Automated warehouse management methods based on the popularity of automated warehouses and items.

Abstract

An automated warehouse is provided that includes a storage warehouse configured to store a plurality of items, where the plurality of items are stored in item containers, a plurality of picking stations including an asynchronous picking station and a synchronous picking station, one or more robots configured to transport the item containers to the plurality of picking stations, and at least one computerized system configured to control transport of the item containers based on popularity of items contained in the item containers.

Description

Technical Field

[0001] The present invention relates to an automated warehouse and a method for managing an automated warehouse based on the popularity of items.

Background Art

[0002] In order to have commercial competitiveness, it is necessary to process orders placed via the Internet in a relatively short period of time.

[0003] The same is true for orders by phone, fax or mail based on merchandising using catalogs or TV. Such order processing is known as e-commerce and is required for an order processing system to fulfill such obligations. This is further complicated by the fact that e-commerce usually involves a large number of small orders (each containing only 1 item) selected from a large number of potential items.

[0004] Each unique item has a specific inventory identifier known in the industry as a Stock Keeping Unit (SKU). Each item usually has an optical code that identifies the item's SKU, such as a barcode or a Radio Frequency Identification (RFID) tag.

[0005] In the picking station of an automated warehouse, boxes arrive from the storage to a specific station (by a robot), and a picker (human or robot) takes out 1 or more items from the box and places those items on a put wall, whereby a packer packs 1 or more items to provide 1 or more packages, and they are output from the automated warehouse. The box waits until the picker takes out 1 or more items, and then is returned to the storage immediately afterwards.

[0006] In this type of picking station, the robot and the picker need to be synchronized so that the robot can provide the currently requested one or more items each time that item (or more items) is requested.

[0007] However, if a box contains highly sought-after items (also known as high runners), the box containing those items will have to be brought to the picking station multiple times, which is inefficient.

[0008] There is a need to provide a way to efficiently manage the supply of highly popular items. [Overview of the project]

[0009] As illustrated in this application, one or more automated warehouses and / or methods and / or non-transient computer-readable media may be provided. [Brief explanation of the drawing]

[0010] To understand the present invention and how it can be put into practice, several embodiments will be described, as merely non-limiting examples, with reference to the accompanying drawings. [Figure 1] Figure 1 shows an example of an automated warehouse. [Figure 2] Figure 2 shows an example of an automated warehouse. [Figure 3] Figure 3 shows an example of a buffer-type synchronous picking station. [Figure 4] Figure 4 shows an example of information flow. [Figure 5] Figure 5 shows an example of the method. [Figure 6] Figure 6 shows an asynchronous picking station. [Figure 7] Figure 7 shows an example of a hybrid picking station. [Modes for carrying out the invention]

[0011] The following detailed description includes many specific details in order to provide a complete understanding of the invention. However, those skilled in the art will understand that the invention can be carried out without those specific details. In other examples, well-known methods, procedures, and components are not described in detail so as not to obscure the invention.

[0012] The subject matter considered to be the present invention is specifically pointed out and explicitly claimed in the concluding section of this specification. However, the present invention, with respect to both its configuration and method of operation, along with its object, features and advantages, will be best understood by referring to the following detailed description together with the accompanying drawings.

[0013] For the sake of brevity and clarity, please understand that elements in the drawings are not necessarily drawn to scale. For example, the dimensions of some elements may be exaggerated compared to others for clarity. Furthermore, where appropriate, reference numerals may be repeated between drawings to indicate corresponding or similar elements.

[0014] Since the illustrated embodiments of the present invention can be implemented using electronic components and circuits largely known to those skilled in the art, we will not provide any more detailed explanations than are considered necessary, as described above, in order to understand and grasp the basic concepts of the present invention and to avoid obscuring or hindering the teachings of the present invention.

[0015] Any reference to a method in this specification shall apply mutatis mutandis to a device or system capable of performing that method, and / or to a non-temporary computer-readable medium storing instructions for performing that method.

[0016] Any reference to a system or device in this specification shall be equally applicable to a method executable by the system and / or to a non - transient computer - readable medium storing instructions executable by the system.

[0017] Any reference to a non - transient computer - readable medium in this specification shall be equally applicable to a device or system capable of executing the instructions stored on the non - transient computer - readable medium and / or to a method for executing those instructions.

[0018] Any combination of any of the drawings, any part of this specification, and / or any module or unit described in any of the claims may be provided.

[0019] This specification and / or the drawings may refer to a processor. The processor may be a processing circuit. The processing circuit may be implemented as a central processing unit (CPU) and / or one or more other integrated circuits such as an application - specific integrated circuit (ASIC), a field - programmable gate array (FPGA), a full - custom integrated circuit, or a combination of such integrated circuits. A computerized system may include one or more processors and may include additional units or components such as a memory unit, a communication unit, etc.

[0020] Any combination of any steps of any method illustrated in this specification and / or the drawings may be provided.

[0021] Any combination of any subject matter of any of the claims may be provided.

[0022] Any combination of a system, unit, component, processor, sensor illustrated in this specification and / or the drawings may be provided.

[0023] The following description is provided along all chapters of the present invention so that those skilled in the art can utilize the present invention, and describes the best mode contemplated by the inventors of the present invention for carrying out the present invention.

[0024] However, since the overall principles of the present invention are particularly defined to provide means and methods for transporting articles to people, various modifications will still be apparent to those skilled in the art.

[0025] In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of embodiments of the present invention. However, those skilled in the art will understand that such embodiments can be implemented without those specific details. Each feature can bring about the remaining features in the same way as it evokes the whole. And when the features are finally revealed, quite new features will be evoked.

[0026] References throughout this specification to "one embodiment" or "an embodiment" mean that a particular feature, structure, or characteristic described in connection with that embodiment is included in at least one embodiment of the present invention.

[0027] The phrases "at least one", "one or more", and "and / or" are effective connective and disjunctive open-ended expressions. For example, each of the expressions such as "at least one of A, B, and C", "at least one of A, B, or C", "one or more of A, B, and C", "one or more of A, B, or C", and "A, B, and / or C" means A alone, B alone, C alone, a combination of A and B, a combination of A and C, a combination of B and C, or a combination of A, B, and C.

[0028] Hereinafter, the term "plurality" means any positive integer (e.g., 1, 5, or 10).

[0029] Popular items are also called high runners. The popularity of an item may be determined over a certain period of time. This period may be determined in any way, for example, by the automated warehouse operator, the automated warehouse manager, the automated warehouse operator's customers, or the automated warehouse control system. Such a period may include, for example, more than an hour, more than a day, more than a week, more than a month, etc.

[0030] An item can be considered popular based on factors such as the invitation threshold per period and the supply threshold per period. It can also be judged as popular based on a comparison with the popularity of other items. For example, an item can be considered popular if it has X of the most popular items. X can be set in any way, and can be fixed or change over time.

[0031] In the following text, a box may refer to a box that can hold one or more items. A box is a non-exclusive example of an item container. An item container may be different from a box. The term "box" is used for simplicity of explanation.

[0032] In the following text, shelves that support one or more boxes may be referred to. Shelves are a non-exclusive example of item container support elements. Item container support elements may differ from shelves. The term "shelf" is used for simplicity of explanation.

[0033] An asynchronous picking station can be provided, and we will refer to it as an asynchronous picking station. An asynchronous picking station may include a small storage area that pickers can access. A robot carries boxes to its storage area so that pickers can pick them and process orders at the picking station. When the automated warehouse system detects that a box has been completely used for all relevant orders at the picking station, it instructs the robot to retrieve the box from the picking station's storage area to the main warehouse storage area.

[0034] An automated warehouse includes a storage facility for storing multiple boxes. The storage facility may include one or more storage units. A storage unit may include one or more item container support elements and may be arranged in columns, rows, islands, or matrices, in order or in no particular order.

[0035] An automated warehouse having one or more asynchronous picking stations, and a method for managing the automated warehouse and / or a non-temporary computer-readable medium are provided.

[0036] The automated warehouse is configured to manage items based on their popularity and allocate dedicated resources to popular items. These resources can include one or more asynchronous picking stations.

[0037] An order processing method and a system for carrying out such a method are provided, in particular, a method and system useful for processing a large number of orders (including popular items) in a relatively short time.

[0038] This method can be applied by an automated warehouse. The automated warehouse can be configured to provide goods to one or more picking stations via forklifts or automated carts that can move boxes in and out of shelves.

[0039] An automated warehouse can include one or more picking stations that are asynchronous in the sense that they can store boxes even when the items in the boxes are not currently ordered.

[0040] The automated warehouse can be configured to pass boxes to an asynchronous picking station, for example, by placing them on a shelf or any other support / receiving section of the asynchronous picking station, while the boxes can remain at the asynchronous picking station even if the items stored in the boxes are not currently scheduled to be packaged.

[0041] A picker can access one or more boxes within an asynchronous picking station multiple times without having to move the boxes between the asynchronous picking station and the storage area.

[0042] Orders for specific items can be processed by a picker (if the item is popular) by accessing a box in an asynchronous picking station and retrieving the specific item.

[0043] If an item is deemed unpopular (or if more popular items need to be provided to the asynchronous picking station), the box containing that item can be removed from the asynchronous picking station. If that item and the more popular items can be placed in the asynchronous picking station, the item can be kept there.

[0044] The picker can take an item from the robot (when the robot first accesses the asynchronous picking station with the item). Alternatively, the picker can wait until the box containing the item is placed in the asynchronous picking station.

[0045] A buffer-type synchronous picking station can be provided that can offer a short delay period (shorter than the storage period provided by an asynchronous picking station). The buffer-type synchronous picking station can include an input for receiving boxes from a robot and can output the boxes to an output. The boxes can be retrieved from the output by the same robot (the robot that placed the boxes) or another robot.

[0046] The delay can be determined by a picker (who takes one or more items from one box with a short delay into another box), while a box from which one or more items have been taken can be sent to the output unit. The picker can control the output or indicate that one or more items have been taken from a box, allowing that box to be output.

[0047] A buffer-type synchronous picking station may include a conveyor that can hold multiple boxes at once. A first robot can provide boxes to the input on one side of the conveyor, while the conveyor is ready to be picked up by the first or second robot. The conveyor may or may not be motorized. This prevents the (wasteful) scenario of having multiple robots (usually arranged in sequence) waiting until a picker takes one or more items from the first box.

[0048] For example, if the delay is only a few minutes, the robot does not need to wait for several minutes before returning to the storage area.

[0049] WCS can be configured to pre-emptively partially fill buffer-type synchronous picking stations with items from multiple orders (before pickers arrive).

[0050] An automated warehouse may include one or more asynchronous picking stations. The asynchronous picking stations may have the same box shape, size, and capacity. Alternatively, at least one of the box shapes, sizes, and capacities may differ from that of another asynchronous picking station.

[0051] While items in an automated warehouse operator may require the same type of storage, there may also be different types of items that require different types of storage. For example, some items need to be stored in a controlled environment (e.g., an environment where at least one environmental condition, such as temperature, humidity, or light range, is maintained within a specific range).

[0052] Different types of items may be managed in different ways. Resources (storage resources and / or picking stations and / or asynchronous picking stations and / or synchronous picking stations and / or parts of picking stations and / or parts of asynchronous picking stations and / or parts of synchronous picking stations) can be allocated to each different type of item.

[0053] An automated warehouse can be managed by an automated warehouse control system (WCS). The WCS can run on any type of computer (one or more servers, one or more computers) and can operate in a centralized or distributed manner. A WCR may include a WCS component that can manage various parts of the automated warehouse.

[0054] A WCS can include a Warehouse Management System (WMS), be included in a WMS, or work in conjunction with a WMS. For simplicity, if a WCS has WMS capabilities, it can perform automated warehouse control and management operations.

[0055] WCS can acquire (receive and / or generate) information related to the management of the automated warehouse. This may include at least one of the following: orders, received items, availability of tracks or any other output entities for outputting items from the automated warehouse, box contents (items stored per box and / or quantity of items per box), mapping between item identifiers (SKU, barcode, etc.) and items, item location (storage, picking station), any information about items (including item type, expiration date, storage parameters, transport parameters, fragility, transport location, etc.), packaged boxes, contents of picking stations, historical data (including order history), popularity information, environmental information, etc.

[0056] The WCS can obtain information about the location of the boxes and the contents of the boxes (including, for example, the quantity of one or more items per box) from sensors and / or any tracking system and / or robots and / or pickers. The sensors may be of any type, including vision sensors, cameras, RFID readers, NFC readers, etc.

[0057] The WCS is configured to manage the storage and / or delivery process of items. The delivery process may include at least one of the following: retrieving boxes (containing items), providing boxes to picking stations, returning boxes to storage, managing storage, and performing picking. If picking is managed by humans, the WCS may provide suggestions regarding picking.

[0058] For example, WCS can add received items to the overall inventory, add boxes allocated for items, fill (or partially fill) boxes with items, and add boxes to the box inventory.

[0059] The WCS can be configured to determine the location of boxes within the storage area (for example, by taking into account the distance to one or more picking stations and / or the popularity of the items).

[0060] Popular items can be placed near asynchronous systems.

[0061] Popular items can be arranged in a way that reduces the likelihood of bottlenecks forming among robots that might simultaneously attempt to retrieve boxes containing popular items (by leaving at least a certain distance between adjacent popular items).

[0062] Popular items can be placed at the same height to increase their retrieval speed (especially if some robots are dedicated to retrieving popular items), thereby eliminating the need for the robots to adjust the height of their forks (or equivalent interfaces) while retrieving popular items one after another.

[0063] WCR can perform load balancing between asynchronous picking stations and / or assign picking stations to items, and can determine the location of popular items based on the location of the assigned asynchronous picking stations.

[0064] The position of popular items can be set based on the positions of unpopular items and other popular items.

[0065] WCS can determine location by applying any process that can improve the efficiency of item delivery (especially popular items), reduce delays in item delivery, and / or increase automated warehouse throughput.

[0066] WCS can determine, while taking all or some of these considerations, the location of popular items in the storage, one or more robots to transport items to picking stations, and whether to return items to storage (location can be determined based on assigned asynchronous picking stations, which can be determined based on item popularity and load balancing or other considerations).

[0067] WCS can change the assignment of asynchronous picking stations for each item over time.

[0068] WCR can control the delivery of items from storage at assigned (asynchronous or synchronous) picking stations and the return of boxes to storage.

[0069] The WCS can instruct the robot to retrieve a box from its current location and transport it to a specific picking station. The WCR can instruct the robot to move a box from one picking station to another.

[0070] WCS can be configured to retrieve orders for items to be processed. Orders can be retrieved one after another or in batches.

[0071] An order can include an item identifier and one or more order-related parameters. These parameters can include the due date and quantity for supplying the item.

[0072] WCS is configured to prioritize orders based on one or more prioritization parameters, such as due date, popularity, and item type.

[0073] For example, WCS can individually control the provision of different types of items.

[0074] To simplify the explanation, let's assume that items come in two types: cold items (items that need to be kept at a low temperature) and hot items (items that can be stored at room temperature).

[0075] WCS can split orders into cold item orders and hot item orders.

[0076] WCS can manage different types of orders (hot and cold orders) separately.

[0077] Furthermore, the WCS efficiently manages the supply of items to the picking stations.

[0078] The WCS can be configured to communicate with robots and / or picking stations in any way using any type of communication. For example, the WCS can be run by one or more computerized systems that can communicate with robots and / or sensors and / or picking stations and / or pickers using any means of communication (usually wireless communication).

[0079] WCS can be configured to control the allocation and distribution of items per box, so that the same picking station can simultaneously receive items that may be useful for multiple order lines.

[0080] The batch factor is the number of order lines supplied by a single box brought to the picking station. The batch factor obtained by efficiently having one or more items per box may be greater than 1. The WCS can retrieve order history information to understand which items are being purchased simultaneously (in the same order, within a specific time window, or over a short period such as a few minutes) and assign items to boxes based on that simultaneity.

[0081] A batch factor in the range of 0 to 1 is obtained when an incoming order line has more items in the box than the normal amount (for example, when there is a replenishment of stock). The batch factor is exactly 1 if the system brings one box for each order line.

[0082] The greater the batch coefficient (greater than 1), the more optimized the ordering process at the picking station becomes. The proposed method can achieve a batch coefficient of 1.5–2 in specific areas of interest (e.g., pharmaceuticals) and up to 4 (e.g., groceries).

[0083] The first result of the above is that a single picking station needs to be able to process multiple orders simultaneously. This is called "pick by order" in a "put wall." The latter means that a put wall consisting of multiple positions is provided at the picking station, and each order is assigned to a specific position on the put wall.

[0084] Then, as the picker retrieves an item from the box, they place it in the appropriate position to process a specific order line within the target order.

[0085] Typically, these put walls feature a "put-to-light" system that illuminates the correct position for pickers to place items. The put-to-light system can be implemented by having a fixed display and button beneath each position. When a position corresponds to the current picking, the display lights up, and the picker then presses the button when they actually place the item.

[0086] WCS can control the put-in light area of ​​picking station 1 by activating light sources, and / or receive an indication that a light source has been activated to illuminate a specific item, and / or receive an indication from the picker that the picker has placed the item in the correct position. There may be no theoretical limit to the number of positions within a put wall. However, the more positions there are within a put wall, the larger the footprint occupied by the put wall becomes. This means that pickers will have to walk longer distances to deliver a particular order, which increases the average pick time and decreases picker efficiency.

[0087] Therefore, the size of the putwall and the number of items that can be placed within it can be determined based on the time required to obtain the items (the larger the putwall, the longer the time) and the batch factor (it may be necessary to increase the number of putwalls).

[0088] Therefore, as the number of positions within the put wall increases, the batch coefficient increases, which can lead to a trade-off regarding the number of positions within the put wall. On the other hand, a larger number of positions within the put wall reduces picker efficiency. The second optimization stems from triage between different types of picking stations.

[0089] Certain boxes can handle multiple orders, while other boxes can handle only one order.

[0090] The time a picker spends on a single box can range from tens of seconds to several minutes.

[0091] Asynchronous picking stations are considered efficient when pickers need to retrieve a large number of items from boxes for one or more orders gathered at the picking station at a specific time. This is because, as mentioned above, collecting a large number of items from boxes takes considerable time, and picking time can be up to one minute or more.

[0092] In a typical synchronous picking station, robots must wait until the picker has finished the picking process. Furthermore, all robots waiting at the picking station will also have to wait. When using an asynchronous picking station, robots do not need to wait for the picker to remove all items from the container and can leave the container at the picking station and proceed to the next task.

[0093] Furthermore, for certain items, typically items on sale or highly popular items, the size of the put wall may not be able to accommodate all orders that include this particular item. In such cases, at an asynchronous picking station, the box containing this item may remain at that station to await other orders that will be assigned to that station.

[0094] Boxes of items on sale typically remain at the asynchronous picking station until the box is empty, and there is no need to return them to storage afterward.

[0095] WCS can take into account the demand and frequency of demand for each SKU. Furthermore, to calculate the demand for each SKU, WCS can also consider forecasts based on past and future events, not limited to sales, weather, and season.

[0096] Furthermore, WCS can specify which items are on sale and for what period, which will cause WCS to consider those items as high runners.

[0097] The WCS can then determine which items are "high runners" and make them available to pickers at asynchronous picking stations.

[0098] For example, if an item is expected to be a high runner, that item will be considered a high runner and provided to the asynchronous picking station (for example, events such as rain and / or snow (order trigger events) can accelerate sales of umbrellas and / or raincoats and / or boots). Further examples of order trigger events include the start of summer, which can accelerate sales of swimwear and / or sunscreen and / or sunglasses. Order trigger events associated with certain types of food can accelerate sales of such food and / or items for cooking such food (turkey before Thanksgiving, grills and / or barbecue equipment at the beginning of spring; additional examples of order trigger events include holidays, Christmas decorations in December each year or flowers for Valentine's Day or costumes before Halloween).

[0099] For example, WCS can be configured to learn demand trends for a particular item based on past data, such as demand for that item every Friday, on the 1st of every month, or every Christmas.

[0100] WCS can manage asynchronous picking stations to store the most popular items, even if it is necessary to evacuate one or more unpopular items from the asynchronous picking station, especially if there is not enough space to store the more popular items.

[0101] The WCS can be configured to determine which items to move from the asynchronous picking station based on which items are expected to have low demand in the foreseeable future, i.e., the number of orders that need to be processed by the end of the day.

[0102] This triage of goods between high-running items and unpopular items (low-running items) can be performed regularly at regular intervals, although the intervals may be sufficiently frequent (e.g., every minute or more, every hour or more, several times a day).

[0103] Based on the information described above, the WCS can be configured to control the sending of high runners to asynchronous picking stations and low runners to synchronous picking stations. The latter is a classic picking station where a robot presents bins to pickers and waits for the pickers to retrieve the desired items from boxes on the robot.

[0104] This triage system can also take into account the loads of various stations; that is, the thresholds between low runners and high runners are automatically adjusted to balance the loads across different picking stations.

[0105] Asynchronous picking stations also have the advantage of freeing robots from waiting in line for pickers to retrieve items, thereby allowing different robots to perform other tasks while pickers retrieve items from boxes.

[0106] On the other hand, conventional picking stations (synchronous picking stations) force robots to stay on the line while they wait for their turn, and then wait for pickers to take items from the boxes on top of the robot.

[0107] A picker may be assigned to multiple picking stations, i.e., a combination of one or more asynchronous picking stations and mixed or synchronous picking stations.

[0108] This combination is particularly useful when the same order contains both low-runner and fast-runner items. Therefore, the order is handled by the same picker for items of varying popularity levels, freeing the process from the integration portion of the aforementioned process that would be required when the order is handled in different locations.

[0109] The type of picking station can be changed at any time if the typical order or item profile in the warehouse changes.

[0110] This change may include replacing synchronous picking stations with asynchronous picking stations.

[0111] If a synchronous picking station is different from an asynchronous picking station, the replacement can take time, for example, from a few minutes to several hours, or even longer.

[0112] On the other hand, if the difference between stations lies not in the hardware itself, but in how the boxes are maintained, then the replacement can be done virtually instantly.

[0113] If the exchange takes time, it can only be implemented if the exchange is worthwhile and the benefits gained outweigh the drawbacks of suspending the station. For example, during peak periods in November and December, such as Black Friday, Cyber ​​Monday, and Christmas, the benefits of the exchange may be increased.

[0114] Furthermore, it is possible to combine the two types of picking stations so that the WCS can instruct the robot to either place a box in the picking station area (asynchronous part) or to hand it to the picker synchronously.

[0115] Typically, to accommodate peak periods, picking stations may be converted to asynchronous picking stations, which are better suited to operation during these temporary periods, and then converted back to synchronous or hybrid picking stations.

[0116] WCS can control the pre-filling of one or more picking stations by placing the boxes required for the initial order into asynchronous picking stations and / or buffer-type synchronous picking stations (for example, performing pre-filling before the start of a shift).

[0117] WCS can be configured to control the organization of items within the vault, for example, by placing "high runner" boxes in the correct locations, thereby reducing the time required to transport them to the picking station.

[0118] Pre-filling of picking stations and / or rearranging of items in storage (assigning items per box and / or rearranging boxes in storage) can be done by activating the WCS for a certain period of time (e.g., several minutes to several hours) before the start of a shift. The WCS may be activated by an operator, but may also be activated by itself or by other means.

[0119] During this pre-shift period (the period in which WCS operates before the shift), WCS may already have or be able to acquire at least orders for the start of the shift, and thus (based on said orders and other information such as historical data and / or weather forecasts and / or any relevant information) be able to predict the expected demand for items at least during the start of the shift.

[0120] WCS can request automated warehouse robots to prepare the warehouse by placing relevant items (e.g., expected hot runners for shifts) in relevant locations within the warehouse (e.g., near assigned picking stations) and at least partially filling one or more asynchronous stations and / or buffer-type synchronous picking stations.

[0121] The inventors have found that this pre-shift operation can increase the throughput of an automated warehouse (for example, by up to 30%).

[0122] WCS can be configured to self-organize so that "high runner" boxes do not come too close to each other in order to reduce the load on specific aisles in the warehouse. In fact, as described below, WCS can take into account the congestion that may occur when robots need to pick multiple boxes from the same aisle at the same time, when optimizing the warehouse to bring high-demand boxes closer to the picking station.

[0123] Therefore, warehouse optimization may include distributing necessary boxes across several aisles to reduce foreseeable congestion.

[0124] An asynchronous picking station may include one or more shelves dedicated to storing boxes containing one or more high runners.

[0125] The picking station is height and / or box / shelf position adjustable, thereby allowing the storage to be adapted to pickers of various heights and / or with disabilities.

[0126] The system may include safety mechanisms to ensure human safety.

[0127] WCS can determine the placement of boxes within the picking station to optimize the provision of popular items to pickers.

[0128] This method may include steps involving interaction between a person and the box or its contents.

[0129] Figures 1 and 2 show an example of an automated warehouse 10. The automated warehouse 10 is shown to include (conventional) storage units 22, a cold storage unit 24, robots such as a lift robot 32 and a cart robot 34, a return unit 42, synchronous picking stations 53 and 54, a cold asynchronous picking station 62, a hybrid picking station 66, and a put wall 68. A picker 70 takes items from the picking stations and places them on the put wall. A packer 72 takes items from the put wall 68 and packs them. Figure 1 also shows an inbound truck 42 and an outbound truck 46.

[0130] The number and / or types of robots may differ from those shown in Figures 1, 2, and 6; the picking stations may differ from those shown in Figures 1 and 2 and / or may be of any type; the types of picking stations may differ from those shown in Figures 1 and 2 and may be of any type (synchronous, asynchronous, hybrid, buffer-type synchronous); and the types of storage units may differ from those shown in Figures 1 and 2 and may be of any type (an automated warehouse may include only one type of storage unit, or more than two types of storage units (and corresponding picking stations), e.g., cold only, normal only, or any combination of any type of storage unit)).

[0131] Figure 3 shows an example of a buffer-type synchronous picking station 70, which includes an input unit 71, an output unit 72, a conveyor 74, and a computerized system 73 for interacting with a picker (not shown) to indicate which items to pick from box 18. The picker can easily access an area 75 that can be selectively illuminated by a light source (not shown). Figure 3 also shows a cart robot 34 located in the input and output units.

[0132] Figure 4 shows an example of information flow.

[0133] Figure 4 shows the WCS94, WMS92, robot 30, and sensor / UI80. The UI is a user interface that can be entered by pickers and / or packers. The WCS can perform tasks such as order processing planning95, warehouse planning97, and mission planning99. The robot 30 can receive missions from the WCS and provide reports / feedback (e.g., mission completion, failure, etc.). The sensor and / or UI can provide reports and / or feedback and / or requests to the WCS and obtain information, responses, etc. The WMS92 and WCS94 can exchange reports / feedback, inbound box information, received information, etc. As described above, the WMS and WCS may run on at least one computerized system, and / or the WCS may have WMS functionality or include WMS functionality.

[0134] Figure 5 shows an example of method 100.

[0135] Method 100 is for managing the provision of items in an automated warehouse. Method 100 can begin with step 110, in which at least one computerized system obtains information about items being output from the automated warehouse.

[0136] The information may include, for example, information about order trigger events, purchase history, items purchased together, item popularity, orders, received items, availability of tracks or other output entities for outputting items from the automated warehouse, box contents (items stored per box and / or quantity of items per box), mapping between item identifiers (SKU, barcode, etc.) and items, item location (storage, picking station), any information about items (including item type, expiration date, storage parameters, transport parameters, fragility, transport location, etc.), package boxes, picking station contents, historical data (including order history), popularity information, environmental information, etc. Information about box location and box contents (e.g., quantity of one or more items per box) may be provided by sensors and / or any tracking systems and / or robots and / or pickers. Sensors may be of any type, including vision sensors, cameras, RFID readers, NFC readers, etc.

[0137] Step 110 may be followed by Step 120, in which, based on the information, the delivery of the item container to multiple picking stations in the automated warehouse by one or more robots is controlled according to the popularity of the items contained in the item container. Here, the multiple picking stations may include asynchronous and synchronous picking stations.

[0138] Step 110, which involves acquiring information, can be continued during step 120. Steps 110 and 120 can be repeated multiple times. Information can also be acquired while step 120 is being executed.

[0139] Step 120 is, (a) Control the provision of item containers from multiple picking stations, (b) Controlling the transport of items within a first popularity range to an asynchronous picking station, (c) Control the transport of items from a second popularity range to a synchronous picking station (where the first popularity range may include popularity levels higher than those of the second popularity range), (d) Control the removal of item containers from multiple picking stations based on the popularity of the items contained in the item containers. (e) Controlling the stay duration of item containers at multiple picking stations such that an item container provided to an asynchronous picking station remains at the asynchronous picking station for a period well longer than the stay duration of another item container stored at a synchronous picking station. (f) To enable item containers containing popular items to remain within the asynchronous picking station even when there is a lull in orders for those items. (g) Controlling the provision and removal of popular items based on orders for specific periods having a period equivalent to the order processing period of multiple picking stations, (h) Control the provision and removal of unpopular items based on orders for unpopular items, (i) Controlling the storage location of popular items, (j) Before the start of the shift, control the initial storage of at least the asynchronous picking station. (k) Determine the popularity of an item based on unprocessed orders and at least one of one or more order trigger events. (l) Determine the allocation of items to one or more item containers. (m) Determine the allocation of items ordered simultaneously for each item container. (n) Controlling the transport of boxes to picking stations, including different picking stations for different items. (o) To independently control the supply of different types of items to different picking stations. (p) Controlling the supply of boxes to buffer-type synchronous picking stations, (q) To provide a container to the input of a buffer-type synchronous picking station, and to independently control a first robot to retrieve an item conveyor from the output of the buffer-type synchronous picking station, and (r) Controlling one or more robots to transport item containers from multiple picking stations, It can include at least one of the following.

[0140] Figure 6 shows an asynchronous picking station 52 with boxes 18 stored using a multi-shelf frame 53. A lift robot 32 is shown picking up a box. For simplicity of explanation, all boxes are shown as empty, but contain one or more items.

[0141] Figure 7 shows a hybrid picking station that may include an asynchronous picking station section 66(1) and a synchronous picking station section 66(2). Figure 2 also shows a lift robot 34 and a tray robot 32. Any other type of robot can be provided.

[0142] Each picking station may include means for supporting the boxes, such as shelves, drawers, etc.

[0143] At least one non-temporary computer-readable medium can be provided for managing the provision of items in an automated warehouse, the non-temporary computer-readable medium storing instructions for at least one computerized system to obtain information about items output from the automated warehouse, and instructions for controlling the provision of item containers to multiple picking stations in the automated warehouse by one or more robots, based on the information and according to the popularity of the items contained in the item containers, the multiple picking stations may include asynchronous picking stations and synchronous picking stations.

[0144] An automated warehouse can be provided, which may include a storage facility configured to store multiple items, wherein the multiple items may be stored in item containers; multiple picking stations, including a hybrid picking station which may include an asynchronous picking station portion and a synchronous picking station portion; one or more robots which may be configured to transport item containers to the picking stations; and at least one computerized system configured to control the transport of item containers based on the popularity of the items contained in the item containers.

[0145] An automated warehouse can be provided, which may include a storage facility configured to store multiple items, wherein the multiple items may be stored in item containers; multiple picking stations, which may include asynchronous picking station sections and buffer-type synchronous picking stations; one or more robots, which may be configured to transport item containers to the picking stations; and at least one computerized system configured to control the transport of item containers.

[0146] An automated warehouse can be provided, which may include a storage facility configured to store multiple items, wherein the multiple items may be stored in item containers; multiple picking stations, which may include asynchronous picking stations and synchronous picking stations; one or more robots, which may be configured to transport item containers to the multiple picking stations; and at least one computerized system configured to control the transport of item containers based on the popularity of the items contained in the item containers.

[0147] At least one computerized system can be configured to control the transport of items within a first popularity range to an asynchronous picking station and to control the transport of items within a second popularity range to a synchronous picking station, wherein the first popularity range may include popularity levels higher than those of the second popularity range.

[0148] At least one computerized system can be configured to control the evacuation of item containers from multiple picking stations based on the popularity of the items contained within them.

[0149] At least one computerized system can be configured to control the dwell time of item containers in multiple picking stations so that an item container provided to an asynchronous picking station remains at the asynchronous picking station for a period well longer than the dwell time of another item container stored in a synchronous picking station.

[0150] At least one computerized system can be configured to allow item containers holding popular items to remain within an asynchronous picking station even during periods when orders for those items are interrupted.

[0151] At least one computerized system can be configured to control the provision and removal of popular items based on orders for specific periods having a duration equivalent to the processing time of multiple orders by a picking station, and to control the provision and removal of unpopular items based on orders for unpopular items.

[0152] At least one computerized system can be configured to control the storage location of popular items.

[0153] At least one computerized system can be configured to control the initial storage of at least an asynchronous picking station before the start of a shift.

[0154] At least one computerized system can be configured to determine the popularity of an item based on an outstanding order and at least one of one or more order trigger events.

[0155] At least one computerized system can be configured to determine the allocation of items per item container, or more items per item container.

[0156] At least one computerized system can be configured to determine the allocation of concurrently ordered items for each item container.

[0157] Multiple picking stations can include different picking stations for different types of items.

[0158] At least one computerized system can be configured to independently control the supply of different types of items to different picking stations.

[0159] Automated warehouses can include buffer-type synchronous picking stations.

[0160] A buffer-type synchronous picking station may include a conveyor configured to support multiple item containers simultaneously.

[0161] At least one computerized system can be configured to independently control a first robot to provide a container to the input of a buffer-type synchronous picking station and to retrieve an item conveyor from the output of the buffer-type synchronous picking station.

[0162] One or more robots can also be configured to transport item containers from multiple picking stations.

[0163] As described above, those skilled in the art will be able to manufacture and use the best possible embodiments of the present invention, but they will also understand and recognize the existence of variations, combinations and equivalents of the specific embodiments, methods and examples described herein. Therefore, the present invention should not be limited by the embodiments, methods and examples described above, but should be limited by all embodiments and methods within the scope and spirit of the claimed invention.

[0164] This specification has described the present invention with reference to specific embodiments of the present invention. However, it will be apparent that various modifications and changes can be made without departing from the broader spirit and scope of the present invention as defined in the appended claims.

[0165] Furthermore, where terms such as “front,” “rear,” “top,” “bottom,” “upward,” and “downward” appear in this specification and the claims, they are used for descriptive purposes and not necessarily to describe permanent relative positions. Terms used in this manner are interchangeable under appropriate circumstances, and it should be understood that embodiments of the invention described herein may operate in orientations different from those illustrated or otherwise described herein, for example.

[0166] Furthermore, the terms “assert” or “set” and “negate” (or “deassert” or “clear”) are used herein to refer to setting a signal, status bit, or similar mechanism to a logically true or logically false state, respectively. If a logically true state is at logical level 1, then a logically false state is at logical level 0. And if a logically true state is at logical level 0, then a logically false state is at logical level 1.

[0167] Those skilled in the art will recognize that the boundaries between logic blocks are merely illustrative, and that alternative embodiments may integrate logic blocks or circuit elements, or add alternative functional decompositions to various logic blocks or circuit elements. Therefore, it should be understood that the architectures described herein are merely illustrative, and in practice, many other architectures can be realized to achieve the same functionality.

[0168] Any arrangement of components to achieve the same function is effectively “associated” in such a way that the desired function is achieved. For this reason, any two components in this specification combined to achieve a particular function can be considered “associated” with each other, regardless of the architecture or intermediate components, in such a way that the desired functionality is achieved. Similarly, any two components thus associated can be considered “operably connected” or “operably coupled” with each other in such a way that the desired functionality is achieved.

[0169] Furthermore, those skilled in the art will recognize that the boundaries between the operations described above are merely illustrative. Multiple operations can be combined into a single operation, a single operation can be distributed among additional operations, and operations can be performed with at least partial overlap in time. Moreover, alternative embodiments may include multiple instances of a particular operation, and the order of operations can be modified in various other embodiments.

[0170] Furthermore, for example, in one embodiment, the illustrated embodiment can be implemented as a circuit arranged on a single integrated circuit or within the same device. Alternatively, these embodiments can be implemented as any number of separate integrated circuits or separate devices interconnected in an appropriate manner.

[0171] However, other modifications, variations, and substitutions are possible. Therefore, this specification and the drawings should be understood as illustrative, not restrictive.

[0172] In the claims, symbols in parentheses should not be interpreted as limiting the claims. The word “equipped with” does not preclude the existence of other elements or steps other than those described in the claims. Furthermore, the terms “a” or “an” as used herein are defined as one or plural. Also, the use of introductory phrases such as “at least one” and “one or more” in the claims should not be interpreted as meaning that the introduction of another claim element by the indefinite article “a” or “an” limits any particular claim containing the introduced claim element to an invention containing only one of those elements, even if the same claim contains the introductory phrase “one or more” or “at least one” and an indefinite article such as “a” or “an”. The same applies to the use of definite articles. Unless otherwise specified, terms such as “first” and “second” are used to arbitrarily distinguish elements that such terms describe. For this reason, these terms are not necessarily intended to indicate a temporal or other priority of such elements. The mere fact that certain means are described in different claims does not mean that a combination of those means cannot be used advantageously.

[0173] While specific features of the present invention have been illustrated and described herein, many modifications, substitutions, alterations, and equivalents will come to mind for those skilled in the art. Therefore, it should be understood that the appended claims are intended to cover all such modifications and alterations that fall within the true spirit of the present invention.

[0174] For clarity, it should also be understood that various features of embodiments of the present disclosure described in the context of separate embodiments may be provided in combination in a single embodiment. Conversely, for brevity, various features of embodiments of the present disclosure described in the context of a single embodiment may be provided separately or in any suitable partial combination.

[0175] Those skilled in the art will understand that embodiments of the present disclosure are not limited to those specifically disclosed and described herein. Rather, the scope of embodiments of the present disclosure is defined by the appended claims and their equivalents.

Claims

1. In an automated warehouse, A storage facility configured to store multiple items, wherein multiple items are stored in item containers, Multiple picking stations, including asynchronous picking stations and synchronous picking stations, One or more robots configured to transport item containers to the aforementioned multiple picking stations, In the aforementioned synchronous picking station, the one or more robots are: (i) Wait for the picker to take multiple items from one or more item containers, (ii) Next, the transported item container is configured to move away from the synchronized picking station, In the asynchronous picking station, one or more robots are configured to leave the item container they have transported at the asynchronous picking station and proceed to the next task of transporting other item containers, An automated warehouse comprising at least one computerized system configured to control whether at least a portion of the item containers are transported by one or more robots to the synchronous picking station or the asynchronous picking station, based on the popularity of the items contained within the item containers.

2. In the automated warehouse described in claim 1, An automated warehouse characterized in that at least one computerized system is configured to control the transport of items within a first popularity range to the asynchronous picking station and to control the transport of items within a second popularity range to the synchronous picking station, wherein the first popularity range has a popularity level higher than the popularity level of the second popularity range.

3. In the automated warehouse described in claim 1, An automated warehouse characterized in that the at least one computerized system is configured to control the removal of item containers from the plurality of picking stations based on the popularity of the items contained in the item containers.

4. In the automated warehouse described in claim 1, An automated warehouse characterized in that the at least one computerized system is configured to control the length of stay of item containers in the plurality of picking stations such that an item container provided to the asynchronous picking station remains at the asynchronous picking station for a period well longer than the length of stay of another item container stored in the synchronous picking station.

5. In the automated warehouse described in claim 1, An automated warehouse characterized in that the at least one computerized system is configured to allow item containers storing popular items to remain in the asynchronous picking station even when there is a lull in orders for those items.

6. In the automated warehouse described in claim 1, An automated warehouse characterized in that the at least one computerized system is configured to control the provision and removal of item containers containing popular items based on orders for specific periods having a period equivalent to the processing period of multiple orders by the picking station, and to control the provision and removal of item containers containing unpopular items based on orders for unpopular items.

7. In the automated warehouse described in claim 1, An automated warehouse characterized in that at least one computerized system is configured to control the storage location of popular items.

8. In the automated warehouse described in claim 1, An automated warehouse characterized in that the at least one computerized system is configured to control the initial storage of at least the asynchronous picking stations before the start of a shift.

9. In the automated warehouse described in claim 1, An automated warehouse characterized in that the at least one computerized system is configured to determine the popularity of an item based on an unprocessed order and at least one of one or more order trigger events.

10. In the automated warehouse described in claim 1, An automated warehouse characterized in that the at least one computerized system is configured to determine the allocation of items for each of the one or more item containers.

11. In the automated warehouse described in claim 1, An automated warehouse characterized in that at least one computerized system is configured to determine the allocation of simultaneously ordered items to each item container.

12. In the automated warehouse described in claim 1, An automated warehouse characterized in that the plurality of picking stations include different picking stations for different types of items.

13. In the automated warehouse according to claim 12, An automated warehouse characterized in that at least one computerized system is configured to independently control the supply of item containers containing different types of items to different picking stations.

14. In the automated warehouse described in claim 1, An automated warehouse characterized by including a buffer-type synchronous picking station.

15. In the automated warehouse according to claim 14, An automated warehouse characterized in that the buffer-type synchronous picking station includes a conveyor configured to support multiple item containers simultaneously.

16. In the automated warehouse described in claim 15, An automated warehouse characterized in that at least one computerized system is configured to independently control a first robot to provide item containers to the input unit of the buffer-type synchronous picking station and to retrieve item containers from the output unit of the buffer-type synchronous picking station.

17. In the automated warehouse described in claim 1, An automated warehouse characterized in that the one or more robots are also configured to transport item containers from the multiple picking stations.

18. In an automated warehouse, A storage facility configured to store multiple items, wherein multiple items are stored in item containers, Multiple picking stations, including a hybrid picking station having an asynchronous picking station section and a synchronous picking station section, One or more robots configured to transport item containers to the aforementioned multiple picking stations, In the aforementioned synchronous picking station section, the one or more robots are: (i) Wait for the picker to take multiple items from one or more item containers, (ii) Next, the transported item container is configured to move away from the synchronized picking station, In the asynchronous picking station section, the one or more robots are configured to leave the item container they have transported at the asynchronous picking station and proceed to the next task of transporting other item containers, and, An automated warehouse comprising: at least one computerized system configured to control the transport of at least a portion of the item containers to the picking station portion by one or more robots, based on the popularity of the items contained in the item containers.

19. In the automated warehouse according to Claim 1, An automated warehouse characterized in that the aforementioned synchronous picking station is a buffer-type synchronous picking station.

20. A method for managing the provision of items in an automated warehouse, The steps include obtaining information about items output from an automated warehouse using at least one computerized system, The process includes the step of controlling the provision of item containers to multiple picking stations of an automated warehouse by one or more robots based on the acquired information, The aforementioned multiple picking stations, A synchronized picking station in which the one or more robots (i) Wait for the picker to take multiple items from one or more item containers, (ii) Next, an asynchronous picking station is configured to move away from the synchronous picking station along with the transported item container, An asynchronous picking station comprising an asynchronous picking station configured such that one or more robots leave the item container they have transported at the asynchronous picking station and proceed to the next task of transporting other item containers, The method is characterized in that the control step includes transporting at least a portion of the item container to either the synchronous picking station or the asynchronous picking station by one or more robots, based on the popularity of the items contained in the item container.

21. In the method of claim 20, A method characterized by including the step of controlling the provision of item containers from the plurality of picking stations.

22. In the method of claim 20, A method comprising the steps of controlling the transport of items of a first popularity range to the asynchronous picking station and the transport of items of a second popularity range to the synchronous picking station by at least one computerized system, wherein the first popularity range includes popularity levels higher than the popularity levels of the second popularity range.

23. In the method of claim 20, A method characterized by including the step of controlling the removal of an item container from a plurality of picking stations based on the popularity of the items contained in the item container using at least one computerized system.

24. In the method of claim 20, A method characterized by including the step of controlling the stay duration of item containers in a plurality of picking stations by at least one computerized system, such that an item container provided to the asynchronous picking station remains at the asynchronous picking station for a period well longer than the stay duration of another item container stored in the synchronous picking station.

25. In the method of claim 20, A method characterized by including the step of enabling an item container storing popular items to remain in the asynchronous picking station even when there is a lull in orders for those items.

26. In the method of claim 20, A method characterized by including the step of using at least one computerized system to control the provision and removal of popular items based on orders for specific periods having a period equivalent to the processing period of multiple orders by the picking station, and to control the provision and removal of unpopular items based on orders for unpopular items.

27. In the method of claim 20, A method characterized by including the step of controlling the storage location of popular items using at least one computerized system.

28. In the method of claim 20, A method characterized by including the step of controlling the initial storage of at least the asynchronous picking station before the start of a shift using at least one computerized system.

29. In the method of claim 20, A method characterized by including the step of determining the popularity of an item based on an unprocessed order and at least one of one or more order trigger events.

30. In the method of claim 20, A method characterized by including the step of determining the allocation of items for one or more item containers.

31. In the method of claim 20, A method characterized by including the step of determining the allocation of simultaneous order items for each item container.

32. In the method of claim 20, A method characterized in that the plurality of picking stations include different picking stations for different types of items.

33. In the method according to claim 32, A method characterized by including the step of independently controlling the provision of different types of items to different picking stations.

34. In the method of claim 20, A method characterized by including a buffer-type synchronous picking station.

35. In the method according to claim 34, The method is characterized in that the buffer-type synchronous picking station includes a conveyor configured to support multiple item containers simultaneously.

36. In the method according to claim 35, A method characterized by including the steps of independently controlling a first robot to provide a container to the input unit of the buffer-type synchronous picking station and taking out an item conveyor from the output unit of the buffer-type synchronous picking station.

37. In the method of claim 20, A method characterized in that the one or more robots are also configured to transport item containers from the multiple picking stations.

38. At least one non-temporary computer-readable medium for managing the provision of items in an automated warehouse, At least one computerized system provides instructions for obtaining information about items output from an automated warehouse, Based on the acquired information, the system stores commands for controlling the provision of item containers to multiple picking stations in an automated warehouse by one or more robots. The aforementioned multiple picking stations, A synchronized picking station in which the one or more robots (i) Wait for the picker to take multiple items from one or more item containers, (ii) Next, an asynchronous picking station is configured to move away from the synchronous picking station along with the transported item container, An asynchronous picking station comprising an asynchronous picking station configured such that one or more robots leave the item container they have transported at the asynchronous picking station and proceed to the next task of transporting other item containers, A non-temporary computer-readable medium characterized in that the control includes transporting at least a portion of the item container to either the synchronous picking station or the asynchronous picking station by one or more robots, based on the popularity of the items contained in the item container.

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