Order fulfillment system and method using stacked container-based storage

Abstract

Some embodiments provide an automated order fulfillment system, the system comprising: a plurality of storage boxes; a storage area having stacks of storage boxes, each stack comprising one or more of the plurality of storage boxes stacked vertically; and a mobile robot configured to transport a set of one or more recovered storage boxes from the stacks of storage boxes through the storage area, the mobile robot comprising: a robot control circuit; a transport system that self-propels the mobile robot through the storage area; and a frame comprising a storage section and a storage box handling section, the storage section storing frame storage box stacks of recovered storage boxes stacked vertically on top of each other, and the storage box handling section comprising one or more storage box handling systems that perform a storage box recovery sequence.

Description

Technology Field

[0001] Cross-reference regarding related applications

[0002] This application claims priority to U.S. provisional patent application No. 63 / 610,331 filed on December 14, 2023, the entire contents of said provisional patent application incorporated herein by reference.

[0003] Technology field

[0004] The present invention generally relates to robot control for inventory. Background Technology

[0005] Some automated order fulfillment systems in use store products withdrawn to fulfill product orders. In these systems, containers can be used to store goods, and the containers can be maintained in a multi-level storage structure featuring vertical and horizontal storage spaces. Mobile robots can be used to move the containers. Improvements to the fulfillment facilities would be beneficial. means of solving the problem

[0006] The present invention provides an automated order fulfillment system, wherein the automated order fulfillment system comprises:

[0007] Multiple storage compartments;

[0008] A storage area equipped with stacks of storage boxes - each stack comprises one or more of the plurality of storage boxes stacked vertically on top of each other -; and

[0009] It includes a mobile robot configured to transport a set of one or more recovered storage boxes from a stack of storage boxes through the storage area, wherein the mobile robot:

[0010] Robot control circuit;

[0011] A transfer system combined with a robot control circuit - said transfer system is configured to self-propel the mobile robot through the storage area based on commands from said robot control circuit -; and

[0012] It includes a frame including a storage section and a storage box handling section, and

[0013] The above storage unit is configured to store frame storage stacks of a set of one or more recovered storage boxes by stacking them vertically on top of each other, and

[0014] The above storage box handling unit includes one or more storage box handling systems, wherein the storage box handling systems are controlled by the robot control circuit and configured to perform a storage box retrieval sequence to retrieve a first storage box from a first stack of storage boxes among stacks of storage boxes instructed to be removed from a first stack of storage boxes.

[0015] The present invention provides a method for automatic order fulfillment, said method being:

[0016] A step of controlling a transfer system of the mobile robot through a robot control circuit of the mobile robot to self-propel a storage area equipped with stacks of storage boxes - each stack comprises one or more storage boxes stacked vertically relative to each other - and positioning the mobile robot near a first stack of storage boxes among the stacks of storage boxes;

[0017] A step of engaging with the first storage box among the first stack of storage boxes that is instructed to be removed from the first stack of storage boxes by a first storage box handling system linked to the storage unit of the mobile robot;

[0018] In implementing a storage box retrieval sequence, the first storage box is retrieved from a first stack of storage boxes by the first storage box handling system; and

[0019] The method includes the step of arranging the first storage box within the storage section of the mobile robot as part of a frame storage box stack of a set of one or more recovered storage boxes that are stacked vertically relative to each other within the storage section and supported by the mobile robot. Brief explanation of the drawing

[0020] This specification discloses embodiments of systems, devices, and methods relating to order fulfillment. This description includes drawings. FIG. 1a illustrates a simplified perspective view of part of an exemplary automated order fulfillment system in a fulfillment facility having sets of one or more storage boxes or multiple rows of stacks stacked without storage structures, according to some embodiments. FIG. 1b shows a simplified plan view of an automated order fulfillment system according to some embodiments. FIG. 2 is a side view of an exemplary part of an automated storage system having a plurality of stacks of storage boxes, and a mobile robot that retrieves and / or returns the storage boxes according to some embodiments. FIG. 3 shows a simplified block diagram of an exemplary mobile robot located within an exemplary passage between two exemplary rows of stacks of exemplary storage boxes, according to some embodiments. FIGS. 4a-4b shows simplified perspective views of exemplary storage boxes according to some embodiments. FIG. 4c shows a plan view of a set of exemplary storage boxes stacked on top of each other according to some embodiments. FIG. 5 shows a simplified perspective view of an exemplary mobile robot according to some embodiments. FIG. 6a shows a simplified perspective view of an exemplary storage box handling system comprising a single exemplary storage box interlocking system in its original position or state, according to some embodiments. FIG. 6b shows a simplified perspective view of an exemplary storage box processing system comprising a plurality of exemplary storage box interlocking systems in original positions or states, according to some embodiments. FIG. 7 shows a simplified perspective view of a portion of an exemplary mobile robot including the exemplary storage box handling system of FIG. 6b, wherein the exemplary multi-storage box interlocking system is in an exemplary extended position or state according to some embodiments. FIG. 8a shows a simplified perspective view of a portion of an exemplary mobile robot having an exemplary upper storage box handling system including an exemplary storage box engaging system in its original position or state, according to some embodiments. FIG. 8b is a simplified perspective view of a portion of an exemplary mobile robot equipped with the exemplary upper storage compartment handling system of FIG. 8a, wherein the exemplary storage compartment engagement system is in an exemplary extended position or state according to some embodiments. FIG. 9a illustrates a simplified perspective view of a portion of an exemplary mobile robot equipped with the exemplary upper storage box handling system of FIG. 8a, wherein, according to some embodiments, the exemplary storage box is securely engaged by the storage box engagement system and retracted into the storage box handling portion. FIG. 9b illustrates a simplified perspective view of a portion of an exemplary mobile robot equipped with an exemplary upper storage box handling system, wherein, according to some embodiments, the exemplary storage box is securely engaged by a storage box engagement system. FIG. 10a-10g shows a simplified perspective view of an exemplary mobile robot or an enlarged portion of an exemplary mobile robot controlling one or more exemplary storage box handling systems in implementing an exemplary storage box retrieval sequence or process according to some embodiments. FIGS. 11a-11f shows simplified perspective views of an exemplary mobile robot or an enlarged portion of an exemplary mobile robot controlling one or more exemplary storage box handling systems in implementing an exemplary storage box alignment sequence or process according to some embodiments. FIGS. 12a-12f show simplified perspective views of an exemplary mobile robot or an enlarged portion of an exemplary mobile robot controlling one or more exemplary storage box handling systems in implementing an exemplary return storage box staging sequence or process according to some embodiments. FIGS. 13a-13d shows simplified perspective views of an exemplary mobile robot or an enlarged portion of an exemplary mobile robot controlling one or more exemplary storage box handling systems in implementing an exemplary storage box return sequence or process according to some embodiments. FIGS. 14a-14i shows a simplified perspective view of an exemplary mobile robot or an enlarged portion of an exemplary mobile robot controlling one or more exemplary box handling systems in implementing an exemplary box return sequence or process as part of a box retrieval sequence or process for retrieving one or more boxes from an external storage stack, according to some embodiments. FIGS. 15a-15i shows a simplified perspective view of an exemplary mobile robot or an enlarged portion of an exemplary mobile robot that controls two exemplary storage box handling systems in implementing a storage box return staging sequence or process and implementing a recovered first storage box into an intended vertical position within a frame storage box stack, according to some embodiments. FIG. 16 shows a simplified perspective view of an exemplary mobile robot that simultaneously moves each of the exemplary storage boxes in an exemplary frame storage box stack, according to some embodiments. FIG. 17 shows a simplified side view of a part of an automated order fulfillment system according to some embodiments. FIG. 18 shows a simplified perspective view of an exemplary work station equipped with a mobile robot linked to the work station in transporting a stack of frame storage boxes to the work station and / or retrieving a stack of storage boxes from the work station, according to some embodiments. FIG. 19a shows a simplified plan view of an exemplary work station equipped with a mobile robot linked to the work station for transporting a stack of frame storage boxes to the work station and / or retrieving a stack of storage boxes from the work station, according to some embodiments. FIG. 19b illustrates a simplified plan view of an exemplary workstation comprising one or more storage buffers and / or linked with said storage buffers, according to some embodiments, and further illustrates a mobile robot linked with the storage buffer tower of the workstation. FIG. 20 shows a simplified flowchart of an exemplary process for managing containers in automated order fulfillment, according to some embodiments. FIG. 21 shows a simplified flowchart of an exemplary storage box return process that returns one or more storage boxes to an external stack of storage boxes, according to some embodiments. FIG. 22 shows a simplified flowchart of an exemplary storage box return process that returns one or more storage boxes to an external storage box stack according to some embodiments. FIG. 23 shows a simplified flowchart of an exemplary storage box return process that returns one or more storage boxes to an external stack of storage boxes, according to some embodiments. FIG. 24 shows a simplified flowchart of an exemplary process for routing a storage box stack to a work station according to some embodiments. FIG. 25 shows a simplified flowchart of an exemplary process of inserting a storage box into a frame storage box stack according to some embodiments. FIG. 26 shows a simplified flowchart of an exemplary process for moving a frame storage stack from a robot to form an external stack and / or integrate it with an existing external stack, according to some embodiments. FIG. 27 shows a simplified flowchart of an exemplary process of container management, container transfer, and container loading within a fulfillment facility, according to some embodiments. FIG. 28 shows a simplified flowchart of an exemplary process for obtaining a return container according to some embodiments. FIGS. 29a-29b shows a simplified flowchart of an exemplary process for managing a loaded storage box according to some embodiments. FIG. 30 illustrates an exemplary system for providing order fulfillment through an organization of stacked container-based storage according to some embodiments and for use in implementing a method, technology, device, apparatus, system, server, or source. Components in the drawings are depicted for simplicity and clarity and are not necessarily drawn to scale. For example, to aid in understanding various embodiments of the invention, the dimensions and / or relative positions of some components in the drawings may be exaggerated relative to others. Additionally, to avoid hindering understanding of various embodiments of the invention, general but well-known elements useful or necessary in commercially viable embodiments are often not depicted in the drawings. While specific actions and / or steps may be described or depicted in a specific order of occurrence, a person skilled in the art will understand that such specificity regarding the order is not actually necessary. Unless otherwise specified herein, the terms and expressions used herein have the ordinary technical meanings that a person skilled in the art would give to such terms and expressions. Specific details for implementing the invention

[0021] The following description should not be construed as limiting and is provided solely for the purpose of explaining the general principles of exemplary embodiments. Throughout this specification, expressions such as “one embodiment,” “some embodiment,” “some embodiments,” “some implementations,” “some applications,” and similar expressions mean that a particular configuration, structure, or feature described in relation to such embodiment is included in at least one embodiment of the present invention. Thus, throughout this specification, expressions such as “one embodiment,” “some embodiment,” “some embodiments,” “some embodiments,” and similar expressions may all refer to the same embodiment, but are not necessarily so.

[0022] Some fulfillment facilities and / or systems are used to supply one or more items to a requesting entity (e.g., a customer, a manufacturing department of one or more manufacturing facilities, a repair technician, a retail store, a retail fulfillment center, etc.). These fulfillment facilities and / or systems are often used in supply chains, for example, in retail supply chains, and can fulfill orders for individual items, product units, and / or goods. Some fulfillment systems may use mobile robots within the facility to transport bins and / or other containers, such as between a storage area and one or more picking workstations, where orders are processed. Typically, products are sequentially retrieved from inventory or product bins and placed into individual order bins, bags, boxes, etc., to fulfill a given order. In many fulfillment facilities, the storage area includes one or more storage structures that can be constructed with vertical and horizontal structural beams and other fixed and supporting hardware, providing multiple layers of shelving to offer various bin storage locations on each level. These supporting structures are large, expensive, heavy, and are typically fixed in specific locations. Additionally, the addition of support structures must support the weight of the storage containers and the cargo inside them. Furthermore, these support structures must be constructed to possess sufficient stability to withstand seismic loads, accidental contact caused by equipment moving within the facility, and / or other safety functions. Such support structures can be costly to construct and are often implemented on a very large scale. In many cases, such support structures may not be feasible or practical for many facilities, and may not be implementable throughout the entire facility. It is beneficial for many facilities to provide alternative methods of storage and arrangement that do not require such large-scale storage structures, such as for small-scale facilities and / or parts of transfer facilities.

[0023] FIG. 1a shows a simplified perspective view of part of an exemplary automated order fulfillment system 100 in a fulfillment facility having multiple rows 102 of stacked stacks 104 or sets of one or more storage boxes 106 without storage structures, shelves, frames, or other structures on which the boxes are placed, according to some embodiments. Instead, in some embodiments, the storage boxes 106 may be stacked directly on top of each other without external intermediate structures. This saves time required for installing storage structures, which can significantly reduce the time required to get the facility up and running, allows relatively small spaces to be quickly utilized as storage areas, significantly reduces the cost of partially implementing the fulfillment system due to the absence of purchasing and assembling storage structures, and also allows additional storage boxes to be stored by utilizing one or more parts of the facility not occupied by the storage structures, even in facilities that include storage structures, and / or other such advantages.

[0024] One or more mobile robots 110 may move through a transfer facility to transfer one or more sets of storage containers 106 to stacks of storage containers or from stacks. The stacks may be arranged in rows 102, and a gap or passageway 112 is established between the rows 102, and in some embodiments, this gap or passageway is sized to enable one or more mobile robots 110 to move along the length of the rows 102 to a position along the row to retrieve and / or return one or more storage containers 106 to the stacks. In some embodiments, the mobile robots 110 retrieve and / or return the storage containers to either side of the passageway 112 to enable greater concentration of the rows 102.

[0025] FIG. 1b shows a simplified plan view of an automated order fulfillment system 100 according to some embodiments. The fulfillment system 100 includes one or more storage structures 150 comprising a plurality of bays or container storage locations 154. The storage structures are assembled from multiple horizontal and vertical beams, booms, joists, spans, columns, and / or other structural support components and fixed together to provide a matrix of storage locations extending along a structural passageway 158. The storage structures 150 further include horizontal and / or vertical tracks, decks, transfer plans, and / or other structures utilized by a robot in moving through the storage structures. In some embodiments, the fulfillment system 100 may include one or more additional storage areas 102 comprising one or more rows of stacks 104 of storage containers loaded directly to each other without external intermediate structures and / or additional separate support structures. The storage locations 154 of the storage structure may each include a yz array of storage locations 154 within horizontal rows and level change towers along the rows, and in the embodiments, these level change towers may be vertical towers. A mobile robot 110 and / or a low-profile mobile robot 152 may move between storage levels in the z direction within the level change towers to acquire and / or return a storage container 106 to another storage location 154 within the storage structure 150. In some implementations, the storage locations extend along a structure aisle 158, and there are opposite pairs of storage locations 154 positioned facing each other, separated by the structure aisle 158. The structure aisle 158 may have a width that allows a low-profile mobile robot 152 moving within the aisle 158 to transfer a storage container or other container to storage locations 154 on either side of the structure aisle 158. In some embodiments, the fulfillment system 100 includes one or more work stations 170.Mobile robot 110 and / or low-profile mobile robot 152 may transport a storage area, stacks of storage containers 104, a storage structure 150 and / or other areas of a fulfillment facility. Other aspects of the storage structure 150, the low-profile robot 152, the coordination and / or movement of robots through the storage structure, an exemplary workstation and / or fulfillment system 100 may be similar to or include aspects of systems and components described in one or more of U.S. Patents No. 9,139,363, 10,435,241 and 11,142,398 and U.S. Patent Application Publications No. 2019 / 0270591, 2021 / 0229271 and 2023 / 0095494, each of which is incorporated herein by reference in its entirety.

[0026] FIG. 2 shows a side view of an exemplary portion of an automated storage system 100 comprising, according to some embodiments, multiple stacks 104 of storage containers 106 and a mobile robot 110 that self-propelled within the facility to retrieve and / or return the storage containers 106. FIG. 3 shows a simplified block diagram of an exemplary mobile robot 110 located within an exemplary passageway 112 between two exemplary stacks 104 of exemplary storage containers 106 according to some embodiments. Referring to FIG. 1a through FIG. 3, in some embodiments, the transfer system 100 may have one or more storage areas where stacks 104 of storage containers 106 may be placed. Each stack 104 may comprise one or more of multiple storage containers 106 stacked vertically relative to each other, and generally there is no additional structure to maintain the vertical stability of the stacks 104. In some embodiments, some or all of the stacks 104 are assembled without any structures placed between the storage compartments and / or without additional structures along the sides of the stacks 104. In some embodiments, one or more storage compartments 106 may include one or more alignment structures that help align the storage compartments within the stacks 104 and / or improve the stability of the stacks 104 of the storage compartments. In some embodiments, the stacks 104 of the storage compartments 106 of the row 102 may be placed on a riser 204, lift, base, or other such structure to place the bottommost storage compartment at a predefined height 206 above the floor 208 or other surface on which the mobile robot 110 moves. In some embodiments, the riser 204 provides protection for the stacks 104.For example, the riser can lift stacks and may have sufficient width to reduce or prevent the risk of the storage bins falling by limiting and / or preventing unintended contact with Robot 110, other mobile robots, human-operated vehicles or systems (e.g., forklift systems, man lift systems, and / or other similar systems operated by workers) and / or other equipment, and by providing protection to such systems and workers. As an example of what is not limited, the riser 204 may additionally limit and / or prevent the mobile robot 110 from driving into the loaded storage bins. Additionally, the riser 204 may provide a flat base on which the stacks of storage bins can be placed and / or constructed.

[0027] FIGS. 4a-4b shows a simplified perspective view of an exemplary storage box 106 according to some embodiments. FIG. 4c shows a plan view of a set of exemplary storage boxes 106 stacked on top of each other according to some embodiments. Referring to FIGS. 1a-4c, the storage boxes 106 include a main body 402 that may include one or more sides. In some embodiments, the storage box 106 is generally a rectangular cube shape in which the sides 404 are joined to the ends 406 or faces at edges 408, seams and / or corners. Other storage boxes may have different shapes. In some implementations, the length of the sides 404 may be longer than the length of the ends 406, whereas in other embodiments, the length of the ends may be equal to or longer than the length of the sides. The storage box 106 provides a cavity 410 defined by the sides 404 and the ends 406, which may be configured to accommodate one or more items. In some embodiments, the storage box 106 may include one or more alignment and / or stabilizing loading features 412, 414. For example, some storage boxes may include one or more upper loading features 412 positioned near and / or along the upper edge of the storage box and / or one or more lower loading features 414 positioned near and / or defining the lower edge of some or all of the storage boxes. For example, the upper loading features may include one or more ridges 412 having a tapered, arched, and / or other specific shape that easily combine with the corresponding mutually or symmetrically lower loading features 414 of other storage boxes. In some embodiments, the lower loading features may include receiving recesses 414 configured to combine with the respective ridges 412 of other storage boxes to which the storage boxes are stacked or coordinated.In some embodiments, each bottom loading feature 414 may be configured to align and slide-interlock with one or more upper loading features 412 of other compartments among the plurality of compartments, thereby ensuring vertical and lateral alignment of the loaded compartments. One or more of the loading features may include additional structures that may help guide and / or join the loading features of two separate compartments. For example, in some embodiments, one or more of the bottom loading features 414 may include a shape 416 that tapers from the end 406 of the compartment toward the center of the compartment, and / or one or more of the upper loading features may include a similar shape to aid in interlocking. In some embodiments, the internal cavity of the compartment may be configured to accommodate a sub-container or sub-compartment and / or partition. Loading features (e.g., protrusions, depressions, etc.) do not interfere with placing the container on a flat surface (e.g., for use in operations such as decanting, but not limited thereto) and / or loading.

[0028] For example, in some implementations, the ridge 412 may include a triangular cross-sectional shape, an elongated pyramidal shape, an elongated semicircular shape, and / or other similar shapes. The receiving groove 414 may have a shape corresponding to one or more different types of ridge 412 or other shapes that can interlock with it. In some embodiments, the interlocking between the ridge 412 and each receiving groove 414 enables the two storage containers 106 to slide easily into each other when loaded. By enabling the interlocking and separation of the loaded containers in part without lifting the upper container, the elongated ridge 412 and the elongated receiving groove 414 operate differently from columns, protrusions, openings, and other similar structures. Instead, one or more upper containers can slide sideways to move one or more upper containers from one or more containers loaded below.

[0029] In some embodiments, the storage boxes 106 may include one or more interlocking structural components 420 on one or more external and / or internal sides and / or bottom of the storage box, which may be utilized to move, transport, position and / or otherwise interlock the storage box. FIG. 4a shows an exemplary storage box including one or more interlocking structural components 420 on side 404 and an interlocking structural component 420 on front or front 406. It will be acknowledged that the storage box may include substantially any number of interlocking structural components, and / or there may be no interlocking structural components at all on one or more surfaces of the storage box.

[0030] FIG. 5 shows a simplified perspective view of an exemplary mobile robot 110 according to some embodiments. Referring to FIGS. 1a through FIGS. 5, in some embodiments, the mobile robot 110 may be configured to transport a set of one or more recovered containers 106a to one or more stacks 104 of containers 106 and / or vice versa, and to transport through one or more storage areas of a facility. Additionally, the mobile robot 110 may generally be operated to recover multiple containers 106 and to transport multiple containers 106 simultaneously through the facility. The mobile robot 110 generally includes one or more robot control circuits 502 comprising one or more processors, microprocessors, computer memory, computers and / or other systems that control the operation of the mobile robot. Additionally, the mobile robot includes a transport system 504 coupled with the robot control circuits 502. The above transfer system is configured to self-propel a mobile robot through one or more storage areas within the facility based on location identification, instructions, and / or commands from a robot control circuit and / or one or more remote control systems (e.g., a central transfer control circuit, a remote server, etc.). The transfer system 504 may include one or more drive systems 506 and / or motors that drive and control one or more axles 508 and / or wheels 510 of the mobile robot, respectively, to induce movement of the mobile robot 110 and / or control steering. The transfer system 504 is similar to and / or may include aspects of the transfer system and / or horizontal drive system of a mobile robot described in U.S. Patent Nos. 9,139,363, 10,435,241 and 11,142,398 and U.S. Patent Application Publications Nos. 2019 / 0270591, 2021 / 0229271 and 2023 / 0095494, each of which is incorporated herein by reference in its entirety.

[0031] As described above, in some embodiments, the mobile robot 110 is configured to transport multiple storage containers 106 simultaneously. In some implementations, the mobile robot 110 may include a frame 120, one or more storage container storage sections 122, and one or more storage container handling sections 124. One or more storage container handling sections 124 may include one or more storage container handling systems 130-131 that are communically connected to and controllable by the robot control circuit 502. In some embodiments, one or more of the storage container handling systems 130-131 may further include a climbing system coupled to the frame 120, which enables one or more of each storage container handling system 130-131 to move vertically within the frame 120. For example, the climbing system may include one or more motors, and these motors are configured to be driven in combination with one or more gears, pinions, belts, cables, pulleys, wheels, and / or other components that engage with one or more tracks, guides, teeth, cables, chains, and / or other structures that enable climbing within the frame 120 in conjunction with the frame 120. The climbing system and / or track may be implemented similarly to one or more vertical movement systems described in U.S. Patent Publications Nos. 2012 / 0197431, 2014 / 0277692, 2014 / 0288696, 2016 / 0075512, 2016 / 0355337, 2016 / 0207710, 2017 / 0010608, 2017 / 0137223, 2017 / 0137222, 2017 / 0313514, 2017 / 0369243, 2018 / 0134492 and 2018 / 0150793, each of which is incorporated herein by reference in its entirety.In another embodiment, the climbing system includes one or more climbing wheels, and the climbing wheels apply force to the frame 120 and enable the drive system to operate the climbing wheels to move each storage box handling system vertically.

[0032] In some embodiments, one or more storage box handling systems 130-131 may include one or more storage box engagement systems 302, which are configured to engage with storage boxes 106 to allow movement in and out of the frame 120 of the mobile robot 110. For example, partially, one or more storage box handling systems 130-131 are controlled by a robot control circuit and instructed to perform one or more storage box movement sequences and / or storage box retrieval sequences to retrieve one or more storage boxes 106 from a stack 104 of storage boxes 106 and to move one or more storage boxes 106a, which are removed from the stack and retrieved, to the frame 120. In some embodiments, an external storage stack 104 of storage boxes is positioned to be approached perpendicular to the direction of movement of the mobile robot 110, and the mobile robot 110 moves along a passage 112.

[0033] Storage unit 122 may be configured to accommodate and temporarily store a set of one or more recovered storage containers 106a, wherein the storage containers 106a are stacked vertically relative to each other within storage unit 122 to define a frame storage stack 202 of a set of one or more recovered storage containers 106a. In some embodiments, one or more of storage container handling systems 130-131 may move one or more storage containers 106 into storage unit 122 to be incorporated into the frame storage stack 202 and move them out of the frame storage stack 202. In some embodiments, storage container handling systems 130-131 may utilize one or more loading features 412, 414 of a plurality of storage containers 106 to align the loading features of two storage containers and engage them in a sliding manner to establish vertical and / or horizontal alignment of a set of storage containers 106a within the frame storage stack 202. In another embodiment, one or more of the mobile robots 110 may be fixed to the frame of the storage unit 122 and / or may include a set of multiple supports, shelves, and racks formed as part of the frame. One or more storage unit handling systems 130-131 may be controlled by a robot control circuit to place the retrieved storage unit at a different location on the shelf. Storage units stored inside the mobile robot may be placed on the support shelves, which may enable any access to the storage units. However, it should be noted that the operation of one or more of the storage unit handling systems 130-131 may similarly provide any access to the storage units stacked on top of each other without support shelves by pulling the sub-stack to the storage unit handling unit 124, adjusting the vertical position of the sub-stack, and returning one or more unwanted storage units to the frame storage unit stack 202. Some embodiments are consistent with and / or include similar support shelves as described in international patent application PCT / US2023 / 032416, the entire contents of which are incorporated herein by reference.Similarly, the facility may include one or more storage racks having one or more shelves, slots, guides, tracks, etc., and a mobile robot 110 may be configured to move to these storage racks to store a storage box and to retrieve a storage box from these storage racks.

[0034] A storage box engagement system 302 is configured to contact and engage with one or more storage boxes 106, and to move the engaged storage boxes 106 to the frame 120 of the mobile robot 110, out of the frame, and / or inside thereof. In some embodiments, one or more storage box engagement systems 302 are configured to extend from a storage box handling section 124 to a storage box storage section 122 to insert the retrieved storage box 106a into a frame storage box stack 202 and / or remove it from a frame storage box stack. Additionally or alternatively, in some embodiments, the storage box engagement system 302 may extend from outside the storage box handling section 124 to the frame 120 to move the storage box 106 into the frame 120 and / or move it out of the frame (e.g., return the storage box to an external storage box stack 104). For example, the lower storage box handling system 130 may be configured to activate one or more storage box engaging systems 302 that extend from the frame 120 and engage with one or more storage boxes 106 in the outer stack of storage boxes 104, retrieve at least one storage box 106 from the outer stack of storage boxes 104, and retract to move the retrieved storage box 106 into the frame 120. In some embodiments, the lower storage box handling system 130 may be further configured to move the retrieved storage box to the frame storage box stack 202 during the storage box retrieval sequence. In some embodiments, the mobile robot 110 may further include a second or upper storage box handling system 131, the system may include one or more storage box engaging systems 302, the storage box engaging systems 302 may hold one or more storage boxes in organizing storage boxes and placing storage boxes within a frame storage box stack 202, and / or may hold one or more storage boxes to be returned to one or more outer stacks 104 of storage boxes 106 during a storage box retrieval sequence and / or a storage box return sequence.

[0035] FIG. 6a shows a simplified perspective view of an exemplary storage box handling system 130 comprising a single exemplary storage box engagement system 302 in its original position or state, according to some embodiments. FIG. 6b shows a simplified perspective view of an exemplary storage box handling system 130 comprising a plurality of exemplary storage box engagement systems 302a-302b in their original positions or states, according to some embodiments. FIG. 7 shows a simplified perspective view of a portion of an exemplary mobile robot comprising the exemplary storage box handling system 130 of FIG. 6b, wherein the exemplary multiple storage box engagement systems 302a-302b are each in an exemplary extended position or state, according to some embodiments. In some embodiments, the multiple storage box engagement systems 302a-302b of a single storage box handling system (e.g., storage box handling system 130) may operate independently, whereas in other cases, they operate together.

[0036] Referring to FIGS. 1a–7, in some embodiments, one or more storage box engagement systems 302 of one or more storage box handling systems 130–131 may include one or more storage box engagement control circuits 702 capable of providing at least some of the control over the one or more storage box engagement systems 302. Additionally, in some embodiments, the storage box engagement system 302 may include one or more storage box engagement motors 704, pulleys, drive systems and / or other components that can be controlled to extend and retract the storage box engagement system 302 and / or perform other actions for engaging and / or disengaging one or more storage boxes 106. In some embodiments, one or more of the storage box engagement systems 302 may include one or more storage box engagement features 602, which engage with the intended storage box and / or, in some embodiments, one or more grooves, posts, handles, ridges, shoulders, holes, or other engagement structure components 420 of the storage box 106, or a combination of two or more of these engagement structure components 420. Similarly, the engagement structure components may have substantially any relevant shape to provide the intended engagement and / or interlocking with the storage box handling system 130-131 and / or other systems of the fulfillment system. One or more of the engagement structure components may be positioned on one or more of the front end or front of the storage box facing the mobile robot when in the storage stack, the rear strap portion or face opposite the front, and / or a side generally perpendicular to the front.For example, in some embodiments, one or more storage box engaging systems may be extended from the frame 120 to accommodate one or more storage box engaging features 602, engage an intended storage box, and be controlled to move the intended storage box in and out of the frame by sliding it from a storage box or other supporting structure of the facility in which the intended storage box is supported and loaded.

[0037] In some embodiments, one or more of the storage box handling systems 130-131 may include one or more storage box handling control circuits 706, which may provide at least some control over one or more storage box engagement systems 302, one or more storage box handling motors, pulleys, drive systems and / or other components that may be controlled to move one or more storage box handling systems 130 vertically within the storage box handling section 124. The storage box engagement control circuit 702 and / or the storage box handling control circuit 706 may be coupled to communicate with the robot control circuit 502 and / or external control circuit and / or system to receive control commands to be executed in retrieving, moving, and / or placing one or more storage boxes to and / or out of the mobile robot 110. In another embodiment, the storage box interlocking system 302 and / or storage box handling system 130 does not include the interlocking control circuit 702 and / or storage box handling control circuit 706, and the robot control circuit 502 controls the operation of the storage box handling system and / or storage box interlocking system.

[0038] Generally, the storage box engagement system 302 activates one or more storage box engagement motors 704 to extend part or all of the engagement system (e.g., one or more storage box engagement features 602) between an original position and one or more extended positions and engage one or more storage boxes 106. For example, the storage box engagement system includes a telescoping arm having several sections that extend and retract, wherein the storage box engagement features 602 are configured to engage with one or more storage boxes. The engagement features may include protrusions and / or extensions configured to engage with a recess of a storage box, a recess configured to engage with a protrusion of a storage box, magnets, biasing, hooks, latches, other engaging mechanisms, or a combination of two or more of such mechanisms that assist in engagement between the storage box engagement system and the storage boxes. In some embodiments, the storage box engaging system may engage the storage boxes by providing a clamping force by biasing the ends of the storage box engaging systems, and may engage the storage boxes by using one or more motors to move the ends of the storage box engaging systems to partially close and / or partially open the storage boxes to clamp and / or unclamp the storage boxes, and may engage the storage boxes by using a magnetic system to engage with one or more features of the storage boxes by engaging with a magnetic material on the storage boxes, or by other similar operations or a combination of two or more of these operations. Additionally or alternatively, the engaging system may provide sufficient rigidity to maintain the engagement between one or more storage box engaging features 602 and one or more engaging structural components 420 of the storage box 106.

[0039] In some embodiments, a storage box handling system 130-131 comprising a plurality of storage box engaging systems 302a-302b is configured to move one or more storage boxes vertically up or down between an upper storage box engaging system 302a and a lower storage box engaging system 302b. For example, the lower storage box engaging system 302b engages with a set of one or more lower engaging structural components 420 and moves the storage box vertically to enable the upper storage box engaging system 302a to engage with a set of one or more upper engaging structural components 420. Additionally or alternatively, the storage compartment engaging systems 302a-302b may be spaced vertically apart and / or the vertical spacing between the storage compartment engaging systems 302a-302b may be adjusted so that both systems engage with a single compartment, or each may operate to engage with a separate compartment (e.g., two compartments stacked on top of each other). Similarly, one or more storage compartment engaging systems 302a-302b of the lower compartment handling system 130 vertically move the compartment, enabling one or more storage compartment engaging systems of the upper compartment handling system 131 to engage and hold the compartment (e.g., return compartment). Additionally, in some embodiments, the vertical movement by the storage compartment engaging systems 302a-302b may enable one or more compartments in the outer stack to be lifted. For example, the lower interlocking system 302b can be extended to interlock with a desired storage box, and the upper interlocking system 302a interlocks with a storage box supported by the desired storage box. The upper interlocking system 302a can vertically lift the storage box supported on the upper side, which enables the lower storage box interlocking system 302b to pull the desired storage box to the storage box processing unit without pulling the storage box from the stack above the desired storage box.The storage box interlocking systems 302a-302b may include two, four, six, eight, or other numbers of storage box interlocking features 602. Similarly, in some embodiments, the upper and lower storage box interlocking systems 302a-302b each may include two, four, or more arms or other systems for interlocking and moving the storage boxes in and out of the mobile robot.

[0040] In some embodiments, one or more of the storage box handling systems 130-131 may include a storage box engagement base 604 positioned relative to one of the storage box engagement systems 302. The storage box engagement base 604 may be configured to support one or more storage boxes 106 while being held by the storage box handling systems 130-131 and / or moving within the frame. In some embodiments, the storage box engagement system may slide one or more storage boxes into the storage box handling system and over the storage box engagement base 604 to support the weight of the storage box or storage boxes sliding with the mobile robot. In some embodiments, the storage box engagement base 604 may include one or more storage box loading features 412 (not shown) to engage with the corresponding loading feature 414 of the storage box. Additionally, in some embodiments, a portion of the storage box interlocking system 130-131 may move along a portion or the entire length of the storage box interlocking base 604 as the storage box moves out of or into the storage box handling system. In other embodiments, the storage box interlocking base 604 moves as the storage box interlocking system extends and / or retracts to pull one or more storage boxes into the storage box processing section 124 or push one or more storage boxes out of the storage box processing section 124.

[0041] In some embodiments, one or more of the storage box handling systems 130-131 may further include one or more climbing systems 708 that enable the storage box handling system 130-131 to move vertically within the storage box handling section 124 within the frame 120 in conjunction with the frame 120. For example, the climbing system may include one or more climbing motors, which are configured to be driven in combination with one or more gears, pinions, belts, cables, pulleys, wheels, and / or other components that engage with one or more tracks, guides, teeth, cables, chains, and / or other structures that enable climbing within the frame 120 in conjunction with the frame 120.

[0042] In some embodiments, the storage box handling system 130 comprises one or more directional and / or rotary motors 710 coupled with a rotary system 712 capable of controlling the rotational direction of one or more storage box engagement systems 302. The directional and / or rotary motors 710 may be controlled by a storage box engagement control circuit 702, a storage box handling control circuit 706, and / or a robot control circuit 502, and may be controlled by one or more shafts, axles, gears, cables, pulleys, belts, or other such mechanical systems, or a combination of two or more such mechanical systems, coupled with and capable of controlling the rotation of the rotary system 712. The rotation enables the storage box engagement system 302 to rotate and align with the frame storage box stack 202 within the outer stack 104 of the storage boxes 106 and the storage section 122. In some embodiments, the rotating system and / or other parts of the storage box handling system may be implemented similarly to the system described in International Patent Application No. PcT / US2023 / 032416 and U.S. Provisional Patent Application No. 63 / 406,534, each of which is incorporated herein by reference in its entirety.

[0043] FIG. 8a shows a simplified perspective view of a portion of an exemplary mobile robot 110 equipped with an exemplary upper storage box handling system 131, comprising an exemplary storage box engagement system 302c in its original position or state, according to some embodiments. FIG. 8b is a simplified perspective view of a portion of an exemplary mobile robot 110 equipped with the exemplary upper storage box handling system 131 of FIG. 8a, wherein the exemplary storage box engagement system 302c is in an exemplary extended position or state, according to some embodiments. FIG. 9a shows a simplified perspective view of a portion of an exemplary mobile robot 110 equipped with the exemplary upper storage box handling system 131 of FIG. 8a, wherein, according to some embodiments, an exemplary storage box 106 is securely engaged by the storage box engagement system 302c and retracted into the storage box handling portion 124. FIG. 9a illustrates a simplified perspective view of a portion of an exemplary mobile robot 110 equipped with an exemplary upper storage box handling system 131, wherein, according to some embodiments, an exemplary storage box 106 is securely engaged by a storage box engagement system 302d.

[0044] Referring to FIGS. 1a–9b, in some embodiments, the storage box engagement system 302c of the upper storage box handling system 131 may include one or more storage box engagement control circuits 702 capable of providing at least some of the control over one or more storage box engagement systems 302c. Additionally, in some embodiments, the storage box engagement system 302c may include one or more storage box engagement motors 704, pulleys, drive systems and / or other components that can be controlled to extend and retract the storage box engagement system 302c and / or perform other actions for engaging and / or disengaging one or more storage boxes 106. In some embodiments, the storage box engagement system 302c comprises one or more storage box engagement features 602 configured to engage with an intended storage box, and in some implementations, engages with one or more engagement structural components 420 (e.g., grooves, posts, shoulders, holes, and / or other structural components) of storage boxes 106. For example, in some embodiments, the storage box engagement system 302c engages with a storage box to be returned to an outer stack, extends to an extended position to move the return storage box away from the frame 120, and can place the return storage box over the storage box of the outer stack (e.g., by sliding one or more bottom loading features 414 each onto one or more upper loading features 412 of the storage box on the outer stack).

[0045] In some embodiments, the upper storage box handling system 131 may include one or more storage box handling control circuits 706, the control circuits may provide at least some of the control over one or more storage box engagement systems 302c, one or more storage box handling motors, pulleys, drive systems and / or other components that can be controlled to vertically move one or more storage box handling systems 130 within the storage box handling section 124. The storage box engagement control circuit 702 and / or the storage box handling control circuit 706 may be coupled to communicate with the robot control circuit 502 and / or external control circuit and / or system to receive control commands to be executed in retrieving, moving, and / or placing one or more storage boxes to and / or out of the mobile robot 110. In another embodiment, the storage box interlocking system 302 and / or storage box handling system 130 does not include the interlocking control circuit 702 and / or storage box handling control circuit 706, and the robot control circuit 502 controls the operation of the storage box handling system and / or storage box interlocking system.

[0046] In some embodiments, the storage box engaging system 302c operates one or more storage box engaging motors 704 to extend one or more parts of the engaging system (e.g., one or more storage box engaging features 602) between their original positions and / or one or more extended positions and engages with one or more storage boxes 106 (e.g., deflecting the ends of the storage box engaging systems to provide a clamping force, using one or more motors to move the ends of the storage box engaging systems to partially close and / or partially open the storage box to clamp and / or unclamp the storage box, using a magnetic system to engage with one or more features of the storage boxes by engaging with a magnetic material on the storage box, and other similar operations or a combination of two or more of these operations). For example, one or more of the storage box engaging systems include a telescoping arm having several sections that extend and retract, wherein the storage box engaging features 602 are configured to engage with one or more storage boxes. The interlocking features may include a protrusion and / or extension configured to engage with a recess of the storage box, a recess configured to engage with a protrusion of the storage box, a magnet, biasing, a hook, a latch, other engaging mechanism, or a combination of two or more of such mechanisms.

[0047] In some embodiments, the upper storage box handling system 131 may further include one or more climbing systems 708 that enable the upper storage box handling system 131 to move vertically within the storage box handling section 124 within the frame 120 in conjunction with the frame 120. For example, the climbing system may include one or more climbing motors, which are configured to be driven in conjunction with one or more gears, pinions, belts, cables, pulleys, wheels, and / or other components that engage with one or more tracks, guides, teeth, cables, chains, and / or other structures that enable climbing within the frame 120 in conjunction with the frame 120.

[0048] In some embodiments, the upper storage box handling system 131 comprises one or more rotary motors 710 coupled with a rotary system 712 capable of controlling the rotational direction of at least one storage box engagement system 302c. The rotary motor 710 may be controlled by a storage box engagement control circuit 702, a storage box handling control circuit 706, and / or a robot control circuit 502, and may be coupled with one or more axes, shafts, gears, cables, pulleys, belts, or other such mechanical systems, or a combination of two or more such mechanical systems, which are coupled with and capable of controlling the rotation of the rotary system 712. The rotation enables the storage box engagement system 302 to rotate and align with the outer stack 104 of the storage boxes 106 and the frame storage box stack 202 within the storage section 122, and / or other such directions.

[0049] FIG. 8c shows a simplified perspective view of a portion of an exemplary mobile robot 110 having an exemplary upper storage box handling system 131n that includes an exemplary storage box engagement system 302n according to some embodiments. The storage box engagement system 302n may include one or more storage box engagement features 602 configured to engage and interlock with the exterior of the storage box and / or one or more engagement structure components 420 of the storage box. In some embodiments, the upper storage box handling system 131n does not extend or retract and also does not include a storage box engagement base 604 or other substructure. This enables the storage box to move vertically upward (e.g., from the lower storage box handling system 130) to the upper storage box handling system 131 and to move vertically downward from the upper storage box handling system 131 (e.g., to the lower storage box handling system 130). The above storage box handling system 131n may include a rotating system, or alternatively, may be fixed without a rotating function.

[0050] FIG. 8d shows a simplified perspective view of a portion of an exemplary mobile robot 110 having an exemplary upper storage box handling system 131m comprising an exemplary storage box engagement system 302m according to some embodiments. The storage box engagement system 302m may include one or more storage box engagement features 602 configured to engage and interlock with the exterior of the storage box and / or one or more engagement structure components 420 of the storage box. In some embodiments, the upper storage box handling system 131m does not include a storage box engagement base 604 or other substructure, which partially enables the storage box to be raised vertically (e.g., from a lower storage box handling system 130) to the upper storage box handling system 131m and to be lowered vertically from the upper storage box handling system 131 (e.g., placing the storage box on an engaged sub-stack). In some embodiments, the storage box engagement system 302m may include one or more extendable arms 802. FIG. 8d shows an exemplary arm 802 in an extended position or state according to some embodiments. While the embodiments of FIG. 8a-8d show an upper storage box handling system having a single storage box engagement system 302c, it is expected that in some embodiments, the upper storage box handling system 131 may include multiple storage box engagement systems. For example, the upper storage box handling system may include a lower storage box engagement system 302b and an upper storage box engagement system 302a, similar to that shown in FIG. 7. Similarly, in some embodiments, the lower storage box handling system 130 may be implemented without a storage box engagement base 604. For example, some embodiments utilize four or more storage box engagement features 602 to engage with a single storage box, providing stable support for the storage box without the need for a storage box engagement base 604.

[0051] To reiterate, FIG. 9a illustrates a simplified perspective view of a portion of an exemplary mobile robot 110 equipped with an exemplary upper storage box handling system 131, wherein, according to some embodiments, an exemplary storage box 106 is securely engaged by a storage box engagement system 302d. In this embodiment, the upper storage box handling system 131 does not include a rotation system 712 and does not include a storage box engagement base 604. The storage box engagement system 302d may be a static system that does not extend or retract, and instead, the lower storage box handling system 130 may include one or more storage box engagement features 602 (not shown in FIG. 9b) that engage with the storage box when the storage box is lifted to contact the upper storage box handling system 131 and joined by the upper storage box handling system 131.

[0052] Referring further to FIGS. 1a–9b, in some embodiments, a storage box handling system 130–131 comprising a plurality of storage box engagement systems 302a–302c may be configured to move one or more storage boxes vertically up and down between an upper storage box engagement system 302a and a lower storage box engagement system 302b. Additionally, or alternatively, storage box engagement systems 302a–302b may be arranged vertically spaced apart and / or the vertical spacing may be adjusted so that both systems engage with a single storage box or operate to engage with separate storage boxes (e.g., two storage boxes stacked together). Also, in some embodiments, vertical movement by storage box engagement systems 302a–302b may enable one or more storage boxes in an external stack to be lifted. For example, the lower engagement system 302b may be extended to engage with a desired storage box, and the upper engagement system 302a engages with a storage box supported by the desired storage box. The upper engagement system 302a can vertically lift the storage box supported on top, which enables the lower storage box engagement system 302b to pull the desired storage box to the storage box handling unit without pulling the storage box from the stack above the desired storage box. Storage box engagement systems 302a-302b may include two, four, six, eight, or other numbers of storage box engagement features 602. Similarly, in some embodiments, each of the upper and lower storage box engagement systems 302a-302b may include two, four, or more arms or other systems for engaging and moving the storage boxes in and out of the mobile robot.

[0053] FIGS. 10a–10g represent simplified perspective views of an exemplary mobile robot 110 or an enlarged portion of an exemplary mobile robot controlling one or more exemplary box handling systems 130–131 in implementing an exemplary box retrieval sequence or process according to some embodiments. Referring to FIGS. 10a–10g, according to some embodiments, the mobile robot 110 may move along a passage 112 between rows 102 of stacks 104 of boxes and approach an intended stack 104a to retriev an intended box 106a. The mobile robot 110 may align with an external intended stack 104a (e.g., see FIG. 10b) to which one or more boxes are to be retrieved and / or one or more boxes are to be returned. A storage box handling control circuit 706 controls the vertical movement of one or more storage box handling systems (e.g., a lower storage box handling system 130) so as to be vertically aligned with an intended storage box 106a to be retrieved (e.g., see FIG. 10c), and can extend one or more storage box engaging systems 302 to engage with said intended storage box 106a. In some implementations, the storage box engaging system 302 may include one or more storage box engaging features 602 configured to extend from a frame 120 to engage with one or more intended storage boxes 106a and to move one or more intended storage boxes into the frame (e.g., by sliding the intended storage box from a lower storage box 106b loaded on an intended stack 104a where the intended storage box is supported). In some embodiments, the storage compartment interlocking system 302 may interlock with one or more compartments of an intended stack 104a including an intended compartment 106a.

[0054] The storage box interlocking system 302 and / or the lower storage box handling system 130 can retract to slide the intended storage box 106a from the lower storage box 106b, which previously supported the intended storage box 106a, onto the storage box handling part 124 of the mobile robot 110 (e.g., see FIG. 10d). In some embodiments, the base structure 714 and / or limiting structure 716 of the storage box handling system can prevent the lower storage box 106b from moving under the intended storage box 106a when the intended storage box 106a slides out of the storage stack 104 (e.g., based on the lower storage box 106b coming into contact with the base structure 714, limiting structure 716, protrusion, auxiliary storage box interlocking system, etc.). In some embodiments, the restraining structure 716 is fixed, whereas in other embodiments, the storage box handling control circuit 706 activates the restraining structure 716 to extend from the base structure 714 and contact the lower storage box 106b, helping to maintain the position of the lower storage box 106b when the intended storage box 106a is pulled from the outer stack, thereby preventing the lower storage box from moving toward the mobile robot and subsequently allowing it to retract (e.g., see FIG. 7 and FIG. 10c-10d). In some embodiments, the restraining structure 716 may engage with one or more interlocking structure components 420 of the storage box (e.g., front handle), whereas in other embodiments, the restraining structure 716 contacts only the face of the storage box. In some embodiments, the storage containers 106c-106d supported by the intended storage container 106a are further pulled into the storage container handling portion 124 as a sub-stack 1002 engaged with the intended storage container 106a, based on the intended storage container 106a supporting the storage containers 106c-106d on the intended storage container 106a (e.g., see FIG. 10c-10d).In some embodiments, one or more storage box engaging systems 302 may be configured to move one or more additional storage boxes 106c-106d, which are in the intended storage box 106a and the intended storage box stack 104a, loaded on the intended storage box 106a, and supported by the intended storage box 106a, into the frame as an engaged sub-stack 1002 at the time of retrieving the intended storage box 106.

[0055] In some embodiments, the upper storage compartment handling system 131 may support a return compartment 106e that is to be returned to the intended stack 104a. In some embodiments, the compartment handling control circuit 706 may control the lower storage compartment handling system 130 to propel itself vertically within the frame 120 until the upper compartment (e.g., compartment 106d) in the lower stack 1002 supported by the lower storage compartment handling system 130 comes into contact with the return compartment 106e supported by the upper storage compartment handling system 131. For example, one or more of the upper loading features 412 of the upper compartment 106d of the lower stack 1002 may be coupled and / or engaged with one or more of the lower loading features 414 of the return compartment 106e (e.g., see FIG. 10e). In some embodiments, the upper storage box handling system 131 can release the return storage box 106e when coupled with the top storage box 106d of the lower stack 1002, and the return storage box 106e becomes the top storage box of the lower stack 1002 supported by the lower storage box handling system (e.g., see FIG. 10f).

[0056] In some embodiments, one or more compartments 106c-106e of a sub-stack 1002 supported by the sub-compartment handling system 130 will be returned to the intended stack 104a or another stack 104 in the same or a different row 102. In some cases, the sub-compartment handling system 130 is configured to return to the intended stack 104a in alignment with the compartment located at the bottom of the sub-stack 1002, which generally results in the recovered intended compartment 106a being located below the current highest compartment 106b of the intended stack 104a (see, e.g., FIG. 10f). In some embodiments, the robot control circuit 502 and / or the storage box handling control circuit 706 may be configured to control one or more storage box engagement systems 302 to move the engaged sub-stack downward within the frame, align the storage box among the storage boxes of the engaged sub-stack and the storage box placed on the intended storage box and supported by the intended storage box with respect to the top storage box 106b of the stack 104a of the intended storage boxes, and to slide the storage boxes on the intended storage box 106a over the top storage box of the stack 104a.

[0057] The lower storage compartment handling system 130 can activate one or more storage compartment engagement systems 302a (e.g., upper storage compartment engagement system 302a of the lower storage compartment handling system 130) so as to move the corresponding compartments 106c-106e in the lower stack 1002 that are not intended to be retrieved and / or returned onto the outer stack 104a (e.g., in the lower storage compartment engagement system 302b of the lower storage compartment handling system 130) so as to move the corresponding compartments 106c-106e in the lower stack back to the outer stack while maintaining the intended compartment 106a. In some embodiments, the upper storage compartment interlocking system 302a slides the bottom storage compartment 106c, which is intended not to be retained in the lower stack, onto the current top storage compartment 106b of the external intended stack 104a, where one or more bottom loading features 414 of the bottom storage compartment 106c of the lower stack 1002 to be returned thereto may slide along the loading features in conjunction with one or more top loading features 412 of the top storage compartment 106b of the intended external stack 104a (e.g., see FIG. 10g). In some embodiments, while the mobile robot 110 moves to the next storage compartment retrieval location, work station, etc., the return storage compartment 106e is retrieved and placed using the upper storage compartment handling system 131. In some embodiments, the storage box handling system lifts the interlocked sub-stack 1002 and places the return storage box 106e on the interlocked sub-stack to be returned, then lowers the interlocked sub-stack and slides the unwanted storage boxes back onto the outer stack, thereby enabling storage box replacement in the recovery and return of the storage box stack in one go. This rapid replacement can significantly improve the efficiency and throughput of the mobile robot and the transport storage box recovery and / or return process.

[0058] FIGS. 11a–11f represent simplified perspective views of an enlarged portion of an exemplary mobile robot 110 or an exemplary mobile robot controlling one or more exemplary storage box handling systems 130–131 in implementing an exemplary storage box alignment sequence or process according to some embodiments. Referring to FIGS. 11a–11f, the recovered storage boxes are often organized within a frame storage box stack 202 and said recovered storage boxes are inspected based on subsequent intended storage box utilization and / or a predetermined storage box order. Following the retrieval of the retrieved storage box 106a (e.g., retrieved according to the retrieval sequence of FIGS. 10a-10g), the robot control circuit 502 and / or the storage box handling control circuit 706 may control a storage box handling system (e.g., lower storage box handling system 130) to rotate and orient one or more of the retrieved storage boxes 106a so as to align with the orientation of one or more of the frame storage box stacks 202 located within the storage section 122 of the mobile robot 110 (e.g., see FIGS. 11a-11b).

[0059] The robot control circuit 502 and / or the storage box handling control circuit 706 controls the first storage box engagement system to move vertically within the frame and vertically position one or more recovered storage boxes 106a at a predetermined position, and can slide the recovered storage box onto the storage box at the top of the frame storage box stack when the intended position of the recovered storage box is higher than the storage box currently at the top. In other cases, a predefined order or sequence of the recovered storage boxes may indicate a predetermined position within the frame storage box stack between two previously acquired storage boxes stored within the frame storage box stack 202. Accordingly, in some embodiments, the lower storage box handling system 130 controls the system to move vertically within the frame and align the recovered storage box 106a with the support storage box 106_2, which was previously recovered and intended to support the recovered storage box 106a within the frame storage box stack 202. This results in the recovered storage box 106a being located below an intended vertical position within the frame storage box stack, such as being below an intended vertical position such as the height of the recovered storage box 106a adjacent to and / or the recovered storage box 106_2 intended to support the recovered storage box 106a, or being below an intended vertical position such as the total height of the recovered storage boxes when multiple storage boxes are recovered from an external stack. In some embodiments, the robot control circuit 502 and / or the storage box handling control circuit 706 may be configured to control the storage box handling system 130 and / or the storage box engagement system 302 so as to engage with at least a second storage box 106_3 among the recovered storage boxes currently at a selected position within the frame storage box stack 202 where the recovered storage box 106a is intended to be placed. In some implementations, one or more other boxes supported by the second box 106_3 may be additionally engaged by one or more box interlocking systems.

[0060] The robot control circuit 502 and / or the storage box handling control circuit 706 can activate the storage box engagement system 302 to switch from an extended position to a retracted position, thereby moving the second storage box 106_3 and potentially one or more other storage boxes supported by the second storage box 106_3 and located on top of the second storage box 106_3 from the frame storage box stack 202 onto the retracted storage box 106a in the storage box handling section 124 of the frame 120 to form a combined stack 1104. The combined stack may include the retracted storage box 106a, the second storage box 106_3, and additional retracted storage boxes (e.g., 106_4-106_6) loaded on top of the second storage box 106_3 (e.g., see FIG. 11c). In some embodiments, with no external intermediate support structure between the second storage box 106_3 and the recovered storage box 106a (or the uppermost recovered storage box), the second storage box 106_3 slides over the recovered storage box 106a (or over the uppermost recovered storage box if multiple storage boxes are recovered from an external stack) and is directly supported by the recovered storage box 106a. In some embodiments, the storage box engagement system 302 may retract one or more arms and / or other structures that engage with one or more engagement features of one or more storage boxes. Additionally, moving the second storage box 106_3 onto the recovered storage box 106a may include sliding the second storage box 106_3 onto the recovered storage box 106a from an intended support storage box 106_2 that is located below the second storage box 106_3 in the frame storage box stack 202 and supports the second storage box 106_3. In some implementations, the above sliding may include interlocking and / or engaging one or more bottom loading features 414 of the second storage box 106_3 with one or more top loading features 412 of the recovered storage box 106a (e.g., see FIG. 11c).Additionally, when the second storage box 106_3 is pulled over the intended storage box 106a, some embodiments interact with the lower support storage box 106_2 that supports the second storage box 106_3. For example, when the second storage box 106_3 and the storage boxes supported by the second storage box are pulled toward the storage box handling section 124, the base structure 714 and / or limit structure 716 of the lower storage box handling system 130 may engage with the support storage box 106_2 to prevent the support storage box 106_2 from moving toward the lower storage box handling system 130. Similarly, when the intended combined stack 1104 slides over the support storage box 106_2, the frame 120 and / or the lower storage box handling system may engage with the support storage box 106_2 to prevent the support storage box 106_2 from moving away from the lower storage box handling system.

[0061] In some embodiments, the storage box handling system 130 can vertically move the recovered storage box 106a and / or combined stack (one or more storage boxes slide over the recovered storage box 106a and are now supported by the recovered storage box 106a) from a selected vertical position to a vertical height 1102 and orient it to align with the top of the intended supporting storage box 106_2 (e.g., see FIG. 11d). The storage box handling control circuit 706 and / or lower storage box handling system 130 can activate the storage box interlocking system 302 to switch from a retracted position to an extended position to move the retracted storage box 106a or the combined stack (the retracted storage box and the storage boxes supported by the retracted storage box (e.g., the second storage box 106_3 and other storage boxes supported by the second storage box)) and move the combined stack (including the retracted storage box 106a and the storage boxes supported by the retracted storage boxes) from the storage box handling unit 124 into the frame storage box stack of the mobile robot 110 and onto the intended support storage box 106_2, wherein the retracted storage box 106a is placed in a selected vertical position. In some embodiments, the storage box interlocking system 302 extends one or more arms and / or other structures to slide the recovered storage box 106a onto the intended support storage box 106_2 and into the frame storage box stack 202 at a selected vertical position that is directly supported by the intended support storage box 106_2 among the recovered storage boxes in the frame storage box stack 202, wherein no external intermediate support structure exists between the recovered storage box 106a and the intended support storage box 106_2.Additionally, in some embodiments, moving the recovered storage box 106a to the frame storage box stack 202 may involve interlocking and / or engaging one or more bottom loading features 414 of the recovered storage box 106a with one or more top loading features 412 of the intended support 106_2 (e.g., see FIG. 11e). This places the recovered storage box 106a within the frame storage box stack 202 at a predetermined vertical storage box position of one or more frame storage box stacks based on a predetermined order (e.g., see FIG. 11f). Enabling the placement of a storage box at a desired location within a frame storage box stack allows for the retrieval of a storage box in any order, generally in an optimal order based on the current position of the mobile robot 110 regarding the intended destination of one or more retrieved storage boxes and / or the loaded locations of one or more storage boxes to be retrieved by said storage box, while ensuring that said retrieved storage boxes are aligned according to a predefined sequence and / or expected order of use of the retrieved storage boxes within the frame storage box stack 202. In some embodiments, insertion of a retrieved storage box 106a into the frame storage box stack may occur while the mobile robot 110 is moving through the facility (e.g., while moving to a subsequent external stack, work station, etc.).

[0062] FIGS. 12a–12f show simplified perspective views of an exemplary mobile robot 110 or an enlarged portion of an exemplary mobile robot controlling one or more exemplary box handling systems 130–131 in implementing an exemplary return box staging sequence or process according to some embodiments. Referring to FIGS. 12a–12f, the mobile robot 110 may be utilized to return a return box 106 to one or more external box storage stacks 104 within one or more storage areas of a fulfillment system 100. Additionally, in some cases, returning the box may be implemented while retrieving one or more boxes from the external stacks. In some embodiments, one of the storage box handling systems 130-131 (e.g., lower storage box handling system 130) may be controlled within frame 120 and moved to be positioned vertically at an aligned vertical level to retrieve an intended return storage box 106x of frame storage box stack 202 within the storage box storage section 122 of mobile robot 110. The intended return storage box may be positioned at any vertical position within the frame storage box stack 202. In the exemplary embodiments illustrated in FIGS. 12a-12f, the return storage box 106x is currently at the top vertical position within the frame storage box stack 202. However, ordinary technicians will understand that a return box can be retrieved by retrieving the return box 106x and one or more boxes currently supported by the return box together, similar to the positioning order, at any location within the frame box stack, moving the sub-stack vertically downward, and moving one or more of the remaining sub-stacks to be maintained within the frame box stack back up onto the frame box stack. Such retrieval may occur even while the mobile robot continues to move through the facility.

[0063] A robot control circuit 502 and / or a storage box handling control circuit 706 may be configured to control one or more storage box handling systems (e.g., a lower storage box handling system 130) to move and rotate the return storage box 106x to a vertical position so that the storage box engagement system 302 is oriented toward the intended return storage box 106x (e.g., see FIG. 12a). The storage box engagement system 302 may be controlled to engage with the return storage box 106x and to slide the return storage box 106x from the frame storage box stack 202 to the storage box engagement system and into the storage box handling portion 124 (e.g., see FIG. 12b). In some implementations, the retrieval of the return storage box 106x (e.g., after the retrievaled storage box has been placed in a selected vertical position within the frame storage box stack 202) is implemented separately from the retrieval sequence.

[0064] In some embodiments, the lower storage container handling system 130 may rotate the return container 106x to align the upper storage container handling system 131 and / or the return container with the orientation of the outer stack 104 to be returned (e.g., see FIG. 12c-12d). The lower storage container handling system 130 may be controlled to move the return container 106x to engage with the upper storage container handling system 131, which in some cases includes positioning the return container 106x in a vertical position to enable the upper storage container handling system 131 to engage with the return container 106x (e.g., see FIG. 12e where the lower storage container handling system 130 lifts the return container onto the upper storage container handling system 131). The upper storage box handling system 131 may be controlled to engage with the return storage box 106x and secure the return storage box in preparation for return to the outer stack, which enables the lower storage box handling system to move vertically within the frame while the return storage box 106x is prepared to be returned to the outer stack, thereby enabling the implementation of one or more other operations (e.g., see FIG. 12f). In some embodiments, moving the return storage box 106x to the upper storage box handling system 131 may occur while the mobile robot is moving to another outer stack, work station, and / or other location. In some embodiments, one or more storage box handling systems 130-131 may operate independently of the mobile robot's transfer system control to perform one or more operations, such as but not limited to inserting a recovered storage box into the frame storage box stack, moving a storage box to the upper storage box handling system, rearranging one or more storage boxes in the frame storage box stack, other similar operations, or combinations of two or more of these operations. This can improve the efficiency of the logistics system by partially reducing the time for collecting and / or returning storage containers.

[0065] FIGS. 13a–13d represent, according to some embodiments, simplified perspective views of an enlarged portion of an exemplary mobile robot 110 or an exemplary mobile robot controlling one or more exemplary box handling systems 130–131 in implementing an exemplary box return sequence or process. In some embodiments, the upper box handling system 131 acquires a return box 106x as in a return staging process (e.g., see FIGS. 12a–12f). For example, the lower box handling system 130 may retrieve the return box 106x from a frame box stack and move the return box vertically to engage with the upper box handling system 131. In another example, in some embodiments, the upper box handling system 131 moves vertically to align with the return box 106x within the frame box stack and retrieves it by engaging with the return box 106x. In another embodiment, the lower storage box handling system 130 can retrieve return boxes 106x from the frame storage box stack 202 without using the upper storage box handling system 131 and implement the return of one or more boxes (e.g., boxes 106_10-106_20) to an external return stack 104a. Referring to FIGS. 13a–13d, the mobile robot 110 may be instructed to return one or more return boxes 106x to one or more external storage box storage stacks 104 within one or more storage areas of the fulfillment system 100. In some embodiments, the mobile robot 110 receives location information, self-propels, and autonomously controls the movement of the mobile robot to the intended return storage stack 104a through the facility. For example, FIG. 13a shows a simplified perspective view of a mobile robot 110 moving toward an intended return storage stack 104a along a passage 112 adjacent to one or more rows 102 of storage stacks 104 of storage boxes that can be placed in a riser 204.In another embodiment, an external control system may provide some or all instructions to the mobile robot 110 for routing to the return storage stack 104a (e.g., congestion, obstacles, a path that enables one or more other storage containers to be retrieved before returning the return storage container 106x, other similar factors, or a combination of two or more factors).

[0066] The mobile robot 110 can move along surface 208 to align with the intended return storage stack 104a (e.g., see FIG. 13b). In some embodiments, one or more storage container handling systems 130-131 (e.g., upper storage container handling system 131) can be controlled to place the return container 106x at a vertical level aligned with the top container 106_20 of the outer return storage stack 104a (e.g., upper storage container handling system 131 placing the return container 106x relative to the top container 106_20 of the intended return storage stack 104a). The storage compartment interlocking system 302 of the upper storage compartment handling system 131 is controlled by the robot control circuit 502 and / or the storage compartment handling control circuit 706 and extended to move the return storage compartment 106x out of the frame 120 and over the top storage compartment 106_20 of the return storage stack 104a (e.g., see FIG. 13c). In some embodiments, this movement of the return storage compartment 106x may cause interlocking between one or more bottom loading features 414 of the return storage compartment 106x and one or more top loading features 412 of the top storage compartment 106_20 as the return storage compartment 106x slides up over the top storage compartment 106_20, including moving the return storage compartment 106x. The storage box interlocking system 302 can be released (e.g., retracted) from the return storage box 106x, which enables the mobile robot 110 to be freed from the return storage box 106x and the return storage stack 104a, allowing the mobile robot 110 to move to perform one or more other tasks (e.g., see FIG. 13d).

[0067] FIGS. 14a-14i show simplified perspective views of an enlarged portion of an exemplary mobile robot 110 or an exemplary mobile robot controlling one or more exemplary box handling systems 130-131 in implementing an exemplary box return sequence or process as part of a box retrieval sequence or process for retrieving one or more boxes from an external storage stack 104a, according to some embodiments. In some such embodiments, a second storage box handling system (e.g., upper storage box handling system 131) among one or more storage box handling systems that can be coupled to communicate with a robot control circuit can be controlled by a robot control circuit 502 and / or a storage box handling control circuit 706 so as to position a return storage box 106x on an engaged lower stack 1402 before an unwanted storage box (e.g., storage box 106_17) is returned to the return storage stack 104a of storage boxes, so that when one or more unwanted storage boxes (e.g., storage boxes 106_17-106_20) are returned to the return storage stack 104a, the return storage box 106x is also returned to the return storage stack 104a of storage boxes. Referring to FIGS. 14a–14i, a mobile robot 110 may be instructed to return one or more return containers 106x to one or more storage stacks 104a outside of one or more containers within one or more storage areas of a fulfillment system 100. For example, FIG. 14a illustrates a simplified perspective view of a mobile robot 110 moving along a passageway 112 toward an intended return storage stack 104a.

[0068] The mobile robot 110 can be aligned with the intended return storage stack 104a (e.g., see FIG. 14b). In some embodiments, one or more storage container handling systems 130-131 (e.g., upper storage container handling system 131) may be controlled to place the return container 106x at a vertical level aligned with the top container 106_20 of the outer return storage stack 104a (e.g., upper storage container handling system 131 placing the return container 106x relative to the top container 106_20). One or more storage compartment engaging systems 302c of the upper storage compartment handling system 131 can be extended by being controlled by a robot control circuit 502 and / or a storage compartment handling control circuit 706 to remove the return compartment 106x from frame 120 and move it over the top compartment 106_20 of the return storage stack 104a (e.g., see FIG. 14c), and, for example, when the return compartment 106x slides up over the top compartment 106_20, one or more bottom loading features 414 of the return compartment 106x slide into one or more top loading features 412 of the top compartment 106_20.

[0069] In some embodiments, when retrieving one or more containers from the external return storage stack 104a, the robot control circuit 502 and / or the container handling control circuit 706 may control the lower container handling system 130 to move vertically so as to align with the intended retrieval container (e.g., intended retrieval container 106_16) within the return storage stack 104a (e.g., see FIG. 14c-14d). Additionally, the robot control circuit 502 and / or the container handling control circuit 706 may control one or more container engagement systems 302a-302b of the lower container handling system 130 to engage with one or more containers of the return storage stack 104a. For example, the first or lower container engagement system 302b of the lower container handling system 130 may be extended to engage with the intended retrieval container 106_16. In some embodiments, one or more other compartments within the storage stack 104a may be optionally additionally engaged, for example, by controlling the second or upper compartment engagement system 302a of the lower compartment handling system 130 to engage one or more additional compartments above the intended retrieval compartment, thereby stabilizing the retrieval or engaged lower stack 1402 so that it can be pulled by a mobile robot (e.g., upper engagement system 302a engaged with compartment 106_17 placed above retrieval compartment 106_16, see FIG. 14d). One or more lower compartment engagement systems 302b and upper compartment engagement systems 302a of the lower compartment handling system 130 and compartment engagement system 302c of the upper compartment handling system 131 may be controlled in conjunction to move the intended retrieval compartment 106_16 to frame 120. This may include retrieving or moving one or more containers 106_17-106x loaded on top of an intended retrieval container 106_16 into a frame as an interlocked sub-stack 1402 (e.g., see FIG. 14e).As exemplified above, in some embodiments, the return container 106x may be engaged with the return stack 104a before the intended retrieval container 106_16 is retrieved. The robot control circuit 502 and / or the container handling control circuit 706 may be configured to control the upper container handling system 131 to slide the return container 106x onto the top container 106_20 of the return stack 104a before the lower container handling system 130 slides the intended retrieval container 106_16 into the frame.

[0070] In some embodiments, the lower storage container handling system 130 can vertically move and orient the recovered container 106_16 and / or the interlocked lower stack 1402 (one or more containers supported by the recovered container 106_16) to a vertical height 1404 so as to align the container above the intended recovered container 106_16 with the upper surface of the container 106_15 remaining at the top of the outer return storage stack 104a. FIG. 14f shows the lower storage container handling system 130 moving the engaged lower stack 1402 downward (compared to the position shown in FIG. 14e), at which point storage container 106_17 is supported by the current top storage container 106_15 remaining in the return storage stack 104a and the recovered storage container 106_16 aligned at level or height 1404, with the recovered storage container 106_16 located below the level of the top surface of the top storage container of the return storage stack 104a. FIG. 14f shows storage container 106_17 located directly above the recovered storage container 106_16, but it will be acknowledged that two or more storage containers may be intended to be recovery containers and may be placed below vertical height 1404. Additionally, in some embodiments, the upper storage compartment handling system 131 moves vertically in conjunction with the lower storage compartment handling system 130 and / or the retrieved and engaged lower stack 1402, which further maintains the stability of the engaged lower stack 1402 in some embodiments. In other embodiments, the upper storage compartment handling system 131 is separated from the top storage compartment 106x of the engaged lower stack 1402 before the lower storage compartment handling system 130 moves the engaged lower stack 1402 vertically.

[0071] In some embodiments, prior to returning the unwanted storage compartment of the engaged sub-stack 1402, the sub-stack engagement system 302b and / or other storage compartment stabilization features may engage with the current top storage compartment 106_15 of the return storage stack 104a (e.g., see FIG. 14i). This may stabilize the return storage stack 104a when one or more unwanted storage compartments of the sub-stack 1402 (e.g., storage compartments 106_17 - 106x) are returned to the return storage stack 104a. In some embodiments, the storage box handling control circuit 706 and / or the lower storage box handling system 130 can activate one or more of the storage box engagement systems 302a-302c of the upper and / or lower storage box handling systems 130-131 to switch from a retracted position to an extended position, thereby moving one or more storage boxes of the engaged lower stack 1402 (e.g., storage boxes 106_17 - 106x of the engaged lower stack 1402) to be returned to the return storage stack 104a, and the remaining storage boxes of the engaged lower stack can be moved from the storage box handling section 124 onto the return storage stack 104a, into the frame storage box stack of the mobile robot 110, and onto the intended support storage box 106_2, whereby the recovered storage box 106a is placed in a selected vertical position. FIG. 14h illustrates that the upper storage compartment engaging system 302a of the lower storage compartment handling system 130 and the storage compartment engaging system 302c of the upper storage compartment handling system 131 are switched to an extended position to move unwanted compartments of the engaged lower stack back onto the return storage stack 104a. The interlocking operation of multiple storage compartment engaging systems 302 can help stabilize the unwanted compartments of the return storage stack 104a and / or the engaged lower stack 1402.In some implementation examples, unwanted compartments of the engaged lower stack 1402 can be moved so that the bottommost oriented unwanted compartment 106_17 slides directly onto the current topmost compartment 106_15 of the return storage stack 104a (e.g., engaging one or more bottom loading features 414 of the recovered compartment 106a with one or more top loading features 412 of the intended support 106_2) (e.g., see FIG. 14h), whereby the bottom compartment handling system 130 holds the intended recovered compartment 106_16 (e.g., see FIG. 14h-14i). In some embodiments, the storage box interlocking system 302 may extend one or more arms and / or other structures to allow unwanted storage boxes 106_17-106x to slide onto intended support storage boxes 106_15 to become part of the return storage stack 104a. As such, some embodiments use a storage box stack to enable storage box replacement in a single retrieval and return sequence. The mobile robot 110 activates one or more sensors to capture identification information of the return storage stack 104a and / or one or more returned unwanted storage boxes 106_17-106x, and conveys identification information formation and / or correlation between the locations of the returned unwanted storage boxes and the return storage stack 104a, which can enable accurate tracking of the locations of storage boxes 106 and products within the storage facilities. In another embodiment, one or more storage box engagement systems may enable vertical movement of one or more storage boxes, which may be utilized in retrieving the intended retrieval storage box 106_16. For example, the upper storage box engagement system 302a engages with an unwanted storage box 106_17 that is on an outer stack and supported by the intended storage box 106_16, and can vertically lift the supported unwanted storage box 106_17 (and all storage boxes supported by the unwanted storage box 106_17).In some embodiments, one or more compartment engagement systems of the upper compartment handling system 131 may be additionally utilized to stabilize the stack. The lower compartment engagement system 302b of the lower compartment handling system 130 may engage with the intended retrieval compartment 106_16 and pull the intended retrieval compartment 106_16 into the mobile robot while the upper compartment engagement system 302a lifts the unwanted compartment 106_17. Once the intended retrieval compartment 106_16 is acquired, the upper compartment engagement system 302b of the lower compartment handling system 130 may then be controlled to lower the unwanted lower stack back over the remaining compartments of the outer stack.

[0072] FIGS. 15a-15i illustrate, according to some embodiments, simplified perspective views of an exemplary mobile robot 110 or an enlarged portion of an exemplary mobile robot controlling two exemplary box handling systems 130-131 in implementing a box return staging sequence or process and placing the first recovered box 106a into an intended vertical position within a frame box stack 202. As such, in some embodiments, a second box handling system (e.g., upper box handling system 131) among one or more box handling systems that may be communicably coupled with a robot control circuit may be controlled by a robot control circuit 502 and / or a box handling control circuit 706 to move vertically into a vertical position aligned with one or more intended return boxes 106x within a box handling section 124 (e.g., see FIG. 15a). In some embodiments, the rotation system 712 may be controlled to orient one or more storage box engagement systems 302c with respect to the intended return storage box 106x and to align one or more storage box engagement systems with the return storage box 106x.

[0073] In some embodiments, the lower storage box handling system 130 may be activated when the upper storage box handling system 131 is aligned with the return storage box 106x. In some embodiments, the lower storage box handling system 130 may be controlled to operate independently of the operation of the upper storage box handling system 131, excluding cases where the lower storage box handling system 130 is intended to engage and / or interlock with the upper storage box handling system 131. As such, the lower storage box handling system 130 may have a first recovery storage box 106a previously recovered from the source of the external storage stack 104 or other storage boxes. The lower storage box handling system 130 may be controlled by the robot control circuit 502 and / or the storage box handling control circuit 706 to move vertically within the storage box handling section 124 to a vertical position aligned with the intended position within the frame storage box stack 202 (e.g., see FIG. 15a). The robot control circuit 502 and / or the storage box handling control circuit 706 can control the direction of the rotation system 712 to determine the direction of one or more storage box engagement systems 302a-302b of the lower storage box handling system 130, thereby determining the direction of the first recovered storage box 106a with respect to the frame storage box stack 202 (e.g., see FIGS. 15b-15c).

[0074] A robot control circuit 502 and / or a storage box handling control circuit 706 may be configured to control an upper storage box handling system 131, which moves vertically within a storage box handling section 124 and slides into the storage box handling section by engaging with the current top recovered storage box from the frame storage box stack, wherein the top recovered storage box is a return storage box to be returned to one of the stacks of storage boxes during the execution of the next storage box recovery sequence.

[0075] The robot control circuit 502 and / or the storage box handling control circuit 706 may be configured to control the upper storage box handling system 131 so as to activate one or more storage box engagement systems to engage with one or more return storage boxes 106x from the frame storage box stack 202 and retract into the upper storage box handling system 131 (e.g., see FIG. 15d). FIG. 15d shows the retrieval of one return storage box 106x, but it will be understood that in some embodiments, the upper storage box handling system may retriev two or more return storage boxes simultaneously. In some embodiments, one or more return storage boxes 106x are the top storage boxes of the frame storage box stack 202, whereas in other embodiments, the upper storage box handling system and the lower storage box handling system may operate in conjunction to retriev from within the frame storage box stack and from the intended return storage box. Once the return storage box 106x is acquired, the upper storage box handling system 131 may be configured to rotate the return storage box 106x to orient it toward the external storage stack 104 of the storage box 106 (e.g., see FIG. 15e). In some embodiments, the upper storage box handling system 131 engages the return storage box 106x from the support storage box 106_30 of the frame storage box stack 202 and slides it into the storage box handling section 124, where the return storage box 106x may be returned to one of the external storage stacks 104 during the next execution of the storage box return sequence and / or storage box retrieval sequence.

[0076] A predefined order of the recovered containers may be defined such that the first recovered container 106a is placed between two previously acquired containers (e.g., lower recovered container 106_31 and upper recovered container 106_32) stored within the frame container stack 202. Accordingly, in some embodiments, the robot control circuit 502 and / or container handling control circuit 706 may control the lower container handling system 130 to move vertically within the frame 120 and align one or more container engagement systems of the lower container handling system 130 (e.g., upper container engagement system 302a) with the upper recovered container 106_32 and activate the container engagement system 302a to engage with the upper recovered container 106_32 (e.g., see FIG. 15f). In some embodiments, the reclaimed container 106a is positioned below an intended vertical position within the frame container stack 202, such as adjacent to the lower reclaimed container 106_31 intended to support the reclaimed container 106a. The container engagement system 302a may be further controlled to slide the upper reclaimed container 106_32, and other reclaimed containers of the frame container stack 202 are supported by the upper reclaimed container 106_32 if present. This movement of the upper reclaimed container 106_32 may include sliding the upper reclaimed container 106_32 from the lower reclaimed container 106_31 and sliding the upper reclaimed container 106_32 over the reclaimed container 106a to establish the reclaimed coupling stack 1104 (e.g., see FIG. 15g).

[0077] In some embodiments, the lower storage box handling system 130 can vertically move and orient the recovered storage box 106a and / or combined stack 1104 to align the recovered storage box 106a with the top of the intended supporting lower storage box 106_31 (e.g., see FIG. 15h). The robot control circuit 502 and / or the storage box handling control circuit 706 activates one or more of the storage box engagement systems 302 of the lower storage box handling system 130 to transition from a retracted position to an extended position, thereby moving the recovered storage box 106a or the engaged stack 1104 from the storage box handling section 124 to the frame storage box stack 202 and onto the intended supporting lower storage box 106_31, wherein the recovered storage box 106a is placed in a selected vertical position (e.g., see FIG. 15i).

[0078] In some embodiments, it is possible to simultaneously remove all recovered containers of the frame container stack 202 from the mobile robot 110. FIG. 16 illustrates a simplified perspective view of an exemplary mobile robot 110 that simultaneously moves each of the exemplary containers in the exemplary frame container stack 202 according to some embodiments. In some embodiments, the robot control circuit 502 and / or the container handling control circuit 706 may be configured to control at least one of the container handling systems (e.g., a lower container handling system 130) so as to move vertically within the frame and align one or more container engagement systems of the lower container handling system with the recovered container 106_50, which is the lowest direction of the frame container stack 202. The above storage box interlocking system can be activated to extend to interlock with the lowest oriented retracted storage box 106_50, and then the storage box interlocking system can be retracted while interlocked with the lowest retracted storage box 106_50. Some embodiments may further control the upper storage box handling system 131 to optionally move vertically within the frame and align one or more storage box interlocking systems with one or more storage boxes (e.g., the top or uppermost storage box 106_51) located above the lowest storage box 106_50 of the frame storage box stack 202. The storage box interlocking system can be activated to extend so that the uppermost retrieved storage box 106_50 is interlocked, and subsequently, the storage box interlocking system is retracted sequentially or simultaneously with the retraction system of the lower storage box handling system 130, at which time the upper storage box handling system 131 is interlocked with the uppermost retrieved storage box 106_51. In some embodiments, the lower storage box handling system 130 and the upper storage box handling system 131 are additionally rotated simultaneously to adjust the orientation of the storage box for removal from the mobile robot 110.The lower storage box handling system 130 and the upper storage box handling system 131 are similarly activated simultaneously to extend one or more of their respective storage box interlocking systems to move the storage boxes of the frame storage box stack 202 from the mobile robot 110 (e.g., see FIG. 16). This makes it possible to simultaneously lower each of the recovered storage boxes of the frame storage box stack 202 as a stack to a loading location. A similar process is performed so that the lower storage box handling system 130 and the upper storage box handling system 131 are simultaneously controlled to extend one or more of their respective storage box interlocking systems to interlock with one or more of the storage boxes in the outer stack 104 of storage boxes, and simultaneously retract the storage box interlocking systems to move the entire stack of storage boxes to the mobile robot 110.

[0079] FIG. 17 illustrates a simplified side view of a portion of an automated order fulfillment system 100 according to some embodiments. The fulfillment system 100 may include one or more work stations 170. When delivering stacks of one or more containers 106 to work station 170 and / or retrieving stacks of containers from work station 170, one or more mobile robots 110 may move through a fulfillment facility between one or more storage areas 1706, where rows of stacks 104 of containers 106 are arranged, and one or more work stations 170. FIG. 18 illustrates a simplified perspective view of an exemplary work station 170 equipped with a mobile robot 110 coupled to a work station in transporting a frame container stack 202 to a work station and / or retrieving stacks of containers from a work station, according to some embodiments. FIG. 19a shows a simplified plan view of an exemplary work station 170 equipped with a mobile robot 110 coupled to the work station in transporting a frame storage stack 202 to the work station and / or retrieving a stack of storage boxes from the work station, according to some embodiments. FIG. 19b shows a simplified plan view of an exemplary work station 170 including one or more storage buffers and / or coupled to said storage buffers, according to some embodiments, and further shows a mobile robot 110 coupled to a storage buffer tower 1702 of the work station 170.

[0080] Referring to FIGS. 1a–3 and FIGS. 17–19b, in some embodiments, containers 106 are transferred to work stations where one or more items can be retrieved from the delivered containers by a worker 1704, a picking robot, other such system, or a combination of two or more such picking systems in fulfilling at least part of an order for one or more items. The retrieved items may be placed inside order containers, bags, or boxes, placed on a conveyor system to be packaged for delivery and / or routed, and processed by other similar measures or a combination of these measures. The selection and / or performance of an order may be similar to the performance of an order described in U.S. Patent Nos. 9,139,363, 10,435,241 and 11,142,398 and U.S. Patent Application Publications Nos. 2019 / 0270591, 2021 / 0229271 and 2023 / 0095494, each of which is incorporated herein by reference in its entirety.

[0081] A robot control circuit 502 can control a transfer system 504 to transfer and move a mobile robot 110 between one or more storage areas 1706 and one or more workstations 170. In some embodiments, the control circuit 502 and / or one or more storage container handling control circuits 706 can control one or more storage container handling systems 130-131 to move a recovered storage container 106 located within a frame storage container stack 202 from the mobile robot to the workstation 170. The transfer of storage containers 106 may be carried out in some cases by transferring individual containers one by one, and in other cases, multiple containers may be transferred to or from the workstation 170 simultaneously. In some embodiments, the work station may include one or more picking conveyors 1712, decks, bays, and / or other such systems, along which bins 106 can be moved so as to enable picking by a worker 1704, a picking robot, and / or other systems. Additionally, in some embodiments, one or more picking conveyors 1712, decks, bays, and / or other similar systems may move bins 106 from the picking area after processing at the work station (e.g., when one or more items are removed from a bin upon order fulfillment, when one or more items are added to a bin serving as an order bin where order items can be integrated, and when one or more items are added to a bin when transferring a collection of items (e.g., cases, pallets, etc.) to be moved to a storage area (e.g., stack 104 and / or storage structure 150). And in preparing these processed containers to be returned to a storage area and / or another workstation, these processed containers may be moved to one or more buffer towers 1702. The routing to a specific buffer tower may be controlled by a central control system that provides instructions to the workstation control circuit and / or conveyor control circuit.

[0082] In some embodiments, one or more storage box handling systems 130-131 can move vertically within frame 120 and can sequentially retrieve individual storage boxes 106 in a predetermined order based on the order in which storage boxes retrieved from order fulfillment are processed through work station 170. For example, a mobile robot 110 can be placed securely at the work station and can repeatedly supply one storage box at a time to a conveyor system 1712 (see, e.g., FIG. 19a). In other embodiments, one or more of the storage box handling systems 130-131 can be controlled to retrieve multiple storage boxes 106 and to simultaneously transfer multiple storage boxes to a buffer tower 1702 configured to receive and hold multiple storage boxes. One or more of the buffer towers 1702 may include one or more lift and / or elevator systems 1708 configured to move storage boxes 106 vertically within their respective buffer towers 1702. Additionally or alternatively, in some embodiments, one or more buffer towers 1702 may include one or more storage box handling systems similar or identical to the storage box handling system 130-131 of a mobile robot, which may be controlled to retrieve storage boxes from the mobile robot, move storage boxes within the buffer tower, and / or move storage boxes to and / or from a workstation picking conveyor 1712, deck, bay, etc.

[0083] In some embodiments, the mobile robot 110 may bring the recovered bin 106 to the work station and transfer one or more of the bins in the frame bin stack 202, generally each bin to the receiving buffer tower 1702. This allows the mobile robot to return to the storage area to retrieve the set of bins to be transferred to the work station and / or perform other tasks. The robot control circuit 502 and / or the engagement control circuit 702 may control one or more of the bin handling systems 130-131 of the mobile robot 110 to simultaneously move the recovered bins in the frame bin stack 202 to the buffer tower 1702 of the work station 170. Additionally or alternatively, the mobile robot 110 may move to the buffer tower 1702, which is waiting to recover and return to the storage area bins that have already been processed in fulfilling one or more orders. Mobile robot 110 can be aligned with buffer tower 1702, and one or more storage box handling systems 130-131 of the mobile robot and / or buffer tower can slide one or more storage boxes, and generally multiple storage boxes simultaneously, into the storage box processing unit 124 of the mobile robot, and the mobile robot can transfer the recovered storage boxes in one or more stacks to the storage area and / or create new stacks and transfer them to one or more other workstations or to other paths directed by a central control system, etc. For example, a frame storage box stack is recovered from buffer tower 1702 and transferred to the storage area, and the entire frame storage box stack is transferred from the mobile robot to riser 204 to establish a new stack within the storage area. In some embodiments, the riser 204 may include one or more alignment and / or stabilization loading features 412 spaced apart along one or more parts or the entire length of the riser (e.g., see FIG. 2), which may interact with the respective stabilization loading features 414 of the storage compartments 106.

[0084] FIG. 20 illustrates a simplified flowchart of an exemplary process 2000 for managing containers in automated order fulfillment, according to some embodiments. In step 2002, a mobile robot control circuit 502 controls a transfer system 504 of a mobile robot 110 to propel itself through one or more storage areas 1706 having stacks 104 of containers 106. Each stack 104 may contain one or more containers 106 stacked vertically relative to each other. In step 2004, the mobile robot positions itself near an intended stack 104 outside the containers. In step 2006, one or more container handling systems 130-131 of the mobile robot 110 may be activated. In step 2008, one or more storage box handling systems 130-131 engage at least with the intended storage box 106 of the outer stack 104 that is instructed to be removed from the outer stack 104. In some embodiments, one or more storage box engaging systems of the one or more storage box handling systems may extend from the frame 120 of the mobile robot 110. In some embodiments, the engagement of the storage box 106 may include the interlocking of the storage box engaging feature 602 of the one or more storage box engaging systems and one or more engaging structural components 420 of the storage box 106 (e.g., groove, post, handle, ridge, shoulder, hole, other such engaging structural components or a combination of two or more such engaging structural components).

[0085] In step 2010, at least one intended storage box is retrieved from the intended outer stack 104 of storage boxes by at least one storage box handling system 130 while implementing the storage box retrieval sequence and moved to the frame of the mobile robot 110 (e.g., storage box handling unit 124). Prior to retrieval, some embodiments may control one or more storage box handling systems (e.g., upper storage box handling system 131) to place the return storage box on the top storage box of the outer stack of storage boxes before the storage box handling system slides the intended storage box onto the frame. In some embodiments, the retrieval of the intended storage box comprises retracting at least one storage box engagement system 302 following the engagement of the intended storage box and sliding the intended storage box 106a out of the second storage box in the outer stack 104 of storage boxes where the intended storage box is supported and loaded. In some embodiments, retrieving one or more intended storage containers involves retrieving one or more additional storage containers (e.g., including at least one container immediately above the intended storage container) that were on the intended storage container and are supported within an outer stack by the intended storage container. As such, sliding the intended storage container out of the outer stack may involve sliding the intended storage container and one or more storage containers (including a third container loaded immediately above the intended storage container) that are on the outer stack at the time of retrieving the intended storage container, are loaded on the intended storage container, and are supported by the intended storage container into the frame as an interlocking sub-stack supported by the intended storage container.

[0086] In some embodiments, process 2000 includes an optional step 2012 in which one or more return containers are placed on the interlocked sub-stack in preparation for return to the outer stack (or another outer stack). This may include controlling one or more container handling systems (e.g., upper container handling system 131) to prepare for placement on the interlocked sub-stack (e.g., from a frame container stack 202) to acquire the return container and return it to the outer stack of containers during a subsequent execution of a container retrieval sequence from another outer stack.

[0087] In step 2014, one or more additional containers (which may include one or more return containers) that are supported by the intended container and are not intended to be retrieved are returned to the outer stack. In some embodiments, returning one or more additional containers may involve activating one or more container handling systems 130-131 to vertically move the interlocked sub-stack to align the bottom container to be returned with the top container of the outer stack and to move the one or more containers to be returned from the frame. For example, the lower storage box handling system 130 can be controlled to move the interlocked lower stack downward within the frame, align the lowermost storage box that is not retained by the interlocked lower stack and is placed above in direct contact with the recovered storage box and supported by the recovered storage box with respect to the uppermost storage box of the outer stack of storage boxes, and move the one or more storage boxes to the outer stack, wherein an external support structure is usually not intervened between the lowered return storage box and the storage box of the outer stack that was the uppermost storage box until the one or more return storage boxes were moved to the outer stack. In some implementations, this movement out of the frame may include sliding additional storage containers from a mobile robot to slide one or more bottom loading features 414 of the bottommost storage container among the additional storage containers into slidingly engaging one or more top loading features 412 of the topmost storage container remaining in the outer stack, thereby aligning one or more additional storage containers vertically and horizontally with the outer intended stack, and automatically aligning said additional storage containers with one or more storage containers of said directed outer stack. The retrieved intended storage container may be stored by a storage container handling system 130 (e.g., a bottom storage container handling system).Engaging one or more bottom loading features of the bottommost of one or more returnable compartments with the top loading features of the topmost compartment of the outer stack provides that the bottommost compartment (and compartments loaded on top of the bottommost compartment) automatically aligns with the topmost compartment of the outer stack (thus aligns vertically with the outer stack), which is accomplished by slidingly engaging the bottom loading features of the bottommost compartment with the top loading features of the topmost compartment of the outer stack to align the bottommost returnable compartment vertically and horizontally with the outer stack.

[0088] In step 2016, the intended retrieval container is placed within the storage section 122 of the mobile robot 110 as part of a frame container stack 202 of a set of one or more retrieval containers stacked vertically without external intermediate structures, generally within the storage section 122 and supported by the mobile robot. Storing the retrieval container may include vertically positioning the retrieval container (e.g., above the top container within the frame container stack) at a selected vertical position relative to the frame container stack (e.g., above the top container within the frame container stack) (e.g., by a lower container handling system 130). The container handling system is then controlled to slide the retrieval container into the frame container stack, which is directly supported by the top container among the retrieval containers within the frame container stack, wherein there are no external intermediate structures between the retrieval container and the top container previously integrated into the frame container stack. Additionally or alternatively, in some embodiments, one or more storage box handling systems 130-131 are moved vertically within a frame, a recovered storage box is positioned vertically at a selected vertical position relative to a frame storage box stack, and said recovered storage box is slid into a frame storage box stack that is directly supported by said storage box and over one of the recovered storage boxes within the frame storage box stack, wherein there is no external intermediate support structure between said recovered storage box and one of the storage boxes within the frame storage box stack.In some embodiments, placing the recovered storage box within the storage section of the mobile robot as part of a frame storage box stack comprises engaging the lower loading features 414 of the recovered storage box with the upper loading features 412 of the previously recovered storage box within the frame storage box stack, and automatically aligning the recovered storage box with the previously recovered storage box by slidingly engaging the lower loading features of the recovered storage box with the upper loading features of the previously recovered storage box within the frame storage box stack in order to align the recovered storage box vertically and laterally with the frame storage box stack.

[0089] FIG. 21 illustrates a simplified flowchart of an exemplary storage box return process 2100 that returns one or more storage boxes to an external storage box stack 104, according to some embodiments. Some implementations include step 2102 in which one or more storage box handling systems (e.g., a lower storage box handling system 130) are controlled to engage the return storage box when placed with a frame storage box stack 202. In step 2104, the return storage box slides out of the frame storage box stack. In some embodiments, removing the return storage box from the frame storage box stack may occur before it is placed on the engaged lower stack 1002. In step 2106, the lower storage box handling system 130 may move the return storage box vertically to engage with an upper storage box handling system 131. The return storage box engaging with the upper storage box handling system 131 in this way can make it possible to prepare the return storage box and any storage box among the engaged sub-stacks to be returned to be placed on top of one or more storage boxes of the engaged sub-stack 1002 before returning them to the outer stack.

[0090] FIG. 22 illustrates a simplified flowchart of an exemplary storage box return process 2200 that returns one or more storage boxes to an external storage box stack 104, according to some embodiments. In step 2202, a lower storage box handling system 130 is controlled to vertically align and engage with the top storage box previously retrieved from the frame storage box stack 202. In step 2204, the lower storage box handling system 130 slides the intended retrieval storage box into the storage box handling section after the intended retrieval storage box or the top storage box of the engaged lower stack is aligned with the bottom portion of the previously retrieved storage box, by being retrieved and placed in a selected vertical position. Some embodiments include an optional step 2206, in which the lower storage container handling system 130 moves the recovered upper storage container to engage with the upper storage container handling system 131 of the mobile robot, wherein the recovered upper storage container is a return container to be returned to one of the external stacks of storage containers.

[0091] FIG. 23 illustrates a simplified flowchart of an exemplary storage box return process 2300 that returns one or more storage boxes to an external storage box stack 104, according to some embodiments. In step 2302, the upper storage box handling system is moved vertically within the frame to align with the lowest storage box among one or more storage boxes in the frame storage box stack to be returned. In step 2304, the upper storage box handling system is controlled to engage with the lowest storage box to be returned. In step 2306, when one or more return storage boxes to be returned to an external stack of storage boxes are acquired during a subsequent storage box retrieval sequence or independently of a subsequent storage box retrieval sequence, the upper storage box handling system slides one or more storage boxes to be returned from the frame storage box stack into storage box handling units 124.

[0092] FIG. 24 illustrates a simplified flowchart of an exemplary process 2400 for routing a stack of storage boxes to a work station according to some embodiments. In step 2402, the robot control circuit receives identification information of the work station to receive the stack of storage boxes. In some embodiments, the identification information is accompanied by routing instructions. In some implementations, the received routing may be provided by a central control system capable of considering a shortened path, congestion, whether one or more additional storage boxes need to be retrieved from the path to the work station, other similar factors, or a combination of two or more of these factors. In other embodiments, the identification information is used by the robot control circuit to determine routing to the intended work station.

[0093] In step 2404, the robot control circuit controls one or more of the robot's propulsion systems to self-propel through the storage area to the workstation. In step 2406, one or more storage box handling systems 130-131 are positioned vertically inside the frame to align with the bottommost storage box of the frame storage box stack 202. In step 2408, one or more storage box handling systems retrieve the retrieved storage box from the frame storage box stack. In some embodiments, one or more storage box handling systems 130-131 may rotate the retrieved storage box stack within the robot's storage box handling section 124 to orient the storage box stack relative to the workstation and / or the buffer tower associated with the workstation. In step 2410, one or more storage box handling systems 130-131 move the storage boxes of the frame storage box stack to be accessible from the mobile robot to the workstation. In some embodiments, the movement of storage boxes from the mobile robot may include simultaneously moving the storage boxes recovered from the frame storage box stack to the buffer tower 1702 of the work station 170. A similar process may be implemented in reverse to recover the stack of storage boxes from the buffer tower and / or work station and return the stack to the storage area.

[0094] FIG. 25 illustrates a simplified flowchart of an exemplary process 2500 for inserting a storage box into a frame storage box stack according to some embodiments. In step 2502, one or more storage box handling systems 130-131 vertically position the recovered storage box at a selected vertical position relative to the frame storage box stack and align the recovered storage box handling system (e.g., lower storage box handling system 130) with the frame storage box stack adjacent to the selected vertical position. In step 2504, one or more storage box handling systems engage the previously recovered storage box among the recovered storage boxes within the frame storage box stack at the selected vertical position. In step 2506, the previously recovered storage box slides into the recovered storage box (or the uppermost storage box if one or more storage boxes to also be inserted into the frame storage box stack are above the recovered storage box) in the storage box handling section of the mobile robot frame to form a combined stack 1104. The combined stack may include the intended retrieval container, the previously retrieval container, and additional previously retrieval containers loaded on top of the previously retrieval container of the frame container stack. In step 2508, one or more container handling systems are controlled to move the combined stack 1104 vertically toward a selected vertical position to align the intended retrieval container with the container remaining at the top of the frame container stack. In step 2510, the combined stack is slid into the frame container stack, and the intended retrieval container is placed at the selected vertical position.

[0095] FIG. 26 illustrates a simplified flowchart 2600 of an exemplary process for moving a frame storage stack 202 from a robot to form an external stack and / or integrate it with an existing external stack, according to some embodiments. In step 2602, the mobile robot receives a directed loading position. In step 2604, the mobile robot propels itself toward the intended loading position. In step 2606, one or more storage handling systems 130-131 are controlled to vertically align at least one of the storage handling systems with the lowest oriented retrieval storage of the frame storage stack 202. In step 2608, the storage engagement system is extended to engage with the lowest oriented retrieval storage. In step 2610, one or more storage box interlocking systems may retract while interlocking with the bottom-oriented retrieved storage box and simultaneously move each of the retrieved storage boxes of the frame storage box stack 202 from the storage section 122 to the storage box handling section 124. Some embodiments include an optional step 2612 in which one or more storage box handling systems rotate the frame storage box stack in an intended direction based on the intended arrangement of the stack. In step 2614, one or more storage box handling systems move the storage boxes of the frame storage box stack out of the frame and simultaneously lower each of the retrieved storage boxes of the frame storage box stack as a stack at the intended loading location.

[0096] FIG. 27 illustrates a simplified flowchart of an exemplary process 2700 of managing, transporting, and loading containers within a fulfillment facility, according to some embodiments. In step 2702, a mobile robot is activated and instructed to move to an intended outer stack 104 of containers. In step 2704, the mobile robot propels itself along one or more passages to approach the target outer stack where the containers are to be placed. In step 2706, the mobile robot aligns adjacently with the target outer stack. In step 2708, one or more container handling systems 130-131 engage with the intended container 106. In some embodiments, one or more container engaging systems 302, which may include, for example, one or more extendable arms, engage with a partial target stack of the outer stack at a designated container level of the intended container.

[0097] In step 2710, one or more of the storage box handling systems 130-131 retrieve the intended storage box. In some embodiments, the storage box engagement system 302 is pulled and retracted by sliding the engaged portion of the outer stack into the frame 120. In step 2712, the one or more storage box handling systems lift the intended storage box to engage with one or more return storage boxes. For example, the lower storage box handling system 130 may lift the intended storage box and any storage boxes supported on the intended storage box to a level for engaging with the return storage box held by the upper storage box handling system 131. In step 2714, the one or more storage box handling systems 130-131 move vertically to align one or more storage boxes to be returned (e.g., the storage box handling system aligns the combined stack so that it can be slidably moved from the frame to the outer stack).

[0098] In step 2716, the upper storage compartment engagement system 302 of the lower storage compartment handling system 130 slides one or more return compartments into the outer stack, and in step 2718, retains the retrieved compartment (for example, the lower storage compartment engagement system 302 of the lower storage compartment handling system 130 maintains engagement with, and the retrieved compartment may be the bottommost compartment while transferring the lower stack to the outer stack and thereafter). In step 2720, one or more return compartments are placed in the outer stack. In step 2722, one or more compartment engagement systems 302 are released from and retract from one or more return compartments located in the outer stack, while in step 2724, the retrieved compartment continues to be retained in the compartment handling system.

[0099] In step 2726, one or more of the storage box handling systems 130-131 rotate the recovered storage box and vertically align the recovered storage box with respect to the frame storage box stack within the frame 120. In step 2728, one or more storage boxes may be moved from the frame storage box stack above the intended position. For example, one or more storage box interlocking systems may be extended to receive, in a sliding manner, the partial storage box stack and the storage box recovered within the storage box handling system from the frame storage box stack above the intended placement position. In step 2730, the partial embodiment storage box from the frame storage box stack interlocks with one or more intended storage boxes supported by the storage box handling system 130 to establish a combined stack 1104. In step 2732, the combined stack is transferred onto the frame storage box stack by one or more storage box handling systems (e.g., the storage box interlocking system may extend one or more arms to place the combined storage box stack on the frame storage box stack). Some embodiments include step 2734 in which one or more return containers are recovered in anticipation of returning one or more return containers to one or more external stacks.

[0100] FIG. 28 illustrates a simplified flowchart of an exemplary process 2800 for acquiring a return container according to some embodiments. In step 2802, a lower container handling system 130 retrieves a return container from a frame container stack. The container handling system may align with the return container to acquire the return container (e.g., which may be at the top of the frame container stack). In step 2804, the lower container handling system 130 receives the return container in a sliding manner. In step 2806, in preparation for a subsequent return to an outer stack, the lower container handling system moves vertically to position the return container so that it engages with the upper container handling system 131.

[0101] FIGS. 29a-29b illustrate a simplified flowchart of an exemplary process 2900 of managing a stacked storage box according to some embodiments. In step 2902, a mobile robot 110 propels itself toward an intended outer stack. The mobile robot may include storage box handling systems 130-131. In step 2904, the mobile robot aligns with the directed outer stack. In step 2906, one or more storage box handling systems (e.g., a lower storage box handling system 130 and an upper storage box handling system 131) rotate to engage with one or more storage boxes of the outer stack when the storage box handling system is not in the desired direction. In step 2908, a storage box engagement system 302 from the upper and lower storage box handling systems 131-130 may extend toward one or more storage boxes of the outer stack. In step 2910, some embodiments control the storage compartment engaging system of the upper storage compartment handling system 131 to extend the top storage compartment of the outer stack and engage with the storage compartment. In step 2912, some embodiments control the storage compartment engaging system of the lower storage compartment handling system 130 to extend and engage at least one storage compartment intended to be retrieved and moved into the frame.

[0102] In step 2914, one or more storage compartment interlocking systems may operate in conjunction to retract. In step 2916, a lower stack of one or more storage compartments may be moved from the outer stack (e.g., by sliding) and moved into the frame by retracting the storage compartment interlocking systems. In step 2918, some embodiments lower the lower storage compartment handling system 130 and the upper storage compartment handling system 131 in conjunction toward the robot's base. In step 2920, vertical movement aligns one or more storage compartments of the lower stack to be returned to the outer stack vertically with the current top storage compartment of the outer stack. In step 2922, some embodiments retain and / or block one or more intended storage compartments by the lower storage compartment handling system.

[0103] In step 2924, the storage compartment interlocking system of the upper and lower storage compartment handling system is activated to transfer one or more unintended storage compartments (e.g., a partial storage compartment stack) from the frame onto an outer stack (e.g., the current top storage compartment of the outer stack), and in step 2926, one or more intended storage compartments intended to be retrieved and transported by a mobile robot are retained.

[0104] In step 2928, some embodiments retract one or more storage box interlocking systems, and the mobile robot may begin to move away from the outer stack (e.g., moving to another outer stack or toward a workstation). In step 2930, some embodiments arrange one or more storage box handling systems (e.g., upper and lower storage box handling systems) to interact with the frame storage box stack. In step 2932, some embodiments vertically align the upper storage box handling system with the return storage box to be returned to the outer stack (e.g., the top storage box within the frame storage box stack, the second storage box following the top storage box if two storage boxes need to be returned, etc.). In step 2934, in some embodiments, the lower storage box handling system 130 holds the recovered storage box.

[0105] In step 2936, the lower storage box handling system vertically aligns the recovered storage box below its intended position within the frame storage box stack, and the upper storage box engaging system of the lower storage box handling system 130 engages with one of the storage boxes in the frame storage box stack at a vertical level above the level at which the previously recovered storage box is to be placed within the frame storage box stack. In step 2938, the upper storage box engaging system of the lower storage box handling system 130 removes one or more storage boxes (e.g., a partial storage box stack) from the frame storage box stack and transfers them onto the recovered storage box. In step 2940, the partial storage box stack slides onto the recovered storage box held within the lower storage box handling system 130, and generally has no external intermediate structure other than the engaging feature of the storage boxes. In step 2942, the lower storage box handling system 130 vertically lifts the recovered storage box (and all storage boxes moved over the recovered storage box from the frame storage box stack) so as to align with an intended vertical position within the frame storage box stack (e.g., providing clearance for the intended storage box, which may often be the lowest storage box in the combined stack). In step 2944, one or more storage box engagement systems 302 of the lower storage box handling system 130 are activated to transfer the recovered storage box and all storage boxes supported by the recovered storage box (e.g., a combined stack of two or more storage boxes) over the current top storage box of the frame storage box stack. In step 2946, one or more storage box engagement systems 302 of the lower storage box handling system 130 are retracted and can rotate to align with the upper storage box handling system 131, and in step 2948, the upper storage box handling system can hold one or more storage boxes to be returned.

[0106] Additionally, circuits, networks, systems, vises, processes, methods, techniques, functions, services, servers, sources, etc. described herein may be utilized, implemented, and / or executed in various types of devices and / or systems. FIG. 30 illustrates an exemplary system 3000 that may be used to implement any of the circuits, functions, systems, devices, processes, or parts of the circuits, functions, devices, devices, processes, or devices mentioned above or below, or any of the other systems or devices described herein, including an automated order fulfillment system 100, a mobile robot 110, a low-profile mobile robot 152, a container handling system 130-131, a robot control circuit 502, a container interlocking system 302, a transfer system 504, a drive system 506, a container interlocking control circuit 702, a container handling control circuit 706, a storage buffer 1702, a workstation 170, a picking conveyor 1712, and / or other systems or devices mentioned above or below. However, using the above-mentioned system 3000 or any part thereof is not strictly necessary.

[0107] For example, the system 3000 may include one or more control circuits or processor modules 3012, one or more memories 3014, and one or more communication links, paths, buses, or similar elements 3018. Some embodiments may include one or more user interfaces 3016 and / or one or more internal and / or external power supplies 3040. The control circuit 3012 may be implemented through one or more processors, microprocessors, central processing units, logic, local digital repositories, firmware, software, and / or other control hardware and / or software, and may be used to execute or support the execution of steps of the processes, methods, functions, and techniques described herein, and to control various communications, decisions, programs, content, lists, services, interfaces, logging, reporting, etc. Additionally, in some embodiments, the control circuit 3012 may be part of a control network and / or control system 3010, which may be implemented through one or more processors capable of accessing one or more memories 3014 that can store instructions, code, etc., implemented by the control circuit and / or processor to perform the intended function. In some applications, the control circuit and / or memory may be distributed over a communication network (e.g., LaN, WaN, Internet) to provide distributed and / or redundant processing and functions. In other words, the system 3000 may be used to implement one or more or parts of the above or below components, circuits, systems, processes, etc.

[0108] User interface 3016 enables a user to interact with System 3000 and receive information through the system. In some cases, user interface 3016 may include a display 3022 and / or one or more user inputs 3024, such as buttons, touchscreens, trackballs, keyboards, mice, etc., which may be part of System 3000 or connected to System 3000 via wired or wireless connections. Generally, System 3000 further includes one or more communication interfaces, ports, transceivers 3020, etc., to enable System 3000 to communicate via a communication bus, a distributed computer and / or communication network (e.g., Local Area Network (LAN), Internet, Wide Area Network (WAN), etc.), a communication link 3018, a communication channel with other networks or other devices, and / or other communication or a combination of two or more of these communication methods. Additionally, the transceiver 3020 may be configured with wired, wireless, optical, fiber optic cable, satellite, or other communication configurations, or a combination of two or more of these communication configurations. Some embodiments include one or more input / output (I / O) ports 3034 to allow one or more devices to be connected to the system 3000. The I / O ports may be substantially any relevant port or combination of ports, including but not limited to USB, Ethernet, or other similar ports. The I / O interface 3034 may be configured to allow wired and / or wireless communication connections with external components. For example, the I / O interface may provide wired and / or wireless communication (e.g., Wi-Fi, Bluetooth, cellular, RF, and / or other wireless communication), and in some cases, may include any known wired and / or wireless interface device, circuit, and / or connection device, including but not limited to one or more transmitters, receivers, transceivers, or combinations of two or more of these devices.

[0109] In some embodiments, the system may include one or more sensors 3026 for providing information to the system and / or sensor information transmitted to other components such as a central control system, a delivery vehicle, etc. These sensors may include distance measuring sensors (e.g., optical units, acoustic / ultrasonic units, etc.), optical-based scanning sensors that detect and read optical patterns (e.g., barcodes), RFID (radio frequency identification) tag reading sensors capable of reading RFID tags in proximity to the sensor, motion sensors, cameras, accelerometers, GPS, gyroscopes, inertial sensors, and substantially any other relevant sensors. The above examples are intended to be illustrative and are not intended to list all possible sensors. Rather, it will be understood that these teachings will be applied to detecting any of the very diverse environments in a given application environment.

[0110] The above system 3000 includes examples of control and / or processor-based systems comprising a control circuit 3012. In other words, the control circuit 3012 may be implemented through one or more processors, controllers, central processing units, logic, software, etc. Additionally, in some implementations, the control circuit 3012 may provide multiprocessor capabilities.

[0111] Memory 3014 accessible by control circuit 3012 generally comprises at least one processor-readable and / or computer-readable medium accessed by control circuit 3012, and may comprise volatile and / or non-volatile media such as RAM, ROM, EEPROM, flash memory and / or other memory technologies. Additionally, although memory 3014 is indicated as being located inside the control system 3010, memory 3014 may be internal memory, external memory, or a combination of internal and external memory. Likewise, part or all of memory 3014 may be internal memory, external memory, or a combination of internal and external memory of control circuit 3012. External memory includes, but is not limited to, substantially all related memory such as solid-state storage devices or drives, hard drives, USB sticks or drives, flash memory, SD cards, and other memory cards, and may also include a combination of two or more of such memory, and part or all of such memory may be distributed across multiple locations via a computer network. Memory 3014 can store code, software, executable files, scripts, data, content, lists, programming, programs, log or historical data, user information, customer information, product information, etc. Fig. 30 shows various components connected to each other via a bus, but it should be understood that in reality, these various components may be connected to a control circuit and / or one or more other components.

[0112] Some embodiments provide an automated order fulfillment system, device and corresponding method, comprising: a plurality of totes; a storage area having stacks of totes, each stack comprising one or more of the plurality of totes stacked vertically with respect to each other; and a mobile robot configured to transport a set of one or more recovered totes from the stacks of totes through the storage area, wherein the mobile robot comprises: a robot control circuit; a transport system coupled with the robot control circuit, the transport system configured to self-propel the mobile robot through the storage area based on commands from the robot control circuit; and a frame comprising a storage section and a tote handling section, wherein the storage section stores a frame stack of one or more sets of recovered totes stacked vertically with respect to each other, and the tote handling section comprises one or more tote handling systems, wherein the tote handling systems are controlled by the robot control circuit and perform a tote retrieval sequence to recover a first tote from a first stack of totes among the stacks of totes instructed to be removed from a first stack of totes.

[0113] Some embodiments provide a method for automatically processing orders, the method comprising: controlling a transport system of a mobile robot through a mobile robot control circuit of the mobile robot to self-propell a storage area having stacks of storage boxes, each stack comprising one or more storage boxes stacked vertically with respect to each other, and positioning the mobile robot near a first stack of storage boxes among the stacks of storage boxes; engaging a first storage box among the first stack of storage boxes that is instructed to be removed from the first stack of storage boxes by a first storage box handling system coupled with the storage unit of the mobile robot; recovering the first storage box from the first stack of storage boxes by the first storage box handling system in implementing a storage box recovery sequence; and positioning the first storage box within the storage unit of the mobile robot as part of a frame storage box stack of a set of one or more recovered storage boxes stacked vertically with respect to each other within the storage unit and supported by the mobile robot.

[0114] Those skilled in the art will recognize that various other modifications, changes, and combinations may be made with respect to the embodiments described above without departing from the scope of the invention, and that such modifications, changes, and combinations should also be considered to be within the scope of the concept of the invention. Various alternative embodiments of the invention will be apparent to those skilled in the art in light of the foregoing description. Accordingly, this description should be interpreted merely as illustrative and is provided solely for the purpose of teaching those skilled in the art the best mode of practice for the invention. Details of the structure may vary substantially without departing from the spirit of the invention, and the exclusive right to use any modifications included within the scope of the appended claims is reserved. Although embodiments are described in this specification to provide a clear and concise specification, it is intended to be acknowledged that embodiments and related parts thereof may be combined or separated in various ways without departing from the invention. The invention is intended to be limited only to the extent required by the appended claims and applicable legal provisions.

Claims

Claim 1 An automated order fulfillment system, wherein the automated order fulfillment system comprises: a plurality of storage boxes; a storage area having stacks of storage boxes, each stack comprising one or more of the plurality of storage boxes stacked vertically with respect to each other; and a mobile robot configured to transport a set of one or more recovered storage boxes among the stacks of storage boxes through the storage area, wherein the mobile robot comprises: Robot control circuit; A transfer system combined with a robot control circuit - said transfer system is configured to self-propel the mobile robot through the storage area based on commands from said robot control circuit -; and An automated order fulfillment system comprising a frame including a storage unit and a storage box handling unit, wherein the storage unit is configured to store a frame storage box stack of a set of one or more recovered storage boxes by stacking them vertically on top of each other, and wherein the storage box handling unit includes one or more storage box handling systems, wherein the storage box handling systems are controlled by the robot control circuit and configured to perform a storage box retrieval sequence to retrieve a first storage box from a first stack of storage boxes among stacks of storage boxes instructed to be removed from a first stack of storage boxes. Claim 2 An automated order fulfillment system according to claim 1, wherein the mobile robot comprises: a first storage box handling system among the one or more storage box handling systems configured to retrieve a first storage box from a first stack of storage boxes during the storage box retrieval sequence and insert the first storage box into the frame storage box stack; and a second storage box handling system among the one or more storage box handling systems configured to hold a return storage box to be returned to the first stack of storage boxes during the storage box retrieval sequence. Claim 3 An automated order fulfillment system according to claim 1, wherein the first storage box handling system among the one or more storage box handling systems comprises: a first storage box engaging system, wherein the first storage box engaging system extends from the frame and engages with the first storage box, and is configured to slide the first storage box into the frame by sliding the first storage box from the second storage box in the first stack of storage boxes in which the first storage box is supported and loaded. Claim 4 In paragraph 3, the robot control circuit is configured to control the first storage box handling system, so as to move the first storage box to the frame, the first storage box and one or more additional storage boxes to the frame in an interlocked sub-stack, the additional storage boxes are in the first stack of storage boxes and are supported by the first storage box at the time of retrieval of the first storage box, an automated order fulfillment system. Claim 5 An automated order fulfillment system, wherein the robot control circuit is configured to control a first storage box handling system, moving the interlocked sub-stack downward within a frame, aligning a third storage box of the interlocked sub-stack, which is positioned above the first storage box and supported by the first storage box, with respect to a second storage box among the first stacks of storage boxes, and sliding the third storage box over the second storage box. Claim 6 An automated order fulfillment system according to claim 5, wherein the mobile robot further comprises a second storage box handling system among one or more storage box handling systems coupled to communicate with the robot control circuit, and the robot control circuit is configured to control the second storage box handling system to place a return storage box on the interlocked lower stack before the third storage box is returned to the first stack of storage boxes, so that when the third storage box is returned to the first stack of storage boxes, the return storage box is also returned to the first stack of storage boxes. Claim 7 An automated order fulfillment system according to claim 6, wherein the robot control circuit controls a first storage box handling system to vertically position the first storage box and, at a selected vertical position, to slide the first storage box onto the frame storage box stack so as to be directly supported by the fourth storage box within the frame storage box stack, without an intermediate support structure between the first storage box and the fourth storage box among the recovered storage boxes within the frame storage box stack. Claim 8 An automated order fulfillment system according to claim 6, wherein the robot control circuit is configured to control the first storage box handling system, to slide the return storage box out of the frame storage box stack by engaging the return storage box before placing the return storage box onto the engaged lower stack, and to move the return storage box to engage the second storage box handling system. Claim 9 An automated order fulfillment system according to claim 5, wherein the mobile robot further comprises a second storage box handling system among one or more storage box handling systems coupled to communicate with a robot control circuit, and the robot control circuit is configured to control the second storage box handling system to slide a return storage box over the top storage box of a first stack of storage boxes before the first storage box handling system slides the first storage box into the frame. Claim 10 An automated order fulfillment system, wherein the one or more storage box handling systems include a first storage box handling system coupled to communicate with the robot control circuit, and the robot control circuit controls the first storage box handling system to move vertically within the frame and to position the first storage box vertically, and at a selected vertical position of the frame storage box stack, to slide the first storage box onto the frame storage box stack so as to be directly supported by the second storage box within the frame storage box stack, without an intermediate support structure between the first storage box and the second storage box among the recovered storage boxes within the frame storage box stack, and the selected vertical position is based on a predetermined order of the recovered storage boxes in the frame storage box stack. Claim 11 An automated order fulfillment system according to claim 10, further comprising a work station; wherein the robot control circuit controls the transfer system to transfer the mobile robot between the storage area and the work station, and controls the first storage box handling system to move the recovered storage boxes within the frame storage box stack from the mobile robot to the work station, and wherein the predetermined order of the recovered storage boxes is based on the order of the recovered storage boxes to be processed through the work station. Claim 12 An automated order fulfillment system according to claim 11, further comprising a buffer tower linked to the above work station; wherein the robot control circuit is configured to control the first storage box handling system to move the recovered storage boxes simultaneously from the frame storage box stack to the buffer tower at the above work station in controlling the first storage box handling system to move the recovered storage boxes. Claim 13 In claim 10, the robot control circuit is configured to control the first storage box handling system when inserting the first storage box into the frame storage box stack at a selected vertical position of the frame storage box stack, wherein the first storage box handling system is configured to: align with the frame storage box stack adjacent to the selected vertical position; engage the fourth storage box among the recovered storage boxes at the selected vertical position; slide the fourth storage box over the first storage box at the storage box handling portion of the frame to form a combined stack - the combined stack includes the first storage box -; and move the combined stack vertically with respect to the selected vertical position and slide the combined stack into the frame storage box stack while placing the first storage box at the selected vertical position, an automated order fulfillment system. Claim 14 An automated order fulfillment system, wherein, in paragraph 13, the robot control circuit is configured to control a first storage box handling system, so that after the first retrieval box is placed at the selected vertical position, the retrieval box from the top of the frame storage box stack engages with the storage box and slides to the storage box handling section, and the retrieval box from the top engages with a second storage box handling system among the one or more storage box handling systems, and the retrieval box from the top is a return storage box to be returned to one of the stacks of storage boxes. Claim 15 An automated order fulfillment system, wherein the one or more storage box handling systems include a second storage box handling system coupled to communicate with the robot control circuit, the robot control circuit is configured to control the second storage box handling system to move vertically within the storage box handling section and to engage with the storage box retrieved from the top of the frame storage box stack and slide into the storage box handling section, the top storage box being a return storage box to be returned to one of the stacks of storage boxes during the next execution of the storage box retrieval sequence. Claim 16 An automated order fulfillment system according to claim 1, comprising a first storage box handling system among the one or more storage box handling systems, wherein the robot control circuit is configured to control the first storage box handling system: vertically aligning the first storage box engaging system of the first storage box handling system with a recovered storage box located at the bottom of the frame storage box stack; extending the first storage box engaging system of the first storage box handling system to engage with the recovered storage box located at the bottom; retracting the first storage box engaging system while engaging with the recovered storage box located at the bottom, and simultaneously moving each of the recovered storage boxes of the frame storage box stack from the storage section; and simultaneously lowering each of the recovered storage boxes of the frame storage box stack as a stack at a loading location. Claim 17 An automated order fulfillment system according to claim 1, wherein each of the plurality of storage boxes includes upper loading features and lower loading features, and the lower loading features are configured to align with and interlock in a sliding manner with the upper loading features of other storage boxes among the plurality of storage boxes to establish vertical and lateral alignment of the frame storage box stack. Claim 18 A method for automatic order fulfillment, the method comprises: controlling a transfer system of the mobile robot through a robot control circuit of the mobile robot to self-propell a storage area having stacks of storage boxes, wherein each stack comprises one or more storage boxes stacked vertically with respect to each other, and positioning the mobile robot near a first stack of storage boxes among the stacks of storage boxes; engaging a first storage box among the first stack of storage boxes that is instructed to be removed from the first stack of storage boxes by a first storage box handling system linked to the storage unit of the mobile robot; recovering the first storage box from the first stack of storage boxes by the first storage box handling system in implementing a storage box recovery sequence; and positioning the first storage box within the storage unit of the mobile robot as part of a frame storage box stack of a set of one or more recovered storage boxes that are stacked vertically with respect to each other within the storage unit and supported by the mobile robot. Claim 19 A method according to claim 18, further comprising the step of acquiring a return container to be returned to a first stack of containers during the container retrieval sequence by the second container handling system of the mobile robot. Claim 20 In claim 18, the step of retrieving the first storage box from the first stack of storage boxes comprises: extending the first storage box engaging system of the first storage box handling system from the frame of the mobile robot; after engaging the first storage box, retracting the first storage box engaging system to slide the first storage box out of the second storage box in the first stack of storage boxes in which the first storage box is supported and loaded; and moving the first storage box into the frame. Claim 21 In claim 20, the step of sliding a first storage box out of a second storage box comprises: sliding one or more additional storage boxes loaded on top of the first storage box and supported by the first storage box at the time of retrieving the first storage box from a first stack of storage boxes, including the first storage box and a third storage box loaded directly on top of the first storage box; and moving the one or more additional storage boxes together with the first storage box as an interlocked sub-stack. Claim 22 A method according to claim 21, further comprising the steps of: moving the interlocking sub-stack downward within the frame via a first storage box handling system, and aligning a third storage box of the interlocking sub-stack, which is placed on the first storage box and supported by the first storage box, with respect to a second storage box among the first stacks of storage boxes; and sliding the third storage box over the second storage box. Claim 23 A method according to claim 22, further comprising the step of placing a return storage box by a second storage box handling system over the interlocked lower stack before the third storage box is returned to the first stack of storage boxes, wherein the return storage box is returned to the first stack of storage boxes when the third storage box is returned to the first stack of storage boxes. Claim 24 A method according to claim 23, further comprising: a step of positioning a first storage box vertically with respect to a frame storage box stack at a selected vertical position by means of the first storage box handling system; and a step of sliding the first storage box into the frame storage box stack while being directly supported by the fourth storage box within the frame storage box stack without an intermediate support structure between the first storage box and the fourth storage box among the recovered storage boxes within the frame storage box stack. Claim 25 A method according to claim 23, further comprising: a step of engaging the return storage box by the first storage box handling system while being placed together with the frame storage box stack; a step of sliding the return storage box from the frame storage box stack before being placed on the engaged sub-stack; and a step of moving the return storage box to engage with the second storage box processing system. Claim 26 A method according to claim 22, further comprising the step of sliding a return storage box onto the top storage box of a first stack of storage boxes by the second storage box handling system of the mobile robot before the first storage box handling system slides the first storage box into the frame. Claim 27 A method according to claim 18, further comprising the steps of: vertically moving the first storage box handling system within the frame of the mobile robot and vertically positioning the first storage box at a selected vertical position relative to the frame storage box stack; and sliding the first storage box into the frame storage box stack while being directly supported by the second storage box within the frame storage box stack without an intermediate support structure between the first storage box and the second storage box among the recovered storage boxes within the frame storage box stack. Claim 28 A method according to claim 27, further comprising the step of self-propelling by the mobile robot through the storage area to the work station; and the step of moving the recovered storage boxes within the frame storage box stack from the mobile robot to the work station by the first storage box handling system. Claim 29 In claim 28, the step of moving the recovered storage boxes to a work station comprises: the step of simultaneously moving the recovered storage boxes within the frame storage box stack to a buffer tower at the work station. Claim 30 In claim 27, the step of vertically positioning the first storage box at the selected vertical position with respect to the frame storage box stack comprises: aligning the first storage box handling system with the frame storage box stack adjacent to the selected vertical position; engaging the fourth storage box among the recovered storage boxes at the selected vertical position; sliding the fourth storage box over the first storage box at the storage box handling part of the frame of the mobile robot to form a combined stack - the combined stack comprises the first storage box and the fourth storage box -; and moving the combined stack vertically with respect to the selected vertical position and sliding the combined stack into the frame storage box stack while placing the first storage box at the selected vertical position. Claim 31 A method according to claim 30, further comprising: a step of engaging the top recovered storage box from the frame storage box stack with the first storage box handling system; a step of sliding the top recovered storage box into a storage box processing unit after the first storage box is placed in the selected vertical position; and a step of moving the top recovered storage box to engage with the second storage box handling system of the mobile robot, wherein the top recovered storage box is a storage box to be returned to one of the stacks of storage boxes. Claim 32 A method according to claim 30, further comprising the steps of: vertically moving a second storage box handling system within the storage box processing unit to align with the top recovered storage box of the frame storage box stack; sliding the top recovered storage box from the frame storage box stack into the storage box handling unit; and returning the top recovered storage box to one of the stacks of storage boxes during a subsequent storage box retrieval sequence. Claim 33 A method according to claim 18, further comprising: a step of vertically aligning a first storage box interlocking system of a first storage box handling system with a recovered storage box located at the bottom of the frame storage box stack; a step of extending the first storage box interlocking system of the first storage box handling system to interlock with the recovered storage box located at the bottom; a step of contracting the first storage box interlocking system while interlocking with the recovered storage box located at the bottom, and simultaneously moving each of the recovered storage boxes of the frame storage box stack from the storage section; and a step of simultaneously lowering each of the recovered storage boxes of the frame storage box stack as a stack at a loading place. Claim 34 A method according to claim 18, wherein the step of arranging the first storage box as part of a frame storage box stack within the storage section of the mobile robot comprises the step of engaging the lower loading features of the first storage box with the upper loading features of the first recovered storage box of the frame storage box stack, and the step of automatically aligning the first storage box with the first recovered storage box by engaging the lower loading features of the first storage box with the upper loading features of the first recovered storage box in a sliding manner when aligning the first storage box with the frame storage box stack vertically and laterally.

Images