherein the method is A step of providing an autonomous transport vehicle having a frame and a payload connected to the frame, wherein the frame is configured such that the autonomous transport vehicle, as a unit, travels over at least one of a transport deck and a ramp, and the payload holds a product unit loaded into the autonomous transport vehicle. A step of using a controller connected to the frame to cause the autonomous transport vehicle to move on at least one of the transport deck and the ramp so that the autonomous transport vehicle can move freely from a first position to a different second position via autonomous navigation, wherein the first position is the supply position of the product unit, and the second position is the tote filling position based on the order. A step of transporting the autonomous transport vehicle using one or more handles connected to the frame, wherein the one or more handles are shaped and sized for human transport of the autonomous transport vehicle; Methods that include...

32. The method according to claim 31, wherein one or more handles are connected to the frame by a retractable connecting portion.

33. The method according to claim 31, wherein the retractable connecting portion is one or more hinged connecting portions and sliding connecting portions.

34. The method according to claim 31, further comprising the steps of adjusting the arrangement of the merchandise units to be unloaded when filling totes, using a filling arrangement regulator, such that each tote at each tote filling position is repeatedly filled to substantially a predetermined filling level by tote filling, wherein the payload having the filling arrangement regulator is connected to the frame to hold the merchandise units loaded into the autonomous transport vehicle.

35. The method according to claim 34, wherein the filling arrangement regulator adjusts each tote filling in a common tote in a manner substantially independent of the size, shape, and quantity of each product unit.

36. The filling arrangement regulator has at least one side wall that accommodates the payload, and the method The process of extending the aforementioned filling arrangement regulator from a closed position to an open extended position, A step of unloading the product unit from the payload using a position adjustment mechanism of the filling and placement regulator that contacts the product unit so as to offload the product unit from the payload, The method according to claim 34, further comprising:

37. The method according to claim 34, further comprising the step of bringing the product units of the tote filling into the tote while the filling position regulator is extended or retracted, using a position adjustment mechanism for the filling position regulator that is positioned to act on the tote filling, to adjust the tote filling of each tote to a substantially repeatable level of filling.

38. The method according to claim 34, further comprising the step of using the filling and placement regulator of the autonomous transport vehicle to bring about controllable filling of the tote by the tote filling of a product unit via a tote filling feedback device that responds to at least one of the filling level and placement of the tote filling.

39. The method according to claim 34, further comprising the step of generating a feedback signal in response to at least one of the filling level and arrangement of the tote filling using a tote filling feedback device.

40. The method according to claim 39, wherein the tote filling feedback device is at least one of a camera for viewing the payload and a camera for viewing the tote at the tote filling position.

41. The method according to claim 34, further comprising the step of using the filling placement regulator to bring the end effector to a closed position in each placement of the product unit, independently of interference by the tote filling in each placement.

42. The method according to claim 34, wherein the filling arrangement regulator has a movable wall that moves with the retraction of the filling arrangement regulator to eliminate interference with each tote filling.

43. An autonomous transport vehicle for transporting product units for filling shipping totes or containers, wherein the autonomous transport vehicle is The autonomous transport vehicle comprises a frame configured to travel over at least one of a transport deck and a ramp as a unit, A controller connected to the frame and configured to cause the autonomous transport vehicle to move on at least one of the transport deck and the ramp so that the autonomous transport vehicle can move freely from a first position to a different second position via autonomous navigation, wherein the first position is the supply position of the product unit and the second position is the tote filling position based on the order, A payload connected to the frame for holding the product unit loaded onto the autonomous transport vehicle, wherein the payload forms a tray having sides movably connected to the payload so as to extend outward away from the frame from a closed position that closes the payload to an extended position that opens the payload, the sides of the tray forming an end effector, the end effector opening the payload and engaging with the payload as the tray extends to unload the product unit from the payload, and controllingly moving the payload, An autonomous transport vehicle equipped with [the following features].

44. The autonomous transport vehicle according to claim 43, wherein the side portion of the tray is configured to extend and retract the side portion of the tray by sliding with at least one degree of freedom to open and close the payload.

45. The autonomous transport vehicle according to claim 43, wherein the side portion of the tray has a position adjustment edge that biases the tote filling to conform the tote filling to a substantially predetermined level.

46. A method for transporting product units for filling shipping totes or containers, wherein the method is A step of providing an autonomous transport vehicle having a frame and a payload forming a tray connected to the frame, wherein the autonomous transport vehicle, as a unit, travels over at least one of a transport deck and a ramp, and the frame is configured such that the tray holds a product unit loaded onto the autonomous transport vehicle. A step of using a controller connected to the frame to cause the autonomous transport vehicle to move on at least one of the transport deck and the ramp so that the autonomous transport vehicle can move freely from a first position to a different second position via autonomous navigation, wherein the first position is the supply position of the product unit, and the second position is the tote filling position based on the order. A step of opening the payload, engaging with the payload, and controllingly moving the payload using an end effector formed by the tray, wherein the tray has a side portion movably connected to the payload so as to extend outward away from the frame from a closed position that closes the payload to an extended position that opens the payload, and the side portion of the tray forms the end effector. Methods that include...

47. The method according to claim 46, wherein the side portion of the tray slides with at least one degree of freedom to extend and retract the side portion of the tray in order to open and close the payload.

48. The method according to claim 46, further comprising the step of biasing the tote filling to conform the tote filling to a substantially predetermined level using the positioning edge on the side of the tray.

49. An autonomous transport vehicle for transporting product units for filling shipping totes or containers, wherein the autonomous transport vehicle is The autonomous transport vehicle comprises a frame configured to travel over at least one of a transport deck and a ramp as a unit, A controller connected to the frame and configured to cause the autonomous transport vehicle to move on at least one of the transport deck and the ramp so that the autonomous transport vehicle can move freely from a first position to a different second position via autonomous navigation, wherein the first position is the supply position of the product unit and the second position is the tote filling position based on the order, A payload connected to the frame for holding the product unit loaded onto the autonomous transport vehicle, A vision system comprising at least one camera connected to the frame and operably connected to the controller, wherein the at least one camera is positioned to image the payload, and the controller is configured to register images of the payload from the at least one camera and to detect the presence of the product unit in the payload or to identify the product unit from the images, An autonomous transport vehicle equipped with [the following features].

50. The autonomous transport vehicle according to claim 49, wherein the controller is configured to determine the suitability of the payload to predetermined load conditions based on the order, based on the detected presence or identification, and to initialize different transport commands based on the suitability or non-suitability determination.

51. The autonomous transport vehicle according to claim 49, wherein the controller is configured to transmit a communication signal to an operator or management system that indicates a determination of conformity or non-conformity, or that corresponds to a determination of conformity or non-conformity.

52. A method for transporting product units for filling shipping totes or containers, wherein the method is A step of providing an autonomous transport vehicle having a frame and a payload connected to the frame for holding the product unit loaded onto the autonomous transport vehicle, wherein the frame is configured such that the autonomous transport vehicle, as a unit, travels over at least one of a transport deck and a ramp, and the payload holds the product unit loaded onto the autonomous transport vehicle. A step of using a controller connected to the frame to cause the autonomous transport vehicle to move on at least one of the transport deck and the ramp so that the autonomous transport vehicle can move freely from a first position to a different second position via autonomous navigation, wherein the first position is the supply position of the product unit, and the second position is the tote filling position based on the order. A step of imaging the payload using a vision system having at least one camera connected to the frame and operably connected to the controller, Using the controller, register an image of the payload from at least one camera, and from the image, detect the presence of the product unit in the payload or identify the product unit. Methods that include...

53. The method according to claim 52, further comprising the steps of using the controller to determine the suitability of the payload to predetermined load conditions based on the order, based on the detected presence or identification, and initializing different transport commands based on the determination of suitability or non-suitability.

54. The method according to claim 52, further comprising the step of using the controller to transmit a communication signal to an operator or management system that indicates a determination of conformity or nonconformity, or that corresponds to a determination of conformity or nonconformity.

55. An autonomous transport vehicle for transporting product units for filling shipping totes or containers, wherein the autonomous transport vehicle is The autonomous transport vehicle comprises a frame configured to travel over at least one of a transport deck and a ramp as a unit, A controller connected to the frame and configured to cause the autonomous transport vehicle to move on at least one of the transport deck and the ramp so that the autonomous transport vehicle can move freely from a first position to a different second position via autonomous navigation, wherein the first position is the supply position of the product unit and the second position is the tote filling position based on the order, A payload connected to the frame for holding the product unit loaded onto the autonomous transport vehicle, A vision system comprising at least one camera connected to the frame and operably connected to the controller, wherein the at least one camera is positioned to capture images of the second position, and the controller is configured to register images from the at least one camera and to detect the presence of a tote at the second position from the images. An autonomous transport vehicle equipped with [the following features].

56. The autonomous transport vehicle according to claim 55, wherein the controller is configured to determine, based on the detected presence, whether the product unit at the second position is compatible with predetermined unloading conditions, and to select whether to unload or retain the product unit in the payload based on the determination of compatibility or incompatibility.

57. The autonomous transport vehicle according to claim 55, wherein the controller is configured to transmit a communication signal to an operator or management system that indicates a conformity or non-conformity determination, or that corresponds to a conformity or non-conformity determination.

58. A method for transporting product units for filling shipping totes or containers, wherein the method is A step of providing an autonomous transport vehicle having a frame and a payload connected to the frame for holding the product unit loaded onto the autonomous transport vehicle, wherein the frame is configured such that the autonomous transport vehicle, as a unit, travels over at least one of a transport deck and a ramp, and the payload holds the product unit loaded onto the autonomous transport vehicle. A step of using a controller connected to the frame to cause the autonomous transport vehicle to move on at least one of the transport deck and the ramp so that the autonomous transport vehicle can move freely from a first position to a different second position via autonomous navigation, wherein the first position is the supply position of the product unit, and the second position is the tote filling position based on the order. A step of imaging the second position using at least one camera of a visual system, wherein the at least one camera is connected to the frame and operably connected to the controller, The process involves registering images from at least one camera using the controller and detecting the presence of a tote at a second location from the images, Methods that include...

59. The method according to claim 58, further comprising the steps of using the controller to determine, based on the detected presence, whether the product unit at the second position is compatible with predetermined unloading conditions, and selecting whether to unload or retain the product unit in the payload based on the determination of compatibility or incompatibility.

60. The method according to claim 58, further comprising the step of using the controller to transmit a communication signal to an operator or management system that indicates a determination of conformity or nonconformity, or that corresponds to a determination of conformity or nonconformity.

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