Container handling system

Abstract

A system for handling containers and a method for supplying inventory to a fulfillment center in a warehouse or any other location where order fulfillment or delivery of orders, e.g., grocery orders, occurs. The system comprises at least one mobile inventory carrier for storing the containers, a mini-load system with a gripping mechanism for picking up or releasing the containers from the mobile inventory carrier, and an autonomous mobile robotic unit, where the mini-load system, the mobile inventory carrier, and the autonomous mobile robotic unit(s) are separate units and operate independently of each other.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to European Patent Application No. 20217951.1, filed December 31, 2020, the contents of which are incorporated herein by reference in their entirety. [Technical field]

[0002] The present disclosure relates to a system for handling containers, a method for supplying inventory, and uses of said system. [Background technology]

[0003] Over the past two decades, the exponential proliferation of the Internet and the phenomenal increase in e-commerce facilitated by the use of smartphones have profoundly changed the way products are transported from retailers to end customers.

[0004] For decades, this has been done the traditional way: pallets of goods were transported from a production site or wholesaler to a retailer's warehouse. From there, the goods were transferred to the store, usually in the form of mixed pallets (i.e., pallets constructed from boxes, each box containing a unique stock keeping unit (SKU). At the store, the pallets were disassembled and the boxes were put away in the store's warehouse. Finally, the products were placed on the store's shelves, from which the customer picked them up.

[0005] The sudden emergence of electronic commerce has disrupted this decades-old product distribution model, and it is now retailers who must accomplish the picking and packing of ordered items for ultimate delivery to customers.

[0006] These dramatic changes in distribution models have resulted in a significant increase in picking and packing costs, since item-picking labor is much higher than pallet or box-picking labor. Also, handling of boxes and containers in warehouses is more frequent and complicated. These costs are usually passed on to retailers, since customers are very reluctant to pay higher prices when purchasing goods online.

[0007] This problem is even greater in grocery e-commerce, which is the largest segment of the retail market (40%-50% of the total retail market), for the following reasons: -The average number of items per online order is much higher than the rest of the retail sector (around 50 items per average online order). -There is an additional need to maintain multiple temperature zones for perishable items. -Finally, the grocery industry operates on slim margins (typically <2%), which makes it very difficult for the industry to bear the cost of the required investments in infrastructure to reduce picking, packing, and shipping costs and allow online grocery to enjoy a positive bottom line.

[0008] All the above mentioned difficulties have prompted the emergence of innovative material handling systems based on autonomous robotic vehicles that are also equipped with container handling systems. These combined machines are able to move freely in the aisles of the warehouse, pick up containers with products from the shelves, temporarily store the containers on their built-in storage racks and transfer the containers to designated points in the warehouse for further processing (WO2017 / 121747, WO2018 / 234155), while other systems, as for example described in US201514719196, propose similar systems but are able to transport one container at a time.

[0009] A fundamental drawback of these conventional systems is that the robotic machines they propose can only interact (pick up or store) with containers that are directly accessible from the aisle in front of the shelf, which has the drawback that a large area of ​​the warehouse must be used as aisles, thus reducing the area that can be used to shelve / store containers.

[0010] Another drawback of these conventional systems is the fact that the autonomous mobile robot (AMR) unit and the container handling system are securely joined on the same platform and as long as one of them is involved in the process, the other part remains inactive, which limits the utilization time of each part. For example, when the battery of the autonomous mobile robot needs to remain connected to the battery recharging station, at the same time, the container handling system remains inactive. In another example, when the system needs to park at a fulfillment station and supply stock donor containers to an operator, the autonomous mobile robot of the machine cannot stay at the station and perform as long as this task is performed. Furthermore, if either part fails, the other part will also fail, which constitutes a single point of failure system.

[0011] Other systems, such as those described in EP 0235488 and EP 0458722, teach even more rigid robotic machines in the sense that all of their components, i.e. the autonomous mobile robot, the container handling system and the storage rack, are rigidly joined onto the same platform.

[0012] US2017330269A1 discloses a method for managing inventory carriers using mobile robotic units (MRUs) in a pod configured to receive online orders at a replenishment station for pickup by a customer at a delivery station. Such a method includes receiving, by the mobile robotic units, an instruction identifying a first inventory carrier, moving the mobile robotic unit to a location of the identified inventory carrier, and transporting, using the mobile robotic units, the identified inventory carrier to the replenishment station for pickup by a delivery vehicle.

[0013] US10029851B1 describes an inventory system having a plurality of inventory holders and a drive unit for moving the inventory holders. The document discloses the operation of the inventory system to facilitate splitting of inventory handling between automated and manual options, such as between routing inventory items to be extracted from the containers by a human operator or by a robotic manipulator, using bins and / or other features.

[0014] WO2017197285A1 discloses a method for delivering online orders to customers through a fully unmanned system. Such a method includes refilling pods by using inventory carriers carrying containers through a refill hatch and moving the inventory carriers attached to a carrier base by a mobile robot unit in a room with a suitable temperature. In addition, the method includes transporting the inventory carriers at a mini-load station and loading order containers onto a delivery carrier. The method further includes transporting the delivery carrier and attaching it to the delivery hatch so that a customer can pull the drawer following authentication and pick the ordered items.

[0015] WO2019083199A1 describes a product transport system that combines an autonomous combination picking and sorting operation model and operation method using a robot. The product transport system of that document comprises at least one transport cart including a plurality of cells in which products are loaded, and a picking robot capable of moving the products loaded on the transport cart, where the picking robot receives information about the products allocated to the plurality of cells and rearranges the products or compensates for shortages of products.

[0016] There is a need for a fully automated system having one or more autonomous mobile robots that help to carry out all the processes required to optimally fulfill orders placed online by customers. Summary of the Invention

[0017] The present disclosure pertains to a system for handling containers and a method and use of the system for supplying inventory to a fulfillment center in a warehouse or any other location where order fulfillment or delivery of orders, e.g., grocery orders, occurs.

[0018] According to an aspect of the present disclosure, a system for handling containers is provided comprising at least one mobile inventory carrier for storing containers, a mini load system comprising a gripping mechanism for picking up or releasing containers from the at least one mobile inventory carrier, and at least one autonomous mobile robotic unit, wherein the mini load system, the at least one mobile inventory carrier, and the at least one autonomous mobile robotic unit are separate units and operate independently of each other.

[0019] In another aspect of the present disclosure, at least one mobile inventory carrier is freely stationed in a work area and at least one autonomous mobile robotic unit is configured to lift and / or rotate the mobile inventory carrier.

[0020] According to another aspect of the present disclosure, at least one autonomous mobile robotic unit is configured to transport at least one mobile inventory carrier within a work area.

[0021] In another aspect, the mini load system includes a pedestal, the at least one mobile inventory carrier is mounted on the pedestal, and the at least one autonomous mobile robotic unit is configured to move the mini load system and the at least one mobile inventory carrier together within the work area.

[0022] In another aspect, the mini load system includes a rack system including a rack frame, a pair of rack joints for movement on the Z-axis and the X-axis, and a container handler (101e) capable of moving in the Y-axis and rotating on the XY plane.

[0023] In another aspect, the gripping mechanism of the mini-loading system comprises at least one camera and at least one lighting means configured to identify angular and / or linear deviations of the mobile inventory carrier (107) and thereby guide the movement of the pair of platform joints (101c, 101d) and the container handler (101e). In another aspect, the at least one camera and at least one lighting means are configured to generate a streaming video.

[0024] In another embodiment, the at least one mobile inventory carrier is lifted by the autonomous mobile robotic unit and placed on a pedestal-type mini-load pedestal, and the autonomous mobile robotic unit can then propel itself down, raising both the mini-load and the at least one mobile inventory carrier and moving them around the work area.

[0025] In another embodiment, the first pedestal includes a rail and one or more wheels coupled to the rail.

[0026] In another aspect of the present disclosure, the autonomous mobile robotic unit is wireless and includes an integral rechargeable battery.

[0027] In another aspect of the present disclosure, an integrated rechargeable battery of the autonomous mobile robotic unit provides power to the mini road system.

[0028] According to another aspect of the present disclosure, there is provided a method for supplying inventory to a fulfillment station, the method comprising: a) transporting a first mobile inventory carrier having one or more filled donor containers by a first autonomous mobile robotic unit from an inventory area of ​​a fulfillment center to an exchange point; b) loading one or more donor containers from the first mobile inventory carrier by the mini-load system onto a second mobile inventory carrier disposed on a pedestal of the mini-load system, where the second mobile inventory carrier is empty prior to loading; c) repeating steps a and b until the second mobile inventory carrier is completely loaded with the donor inventory container; d) transporting the loaded second mobile inventory carrier by the autonomous mobile robotic unit to a picking station at a fulfillment center; e) transferring a second mobile inventory carrier onto a pedestal of a mini-load system servicing the picking station; f) selecting a first donor container from a second mobile inventory carrier with a mini load gripper and delivering the first donor container to an operator; g) selecting by an operator at least one item from the first donor container and placing it in the order container; Steps f and g are repeated until the operator has selected items from all donor receptacles and placed them in the designated order receptacles.

[0029] In another aspect of the present disclosure, a method for supplying inventory includes: - the autonomous mobile robotic unit arriving at a picking station of a fulfillment center; - a second mobile inventory carrier is lifted by the autonomous mobile robot unit from a pedestal of the mini-load system servicing the picking station; the autonomous mobile robotic unit returning the second mobile inventory carrier to the inventory area of ​​the fulfillment center and placing it on another mini-load system pedestal; Equipped with.

[0030] In another aspect of the present disclosure, the autonomous mobile robot automatically goes to a charging station to be recharged when it is not engaged in a process or when its battery is depleted at a very low level.

[0031] In another embodiment, there is provided a use of the system for handling containers in a fulfillment center.

[0032] The first advantage of having separate units that operate independently of each other is that if any component of the system fails, it can be replaced by another similar component and operate smoothly with the other two components, thus avoiding a single point of failure as well as achieving increased utilization of each and every component. Thus, having a failed unit does not necessarily cause other components of the system to fail. Furthermore, when the autonomous mobile robot unit is recharged, its battery does not impede the operation of the mini-load while the recharge is taking place.

[0033] Additionally, when a mobile inventory carrier has to be transported from point A to point B within the operating area, only the autonomous mobile robotic unit is needed to perform that operation, while the mini-load system can simultaneously operate at another spot, for example a picking station handling donor containers, or can cooperate with another autonomous mobile robotic unit to perform one of the processes offered.

[0034] This freedom in operation of the system's main components, namely the autonomous mobile robotic units, the miniloads, and the mobile inventory carriers, results in increased utilization, resulting in less resource demands for a given level of throughput.

[0035] In addition, the massively parallel operation of the system significantly reduces temporary outages due to machine failures. It is advantageous to have continuous operation, since temporary outages, which are the case with legacy systems with single points of failure, can cause significant delays in the delivery of orders and force the input of additional manpower, thus resulting in an overall increase in costs and questionable quality of the system.

[0036] The term "container" as described herein in this disclosure should be construed by one of ordinary skill in the art to comprise a variety of options of objects suitable for hosting inventory, which may be, for example, but not limited to, a plain tray, or a combination of a tray and a box or dekit container.

[0037] From this it can be seen that the system of the present disclosure allows for a much higher utilization of each and every particular component that makes up the overall system, resulting in fewer resources being required as compared to the machines proposed by the conventional systems discussed above.

[0038] Another advantage achieved by the disclosed system for handling containers is that the system operates effectively in a warehouse where inventory is stored in donor containers, which in turn are stored on mobile inventory carriers mounted on pedestals that allow an autonomous mobile robotic unit to drive underneath it, lift it, turn it around, or move it from point A to point B within the operating area. In state-of-the-art systems (e.g. as in WO2017 / 121747), the inventory carriers are fixedly attached, e.g. bolted, to the ground in the work area, and their gripping mechanisms are capable of picking inventory that is directly accessible via the work area aisles. This causes these systems to have the disadvantage of requiring more space for similar inventory storage.

[0039] Furthermore, the separateness and detachability of the various units of the system allows the mobile inventory carriers to be stored at a much higher density (e.g., back-to-back), which means less storage area is required compared to that required for conventional systems to store a similar amount of inventory, since conventional systems can only operate with containers that are directly accessible from the aisles, resulting in a higher number of aisles being required when conventional systems are considered.

[0040] In addition to these, when the autonomous mobile robotic units of the present disclosure have to move, for example, from point A to point B in a workplace, they can also be propelled using a path through the aisles or under the pedestals of the mobile inventory carriers. This results in less traffic congestion in the aisles, which means that much more efficient path planning can be applied, which ultimately means a reduction in the number of autonomous mobile robotic units needed for similar throughput compared to conventional systems.

[0041] The system disclosed herein as claimed in the accompanying claims allows for a much denser layout of inventory carriers, which ultimately results in a reduction in the space required for similar storage.

[0042] The above description as well as the following detailed description will be better understood when read in conjunction with the illustrated figures. For purposes of illustration, the drawings show certain embodiments of the present disclosure. It is to be understood, however, that the present disclosure is not limited to the specific embodiments and features shown. The accompanying drawings, which are incorporated in and form a part of this description, illustrate embodiments of a system according to the present description and together serve to illustrate advantages and principles according to the present description. [Brief description of the drawings]

[0043] [Figure 1] FIG. 1 is a perspective view of an example of a workplace in which the system can operate, the workplace being a micro-fulfillment center for online orders or any other type of orders, such as orders supplying inventory items to a convenience store or any other type of store. [Diagram 2] FIG. 1 is a perspective view of a platform-type mini road system. [Diagram 3] FIG. 2 is a perspective view of the autonomous mobile robot unit with the lifting mechanism in an elevated position. [Figure 4] FIG. 2 is a perspective view of the autonomous mobile robot unit with the lifting mechanism in a low position. [Diagram 5] FIG. 1 is a perspective view of a mobile inventory carrier with no containers in the storage slots. [Figure 6] FIG. 1 is a perspective view of a mobile inventory carrier with a dekit container (111). [Figure 7] FIG. 1 is a perspective view of a mobile inventory carrier having some empty containers and some containers holding inventory items. [Figure 8] FIG. 1 is a perspective view of an autonomous mobile robotic unit moving to advance beneath a mobile inventory carrier. [Figure 9]FIG. 13 is a perspective view of an autonomous mobile robot unit moving under a mobile inventory carrier, lifting and moving the mobile inventory carrier, and placing it on the base of a mini-loader. [Figure 10] FIG. 1 is a perspective view of a mini-load system, an autonomous mobile robotic unit, and a mobile inventory carrier positioned on a pedestal of the mini-load. [Figure 11] 1 shows a perspective view of a mobile inventory carrier carrying donor containers with inventory items. [Figure 12] 1 shows a mini-load attached to a mobile inventory carrier supported by an autonomous mobile robotic unit, the mini-load retrieving donor containers from the mobile inventory carrier and storing them on storage slots of the mobile inventory carrier. [Figure 13] 1 shows a perspective view of a mobile inventory carrier featuring wheels that are guided and securely fastened in rails attached to the top surface of a pedestal. [Figure 14] 1 shows a view of an inventory receiving station to which an autonomous mobile robotic unit has delivered a mobile inventory carrier. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0044] The following description of examples of the present disclosure will be made with reference to the accompanying drawings, in which like reference numbers indicate the same or similar elements.

[0045] The words and terminology used below are for explanatory purposes and should not be construed as limiting. For example, the use of a single grade such as "1" is not intended to determine the number of actions. Also, the use of local pronouns such as "up", "down", "left", "right", "back", etc. are used in the description to clarify certain elements of the drawings and are not intended to limit the scope of the description or the appended claims. In addition, it should be understood that any of the features of the present disclosure may be used autonomously or in combination with other features. Other functionally equivalent systems, methods, features, uses, and advantages of the present disclosure will become apparent to one of ordinary skill in the art after reviewing the drawings and description. All additional systems, methods, features, uses, and advantages are intended to be within the scope of the present disclosure and protected by the appended claims.

[0046] 1, a system 100 for handling containers is shown. In particular, an autonomous mobile robotic unit 102, mobile inventory carriers 104, 107, a wheeled mobile inventory carrier 108, and a mini load system 101 are shown.

[0047] In the example, the mobile inventory carrier 104 is freely mounted within the work site, as also seen in Figure 5. Freely mounted may be interpreted as the mobile inventory carrier is not bolted to the ground of the work site, but rather capable of being transported, such that the mobile inventory carrier can be picked up, transported, and placed on a pedestal of a mini-load by the autonomous mobile robotic unit 102, as shown in Figures 8, 9, and 10.

[0048] The autonomous mobile robotic unit can then pick up both the mini load system 101 and the mobile inventory carrier 104 mounted on its pedestal and move them from point A to point B within the work area.

[0049] Apart from the increased utilization of each and every component thus achieved, the flexibility and effectiveness of the system is also increased, since no components remain unused or idle, since, for example, empty mobile inventory carriers can be transported and refilled by an autonomous mobile robot unit, thus avoiding any human involvement to transport containers stored on mobile inventory carriers within the workplace.

[0050] Further, the autonomous mobile robotic unit 102 is shown in its lowest position with a lifting mechanism that may have a parallelepiped shape, which includes a top surface, a bottom surface, and one or more sides. The height h may be less than the length l and / or width w, as seen in FIG. 3. Other suitable shapes of the autonomous mobile robotic unit 102 are also contemplated, such as, but not limited to, a cylindrical or cubic shape. The height h of the autonomous mobile robotic unit 102 is such that the autonomous mobile robotic unit 102 fits under the pedestal of the mini load system 101 or inventory carrier 104 and includes the necessary electronics and mechanisms for lifting and transporting such pedestal. Furthermore, the autonomous mobile robotic unit 102 may be wireless and may further include an integrated rechargeable energy storage component, e.g., a rechargeable battery, not shown in the figures, thus ensuring its full autonomous operation and free movement within the workplace. Each of the dimensions of width w and length l may be on the order of 1 m, while the height is on the order of 26 cm. However, one skilled in the art will appreciate that the dimensions of the autonomous mobile robotic unit 102 may vary depending on factors such as the complexity of the electronics, the size of the CPU and energy storage device, as well as the size of the lifted weight and associated center of gravity of the cargo. A specific example autonomous mobile robotic unit 102 is capable of lifting a weight of approximately 2 tn, preferably approximately 500 kg.

[0051] The energy storage device can be replaceable or of a special type, such as (LiFePO4), that is rechargeable with a shorter charging time. In this way, the autonomous mobile robotic unit 102 is available to run at any time and is only charged when it is not involved in any other process or when its battery level is very low. This type of energy storage device also increases safety, since it will not produce a flame if short-circuited. The energy storage device can also be of the supercapacitor type, which recharges extremely fast when the autonomous robotic unit moves over a suitable inductive charging station.

[0052] In other examples, when the autonomous mobile robotic unit 102 is not engaged in any process, the autonomous mobile robotic unit 102 travels to a charging station to recharge its energy storage system as needed.

[0053] In other examples, the autonomous mobile robotic unit 102 may have one or more drive wheels on its bottom surface to allow the autonomous mobile robotic unit 102 to move smoothly. In other examples, the autonomous mobile robotic unit 102 may also be equipped with several caster wheels to properly support the vehicle. The drive wheels and caster wheels may also be installed on the chassis of the vehicle to allow them to adapt to inconsistencies in floor flatness within certain limits. The autonomous mobile robotic unit 102 may have a single wheel in the center of the bottom surface, but those skilled in the art can understand that such a configuration may cause a reduction in the stability of the system 100, especially when loaded. The number of wheels and their dimensions depend on the weight to be lifted by the autonomous mobile robotic unit 102.

[0054] On the top surface, the autonomous mobile robotic unit may have an interface for the lifting mechanism 102a as seen in Figures 3 and 4, and an energy supply for systems not shown in the figures.

[0055] In another example, the autonomous mobile robotic unit 102 may carry both the mini load system 101 and the mobile inventory carrier 104 anywhere in the work area. When the mini load system 101 is brought close to the mobile inventory carrier (or vice versa), the autonomous mobile robotic unit 102 may move under the first pedestal of the mobile inventory carrier 104, lift it up, and fit it in a safe manner onto the second pedestal of the mini load system 101, as seen in Figures 8, 9, and 10. In this manner, the mini load system and the mobile inventory carrier 104 may be moved by the autonomous mobile robotic unit within the work area.

[0056] In another example, the autonomous mobile robotic unit may drive under a mobile inventory carrier having a first pedestal, lift it up, and transport the mobile inventory carrier to any desired location within the work area. Such locations may also be predefined, for example, from a specific point A to a specific point B.

[0057] When a mobile inventory carrier is capable of being transported by an autonomous mobile robotic unit and placed on a pedestal of a mini-load, such inventory carrier may also be referred to as a transportable inventory carrier (104).

[0058] According to the present disclosure, for purposes of clarity, the mobile inventory carriers (107) may simply be capable of being picked up and rotated by the autonomous mobile robotic units. Such mobile inventory carriers (107) are shown in Figures 1 and 11. In other examples, the mobile inventory carriers (104) may be transported to any location within the work site. Furthermore, such mobile inventory carriers may be placed on the pedestal of the mini-load system, so that they can be transported together with the mini-load system by the autonomous mobile robotic units within any location within the work site. Such mobile inventory carriers (104) may also be referred to as transportable inventory carriers, as seen, for example, in Figures 9 and 10.

[0059] Although, in other examples, the autonomous mobile robotic unit 102 may drive under the mobile inventory carrier 107, lift it up, and rotate it to carry it to an appropriate position, preferably next to the mini-load 101, where its gripping mechanism can pick up the container and place it on another mobile inventory carrier 104, which may be transportable as previously defined in this disclosure, as shown in FIG. 12.

[0060] In another example, the autonomous mobile robotic unit 102 may drive under the mini-load system 101, lift it up, and transport it to any desired location within the work area to perform any required operation. In another example, the autonomous mobile robotic unit 102 may drive under the mini-load system while the mobile inventory carrier 104 is positioned on the mini-load pedestal, lift both the mini-load and the mobile inventory carrier 104, and move them from any point A to any point B within the work area.

[0061] In an example, the pedestals of mobile inventory carrier 104 and mini load system 101 may each be in the form of a single plate or may comprise a top surface and several legs. In a preferred embodiment, the pedestal comprises at least three legs, and most preferably four legs as shown in FIG. 10, to ensure stability of the unit while allowing more weight to be placed on mobile inventory carrier 104. However, it should be contemplated that mini load system 101 and mobile inventory carrier 104 may also be effective with a single leg.

[0062] The pedestals may be made of any known material capable of supporting approximately 300 kg, for example, they may be made of metals such as steel or preferably aluminum, which are light-weight and capable of withstanding more weight. It may also be constructed from a suitable synthetic material. The pedestal top surface may be any shape, for example, rectangular, square, circular, etc., but those skilled in the art will appreciate that for cost reasons and improved transportation of the system, it will be beneficial for the shape of the pedestal top surface to follow the shape and size of the mobile inventory carrier 104 or the top surface of the mini-load system and the top surface 202 of the autonomous mobile robotic unit 102. The length of the first and second pedestals may be 0.8 m to 2 m, preferably 1 m to 1.5 m, more preferably 1.2 m, and the width of the pedestals may be 0.8 m to 2 m, preferably 1 m to 1.5 m, more preferably 1.2 m.

[0063] In an example, the mobile inventory carrier comprises several trays of the same or different dimensions. Depending on the size of each shelf, as seen in Figures 5, 6 and 7, the shelf supports several containers 111, between 1 and 30, preferably between 5 and 12, to increase its efficiency. In an example, the mobile inventory carrier 104 may stand on a group of legs, at least three legs, preferably at least four legs for stability reasons. The mobile inventory carrier 104 (Figure 5) and its shelves may be made of any known material, for example metal, preferably steel, so as to hold a total approximate weight of 400 kg and not have a significant weight by itself. The mobile inventory carrier 104 may be produced by any possible method, including 3D printing.

[0064] Mobile inventory carrier 104 can be of any size, but one of ordinary skill in the art can appreciate that the size of mobile inventory carrier 104 depends on the space available for it to move in and the weight it should be able to withstand. The size also depends on the stability desired; for example, a taller mobile inventory carrier 104 will have reduced stability.

[0065] A mobile inventory carrier 107 is preferably used to store donor containers with inventory. It typically comprises several shelves with several container storage slots, usually four or six, but may have any number of storage slots depending on the size of the containers (FIG. 11).

[0066] A donor receptacle as defined in this disclosure is a receptacle that holds inventory, while an order receptacle is a receptacle that is filled at a picking station with items received from a donor receptacle.

[0067] The mobile inventory carrier (104, 107) may also have wheels 112 (FIG. 13), usually four wheels, one on each leg, but it must be contemplated that it may have any number of wheels. The wheels are guided in suitable rails 113, usually two rails, but may have any number of rails, with recesses at the ends that can lock the wheels when they reach their end positions, fixing them and preventing them from moving while being transported. The rails are mounted on the top surface of the pedestal, so that the autonomous mobile robotic unit 102 can drive underneath it, lift the pedestal together with the mobile inventory carrier (104, 107) and move it within the workspace. The wheels serve to roll the mobile inventory carrier (usually called a "roll rack") when it is out of the robot workspace, so that the operator can easily push the mobile inventory carrier (104, 107) around for storage or to load it onto a transport vehicle. However, it should be noted that the roll rack can also be lifted, rotated, and / or transported by an autonomous mobile robotic unit when placed on a suitable pedestal as shown in FIG. 13.

[0068] Each container 111 may be in different forms, for example in the form of a vessel (FIG. 13), or a tray (104a / FIGS. 6 and 7), a box or a card box.

[0069] The mini road system 101 and the autonomous mobile robotic unit 102 are thus completely separate units, and they operate independently of each other. In this way, any potential failure of the other independent unit, i.e., either the autonomous mobile robotic unit 102 or the mini road system 101, does not limit the ability of the other non-failed unit to continue to operate with the other unit. Also, when the autonomous mobile robotic unit 102 needs to be recharged, this does not limit the ability of the mini road to continue to operate in cooperation with another autonomous mobile robotic unit. This capability, which is not disclosed in any of the prior art systems, greatly increases the utilization rate of each of the system's components, ultimately reducing the overall cost of ownership of the system.

[0070] The mini load system 101 includes a gripping mechanism for picking up the container 111 from the mobile inventory carrier 107 and releasing it onto another mobile inventory carrier 104, which may also be referred to as a transportable inventory carrier as defined in this disclosure.

[0071] In another example, the mini-load system can be of the pedestal type 101 (FIG. 2) with a pedestal frame 101b, a pedestal joint Z 101c that moves vertically on the Z axis, a pedestal joint X 101d that moves horizontally on the X axis, and a container handler 101e that can move on the Y axis and can rotate on the XY plane. The pedestal frame can be fixedly mounted on a pedestal 101a that can have the shape of a plate. The pedestal has several legs, usually four legs, allowing enough space under the pedestal for the autonomous mobile robotic unit 102 to drive under the pedestal, to lift the pedestal with all the mini-loads, and to lift the mobile inventory carriers 104 (portable) and move them around in the work area, as described in the other examples.

[0072] In another embodiment, the gripping mechanism of the mini-load comprises a visual servo system configured to guide the movement of the pedestal joints 101c, 101d and the container handler 101e to safely handle the container 111. In another example, the mini-load system 101 may further comprise an elongated column that may comprise rails on which the gripping mechanism is enabled to move vertically linearly either upwards or downwards depending on the location of the desired container on the inventory carrier. In a further example, the elongated column may be fixedly mounted on a pedestal that may have the shape of a plate. In this way, an autonomous mobile robotic unit can go under the pedestal and transport the entire mini-load system. The pedestal may optionally be coupled to a railed walkway, which in turn allows for horizontal movement of the entire mini-load system 101 depending on the location of the inventory carrier.

[0073] In another example, the mini load system 101 can be attached to the top surface of the autonomous mobile robotic unit 102. The autonomous mobile robotic unit 102 provides energy to the mini load system 101 through its energy supply. The autonomous mobile robotic unit 102 has an opening on the top surface through which the necessary harnesses can reach and connect to the mini load system 101. In this way, the autonomous mobile robotic unit 102 provides energy to the mini load system 101 to enable it to reach the mobile inventory carrier 104 and load and unload the containers 111 thereto. In addition, the autonomous mobile robotic unit 102 can also transport the mini load system 101 around the warehouse and / or fulfillment center. Although one skilled in the art can appreciate that providing energy to the mini load system 101 by the autonomous mobile robotic unit 102 is more environmentally friendly and sustainable, in another example, the mini load system 101 can be autonomous and equipped with a rechargeable or disposable plug or energy storage device.

[0074] The autonomous mobile robot unit may, for example, move under the pedestal of the mini-load to which the mobile inventory carrier (104) is attached, lift the system, and move it next to the mobile inventory carrier 107 to pick up a container stored thereon. Due to the expected limited linear and angular deviations of the theoretical roughness, the mobile inventory carrier 107 may have small position errors (typically less than 10 mm lateral error and less than 0.5 degrees angular error) that, if not calculated, could result in the gripper colliding with either the tray or the frame of the mobile inventory carrier. To eliminate such undesirable defects, the gripping mechanism of the mini-load system 101 is equipped with a camera and lighting system capable of generating a streaming video during its movement. The streaming video is further processed by software means to instruct the gripping mechanism to pick up the target container. More specifically, the video is continuously analyzed by custom software capable of understanding any lateral or angular misalignment, and in a closed-loop control, guides the motors controlling the gripper to compensate for any such misalignment and correct the final position of the gripper prior to picking up the container. This system may also be called a "visual servoing" system. With the support of visual servoing, the necessary precision in the gripper movement is achieved to make the system operate smoothly.

[0075] In another example, the autonomous mobile robot moves the combined mini-load and mobile inventory carrier (104) next to another mobile inventory carrier (107), where a first donor inventory container is picked up by the mini-load gripper and, guided by the gripper's visual servo system, placed with appropriate precision on a storage spot on the mobile inventory carrier (104, 107).

[0076] A system according to this disclosure and the appended claims, comprising at least one mobile inventory carrier, autonomous mobile robotic units, and a mini load system, all of which operate independently as separate units, is capable of supporting all functions involved in fulfilling and delivering online orders, as well as all functions in any distribution center that must supply inventory to any brick-and-mortar establishment, such as a store, convenience store, etc.

[0077] In the example, when inventory is received at a warehouse or fulfillment center, such as an inventory receiving station 114 (FIG. 14), the inventory is typically packed in containers or boxes stacked on a pallet 115 (FIG. 14). To efficiently replenish inventory in the warehouse, the autonomous mobile robotic units 102 carry a mobile inventory carrier 104 with multiple empty trays 111 at the inventory receiving station 114 (FIG. 14) and place it on a pedestal of a stationary mini-load servicing the inventory receiving station. The mini-load system 101 picks up the empty tray 111 from the mobile inventory carrier 104 and presents it to an operator who places the desired inventory in the tray 111. For ease of operation, the boxes 117 with the inbound inventory from the pallet may already be on the work platform 116, making it easier for the operator to place the desired inventory in the tray (see FIG. 14). The same process is continuously repeated until all the trays 111 of the mobile inventory carrier 104 are filled with the desired inventory. Once all trays are filled, the autonomous mobile robotic unit transports the mobile inventory carrier 104 to a location close to the inventory storage location where another mini load system 101 is waiting to receive the filled mobile inventory carrier 104 and then, propelled by the autonomous mobile robotic unit, stores each container 111 on other inventory carriers stored in the inventory storage area, such as mobile inventory carrier 107. In an example, when a particular storage location in the storage location is not accessible due to the orientation of the mobile inventory carrier (e.g., the slot of the mobile inventory carrier for storing the container does not face the aisle where the mini load stands), another autonomous mobile robotic unit moves under the mobile inventory carrier, lifts it up, and rotates it up to 180 degrees, thus making the target storage slot of the mobile inventory carrier accessible to the mini load gripper.

[0078] In another embodiment, a method for supplying inventory to a fulfillment station is provided, the method comprising: a) transporting a first mobile inventory carrier having one or more filled donor containers by a first autonomous mobile robotic unit (102) from an inventory area of ​​a fulfillment center to an exchange point; b) loading one or more donor containers (111) of the first mobile inventory carrier (104, 107) onto a second mobile inventory carrier (104, 107) by the mini-load system, where the second mobile inventory carrier (104, 107) is empty prior to the loading; c) repeating steps a and b until the second mobile inventory carrier (104, 107) is fully loaded with containers; d) transporting the fully loaded second mobile inventory carrier (104, 107) by the autonomous mobile robotic unit (102) to a picking station at the fulfillment center; e) transferring a second mobile inventory carrier (104, 107) onto the pedestal of the mini-load system (101) at the picking station; f) selecting a first donor container from a second mobile inventory carrier (104, 107) and delivering the first donor container to an operator; g) selecting by an operator at least one item from the first donor receptacle and placing the item in the order receptacle; Steps f and g are repeated until the operator has selected items from all donor receptacles and placed them in the order receptacle.

[0079] In a further step, an autonomous mobile robotic unit arrives beneath the mobile inventory carrier, lifts it off its pedestal, returns it to the inventory storage area, and returns the donor trays to their original storage slots on the corresponding mobile inventory carrier.

[0080] Such a method ensures rapid and accurate fulfillment of any order from a client, while ensuring that any subsequent orders are available in a reasonable amount of time, as all components of the system work together in unison to transport distribution and inventory carriers to selected locations, fill them, and deliver the selected goods to the operator.

[0081] In examples, the system 100 according to the present disclosure may be used in different locations for handling materials and goods. In a preferred embodiment, the system is used in a warehouse to fulfill online orders. Order fulfillment may occur in a warehouse fulfillment center that includes a stock refill station, an inventory area, a picking station, and a storage area.

[0082] Such systems can also be used to supply inventory needed in stores, especially convenience stores, which due to their very limited storage capacity are not able to store inventory on pallets or even boxes containing a unique stock keeping unit (SKU), but only in containers containing several different SKUs. The invention as originally claimed in the present application is set forth below. [1] A system (100) for handling containers, comprising: at least one mobile inventory carrier (104, 107) for storing containers (111); a mini-loading system (101) comprising a gripping mechanism for picking up or releasing a container (111) from said at least one mobile inventory carrier (104, 107); At least one autonomous mobile robotic unit (102); wherein the mini road system (101), the at least one mobile inventory carrier (104, 107), and the at least one autonomous mobile robotic unit (102) are separate units and operate independently of one another, wherein the mini road system (101) comprises a pedestal (101a), the at least one mobile inventory carrier (104) is mounted on the pedestal (101a), and the at least one autonomous mobile robotic unit (102) is configured to move the mini road system (101) and the at least one mobile inventory carrier (104) together within a work area. [2] The system (100) described in [1], wherein the at least one mobile inventory carrier (107) is freely stationed in a work area and the at least one autonomous mobile robotic unit (102) is configured to lift and / or rotate the mobile inventory carrier (107). [3] The system (100) described in [1], wherein the at least one autonomous mobile robotic unit (102) is configured to transport the at least one mobile inventory carrier (104, 107) within a work area. [4] The system (100) of any one of [1] to [3], wherein the at least one mobile inventory carrier (104) is provided with one or more wheels (112). [5] The system (100) described in any one of [1] to [4], wherein the mini load system (101) comprises a mounting system including a frame (101b), a pair of mounting joints (101c, 101d), and a container handler (101e). [6] The system (100) described in [5], wherein the frame (101b) is fixedly attached to the base (101a). [7] The system (100) described in any one of [1] to [6], wherein the at least one mobile inventory carrier (104) has a base (104c). [8] The system (100) of [7], wherein the base (104c) comprises a rail and one or more wheels coupled to the rail. [9] The system (100) described in any one of [1] to [8], wherein the autonomous mobile robot unit (102) is wireless and equipped with an integrated rechargeable battery.

[10] The system (100) of [9], wherein the integrated rechargeable battery of the at least one autonomous mobile robot unit (102) provides power to the mini road system (101).

[11] A system (100) described in any one of [1] to

[10] , wherein the gripping mechanism of the mini road system (101) is provided with at least one camera and at least one lighting means.

[12] The system (100) of

[11] , wherein the gripping mechanism is configured to identify angular and / or linear deviations of the mobile inventory carrier (107) and guide movement of the pair of platform joints (101c, 101d) and the container handler (101e) accordingly.

[13] The system (100) described in

[11] or

[12] , wherein the at least one camera and the at least one lighting means are configured to generate a streaming video, the streaming video being processed by software means to instruct the gripping mechanism to remove a target container.

[14] A method for supplying inventory to a fulfillment station, comprising: a) transporting a first mobile inventory carrier having one or more filled donor containers by a first autonomous mobile robotic unit (102) from an inventory area of ​​a fulfillment center to an exchange point; b) loading one or more of the donor containers (111) of the first mobile inventory carrier (104, 107) onto a second mobile inventory carrier (104, 107) by a mini-load system, wherein the second mobile inventory carrier (104, 107) is empty prior to loading; c) repeating steps a and b until the second mobile inventory carrier (104, 107) is fully loaded with containers; d) transporting the fully loaded second mobile inventory carrier (104, 107) by an autonomous mobile robotic unit (102) to a picking station at a fulfillment center; e) transferring said second mobile inventory carrier (104, 107) onto a pedestal of a mini-loading system (101) at said picking station; f) selecting a first donor container from said second mobile inventory carrier (104, 107) and delivering said first donor container to an operator; g) selecting, by the operator, at least one item from the first donor receptacle and placing the item in an order receptacle; wherein steps f and g are repeated until the operator has selected the items from all of the donor receptacles and placed them in the order receptacle.

[15] - the arrival of an autonomous mobile robotic unit (102) at said picking station of a fulfillment center; - the second mobile inventory carrier (104, 107) is placed on a pedestal of a mini-load system and lifted by the autonomous mobile robotic unit (102); and - the autonomous mobile robotic unit (102) returns the second mobile inventory carrier (104, 107) to the inventory area of ​​the fulfillment center and places it on a pedestal of the mini-load system (101). The method of claim 14, further comprising:

[16] The method according to

[14] or

[15] , wherein the autonomous mobile robotic unit (102) preferably automatically goes to a charging station to be recharged when not engaged in a process or when its battery is at a low level.

[17] Use of a system (100) for handling containers described in any one of [1] to

[11] within a fulfillment center.

Claims

1. A system (100) for handling containers, comprising: at least one mobile inventory carrier (104, 107) for storing containers (111); a mini-loading system (101) comprising a gripping mechanism for picking up or releasing a container (111) from said at least one mobile inventory carrier (104, 107); At least one autonomous mobile robotic unit (102); wherein the mini road system (101), the at least one mobile inventory carrier (104, 107), and the at least one autonomous mobile robotic unit (102) are separate units and operate independently of one another, the mini road system (101) comprising a pedestal (101a), the at least one mobile inventory carrier (104) being mounted on the pedestal (101a), and the at least one autonomous mobile robotic unit (102) being configured to move the mini road system (101) and the at least one mobile inventory carrier (104) together within a work area.

2. 2. The system (100) of claim 1, wherein the at least one mobile inventory carrier (107) is freely stationed in a work area and the at least one autonomous mobile robotic unit (102) is configured to lift and / or rotate the mobile inventory carrier (107).

3. 2. The system (100) of claim 1, wherein the at least one autonomous mobile robotic unit (102) is configured to transport the at least one mobile inventory carrier (104, 107) within a work area.

4. The system (100) of any one of claims 1 to 3, wherein the at least one mobile inventory carrier (104) comprises one or more wheels (112).

5. The system (100) according to any one of claims 1 to 4, wherein the mini-load system (101) comprises a mounting system comprising a frame (101b), a pair of mounting joints (101c, 101d), and a container handler (101e).

6. The system (100) of claim 5, wherein the frame (101b) is fixedly attached to a base (101a).

7. The system (100) of any one of claims 1 to 6, wherein the at least one mobile inventory carrier (104) comprises a pedestal (104c).

8. The system (100) of claim 7, wherein the base (104c) comprises a rail and one or more wheels coupled to the rail.

9. The system (100) of any one of claims 1 to 8, wherein the autonomous mobile robotic unit (102) is wireless and includes an integral rechargeable battery.

10. 10. The system (100) of claim 9, wherein the integrated rechargeable battery of the at least one autonomous mobile robotic unit (102) provides power to the mini road system (101).

11. The system (100) according to any one of the preceding claims, wherein the gripping mechanism of the mini road system (101) comprises at least one camera and at least one lighting means.

12. The system (100) of claim 11, which recites claim 5, wherein the gripping mechanism is configured to identify angular and / or linear deviations of the mobile inventory carrier (107) and guide movement of the pair of platform joints (101c, 101d) and the container handler (101e) accordingly.

13. The system (100) of claim 11 or 12, wherein the at least one camera and the at least one lighting means are configured to generate a stream of video, the stream of video being processed by software means to instruct the gripping mechanism to remove a target container.

14. 1. A method for supplying inventory to a fulfillment station, comprising: a) transporting a first mobile inventory carrier having one or more filled donor containers by a first autonomous mobile robotic unit (102) from an inventory area of ​​a fulfillment center to an exchange point; b) loading one or more of said donor containers (111) of said first mobile inventory carrier (104, 107) onto a second mobile inventory carrier (104, 107) by a mini-load system, said second mobile inventory carrier (104, 107) being empty prior to loading; c) repeating steps a and b until the second mobile inventory carrier (104, 107) is fully loaded with containers; d) transporting the fully loaded second mobile inventory carrier (104, 107) by an autonomous mobile robotic unit (102) to a picking station at a fulfillment center; e) transferring said second mobile inventory carrier (104, 107) onto a pedestal of a mini-loading system (101) at said picking station; f) selecting a first donor container from said second mobile inventory carrier (104, 107) and delivering said first donor container to an operator; g) selecting, by the operator, at least one item from the first donor receptacle and placing the item in an order receptacle; wherein steps f and g are repeated until the operator has selected the items from all of the donor receptacles and placed them in the order receptacle.

15. - the arrival of an autonomous mobile robotic unit (102) at said picking station of a fulfillment center; - the second mobile inventory carrier (104, 107) is placed on a pedestal of a mini-load system and is lifted by the autonomous mobile robotic unit (102); - the autonomous mobile robotic unit (102) returns the second mobile inventory carrier (104, 107) to the inventory area of ​​the fulfillment center and places it on a pedestal of the mini-load system (101); The method of claim 14 further comprising:

16. 16. The method according to claim 14 or 15, wherein the autonomous mobile robotic unit (102) preferably automatically goes to a charging station to be recharged when not involved in a process or when the battery is at a low level.

17. Use of a system (100) for handling containers according to any one of claims 1 to 11 in a fulfillment center.

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