Automated inventory management system

Abstract

Systems and methods for automated warehouse fulfillment. Modular storage units may be installed in warehouse racks. The storage units may comprise rows of cell compartments configured to hold modular product cells. Each product cell may hold a single product and each of the product cells may be interconnected with one another to form chains of cells. These chains of cells may be loaded in the cell. Grabbing assemblies on automated robots may be used to load, unload and move product cells. One or more servers may convert product orders into tasks that are sent to the robots. The robots may autonomously navigate to a product's location, hook onto a product cell, pull the product cell onto the grabber assembly of the robot, disengage the product cell from other product cells in the cell compartment and navigate to a delivery station with the request product.

Description

AUTOMATED INVENTORY MANAGEMENT SYSTEMCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of priority to U.S. Provisional Application No. 63 / 580,358, filed on September 2, 2023, which is hereby incorporated by reference in its entirety.FIELD

[0002] The present invention relates generally to systems, tools and methods for warehouse automation.BACKGROUND

[0003] In recent years, the demand for efficient and streamlined logistics operations has grown exponentially with the rise of e-commerce, globalization, and consumer expectations for rapid order fulfillment. As a result, there is a significant need for innovative solutions that can optimize the storage, retrieval, and distribution of goods within warehouses. Traditional manual warehouse management systems often need help to meet the demands of modem supply chains, leading to inefficiencies, errors, and increased operational costs.

[0004] The invention recognizes the limitations of manual inventory management processes, including time-consuming order picking, inventory inaccuracies, and labor-intensive tasks. These limitations impact the speed at which orders are fulfilled and increase operational expenses due to labor costs and inventory discrepancies.SUMMARY

[0005] The present invention introduces an automated fulfillment system that leverages innovative technologies to revolutionize how goods are stored, managed, and dispatchedwithin a warehouse environment. The automated fulfillment system offers a comprehensive solution that enhances warehouse operations' efficiency, accuracy, and scalability by combining robotics, artificial intelligence, sensor networks, and data analytics advancements.

[0006] Therefore, the automated warehouse system aims to eliminate these inefficiencies by creating a seamlessly integrated ecosystem where various components work harmoniously to achieve high automation and operational excellence.

[0007] The systems and methods described herein provide for automated warehouse fulfillment. The automated warehouse fulfillment system may comprise: a network; one or more servers; one or more storage racks; one or more storage units installed in each of the one or more storage racks and wherein each of the one or more storage units may comprise one or more cell compartments; one or more product cells loaded into the one or more cell compartment of each of the one or more storage units; one or more robot lift units; and one or more retrieval robots. In some embodiments, the one or more retrieval robots may be configured perform one or more processes corresponding to the one or more product cells, the one or more processes may comprise a loading process, an unloading process and a moving process.

[0008] In some embodiments, each of the one or more storage racks may comprise one or more rail supports and one or more retrieval rails. Each of the one or more robot lift units may further comprise one or more vertical lift tracks and a lift platform.

[0009] In some embodiments, each of the one or more cell compartments may further comprise one or more localization labels. Each of the one or more product cells may further comprise a product holding area, a rack side linking mechanism and a grabber side linking mechanism. A first cell compartment may be loaded with a plurality of product cells and each of the plurality of product cells may be interlocked with adjacent product cells forminga chain of product cells. The interlocking may comprise engaging, at an interface between an initiating product cell and a receiving product cell, the grabber side linking mechanism of the initiating product cell with the rack side linking mechanism of the receiving product cell.

[0010] In some embodiments, the engaging may comprise moving the initiating product cell to a preparatory position. The preparatory position may be vertically offset to the receiving product cell. The preparatory position may align the grabber side linking mechanism of the initiating product cell with the rack side linking mechanism of the receiving product cell. After reaching the preparatory position, the initiating product cell may be moved vertically to a position in which the grabber side linking mechanism of the initiating product cell contacts and forms a physical connection with the rack side linking mechanism of the receiving product cell.

[0011] In some embodiments, each of the one or more retrieval robots may comprise a robot control unit, a robot drive unit, one or more ground wheels, one or more rail wheels, one or more sensor modules and a grabber assembly. The grabber assembly may comprise one or more linear rails, one or more manipulators with a grabber side linking mechanism, one or more linear motion units, one or more grabber cell channels and one or more grabber cameras.

[0012] In some embodiments, the retrieval robot may further include a grabber platform. The grabber platform may comprise a rigid frame, one or more z-axis motion units and a grabber z-axis carriage.

[0013] In some embodiments, the one or more servers may comprise a task scheduler module. The task scheduler module may be configured to receive a first product order for a first product. The first product may be stored in a first product cell. The task scheduler may transform the first product order into a first actionable task. The first actionable task maycomprise a location of the first product cell corresponding to the first product order. The first product cell location may correspond to a first cell compartment positioned in a first rack at a first rack location.

[0014] In some embodiments, the first actionable task may be assigned to a first retrieval robot and sent, over the network, to the first retrieval robot. In some embodiments, the task scheduler module may be configured to track the first retrieval robot’s execution of the first actionable task.

[0015] In some embodiments, the first retrieval robot may be configured to receive, from the task scheduler module, the first actionable task and generate an execution plan based on the first actionable task. The first retrieval robot may identify a target location based on the first actionable task. The retrieval robot may then determine its current position and orientation.

[0016] In some embodiments, the retrieval robot may then plan a first path from the current position to the target location. A first distance of the first path may be calculated and a motion plan may be determined based on the first path and the first distance. The first retrieval robot may be moved to the target location by controlling the robot drive unit based on the determined motion plan. The one or more sensor modules may be configured to scan a localization label of the first cell compartment. Based on the scanning, a position offset between the first retrieval robot’s gabber assembly and the first cell compartment may be calculated.

[0017] In some embodiments, the first retrieval robot may be repositioned based on the position offset. A first grabber cell channel of the grabber assembly may then be aligned with the first cell compartment. The first manipulator may be moved to a first preparatory position in-line with the first grabber channel cell.

[0018] In some embodiments, the first manipulator’s grabber side linking mechanism may be interlocked with the first product cell’s rack side linking mechanism by changing height of the first manipulator. The interlocked first product cell may be pulled into the first grabber cell channel by a first linear motion unit. The first product cell may then be disengaged from an interconnected second product cell in the first cell compartment. The disengaging may comprise changing height of interconnected first product cell and first manipulator. The first product cell may then be delivered to a first delivery station.

[0019] The appended claims may also serve as a summary of this application.

[0020] The features and components of these embodiments will be described in further detail in the description which follows. Additional features and advantages will also be set forth in the description which follows, and in part will be implicit from the description, or may be learned by the practice of the embodiments. The detailed description and specific examples are intended for illustration only and are not intended to limit the scope of the disclosure.BRIEF DESCRIPTION OF THE DRAWINGS

[0021] The present disclosure will become better understood from the detailed description and the drawings, wherein:

[0022] FIG. 1 is a diagram illustrating an automated warehouse fulfilment system in which some embodiments may operate.

[0023] FIG. 2A is a diagram illustrating an exemplary retrieval robot in accordance with aspects of the present disclosure.

[0024] FIG. 2B is a diagram illustrating an exemplary robot lift in accordance with aspects of the present disclosure.

[0025] FIG. 2C is a diagram illustrating an exemplary loading station in accordance with aspects of the present disclosure.

[0026] FIG. 2D is a diagram illustrating an exemplary delivery station in accordance with aspects of the present disclosure.

[0027] FIG. 2E is a diagram illustrating an exemplary client device in accordance with aspects of the present disclosure.

[0028] FIG. 2F is a diagram illustrating an exemplary server in accordance with aspects of the present disclosure.

[0029] FIG. 3 A is a diagram illustrating an exemplary product cell in accordance with aspects of the present disclosure.

[0030] FIG. 3B is a diagram illustrating an exemplary product cell in accordance with aspects of the present disclosure.

[0031] FIG. 3C is a diagram illustrating an exemplary product cell in accordance with aspects of the present disclosure.

[0032] FIG. 3D is a diagram illustrating an exemplary product cell in accordance with aspects of the present disclosure.

[0033] FIG. 3E is a diagram illustrating an exemplary product cell in accordance with aspects of the present disclosure.

[0034] FIG. 3F is a diagram illustrating an exemplary product cell in accordance with aspects of the present disclosure.

[0035] FIG. 3G is a diagram illustrating an exemplary product cell in accordance with aspects of the present disclosure.

[0036] FIG. 3H is a diagram illustrating an exemplary product cell in accordance with aspects of the present disclosure.

[0037] FIG. 31 is a diagram illustrating an exemplary product cell in accordance with aspects of the present disclosure.

[0038] FIG. 3J is a diagram illustrating an exemplary product cell in accordance with aspects of the present disclosure.

[0039] FIG. 3K is a diagram illustrating an exemplary product cell in accordance with aspects of the present disclosure.

[0040] FIG. 3L is a diagram illustrating an exemplary product cell in accordance with aspects of the present disclosure.

[0041] FIG. 3M is a diagram illustrating an exemplary product cell in accordance with aspects of the present disclosure.

[0042] FIG. 3N is a diagram illustrating an exemplary product cell in accordance with aspects of the present disclosure.

[0043] FIG. 30 is a diagram illustrating an exemplary product cell in accordance with aspects of the present disclosure.

[0044] FIG. 3P is a diagram illustrating an exemplary product cell in accordance with aspects of the present disclosure.

[0045] FIG. 3Q is a diagram illustrating an exemplary product cell in accordance with aspects of the present disclosure.

[0046] FIG. 3R is a diagram illustrating an exemplary product cell in accordance with aspects of the present disclosure.

[0047] FIG. 3S is a diagram illustrating an exemplary product cell in accordance with aspects of the present disclosure.

[0048] FIG. 3T is a diagram illustrating an exemplary product cell in accordance with aspects of the present disclosure.

[0049] FIG. 3U is a diagram illustrating an exemplary product cell in accordance with aspects of the present disclosure.

[0050] FIG. 3 V is a diagram illustrating an exemplary product cell in accordance with aspects of the present disclosure.

[0051] FIG. 3W is a diagram illustrating an exemplary product cell in accordance with aspects of the present disclosure.

[0052] FIG. 3X is a diagram illustrating an exemplary product cell in accordance with aspects of the present disclosure.

[0053] FIG. 3 Y is a diagram illustrating an exemplary product cell in accordance with aspects of the present disclosure.

[0054] FIG. 3Z is a diagram illustrating an exemplary product cell in accordance with aspects of the present disclosure.

[0055] FIG. 3 AAis a diagram illustrating an exemplary product cell in accordance with aspects of the present disclosure.

[0056] FIG. 4Ais a diagram illustrating an exemplary modular storage unit in accordance with aspects of the present disclosure.

[0057] FIG. 4B is a diagram illustrating an exemplary modular storage unit in accordance with aspects of the present disclosure.

[0058] FIG. 4C is a diagram illustrating an exemplary storage and retrieval system in accordance with aspects of the present disclosure.

[0059] FIG. 4D is a diagram illustrating an exemplary storage and retrieval system in accordance with aspects of the present disclosure.

[0060] FIG. 4E is a diagram illustrating an exemplary cell compartment in accordance with aspects of the present disclosure.

[0061] FIG. 4F is a diagram illustrating an exemplary cell compartment in accordance with aspects of the present disclosure.

[0062] FIG. 4G is a diagram illustrating an exemplary storage and retrieval system in accordance with aspects of the present disclosure.

[0063] FIG. 4H is a diagram illustrating an exemplary modular storage rack with modular storage units installed in accordance with aspects of the present disclosure.

[0064] FIG. 41 is a diagram illustrating an exemplary static retrieval robot lift in accordance with aspects of the present disclosure.

[0065] FIG. 4J is a diagram illustrating an exemplary dynamic retrieval robot lift in accordance with aspects of the present disclosure.

[0066] FIG. 4K is a diagram illustrating an exemplary retrieval robot lift in accordance with aspects of the present disclosure.

[0067] FIG. 4L is a diagram illustrating an exemplary modular storage rack with retrieval robot rails installed in accordance with aspects of the present disclosure.

[0068] FIG. 4M is a diagram illustrating an exemplary modular storage rack with retrieval robot rails installed in accordance with aspects of the present disclosure.

[0069] FIG. 4N is a diagram illustrating an exemplary modular storage rack with retrieval robot rails installed in accordance with aspects of the present disclosure.

[0070] FIG. 5 A is a diagram illustrating an exemplary empty retrieval robot in accordance with aspects of the present disclosure.

[0071] FIG. 5B is a diagram illustrating an exemplary loaded retrieval robot in accordance with aspects of the present disclosure.

[0072] FIG. 5C is a diagram illustrating an exemplary retrieval robot chassis in accordance with aspects of the present disclosure.

[0073] FIG. 5D is a diagram illustrating an exemplary retrieval robot chassis in accordance with aspects of the present disclosure.

[0074] FIG. 5E is a diagram illustrating an exemplary cell grabber in accordance with aspects of the present disclosure.

[0075] FIG. 5F is a diagram illustrating an exemplary cell grabber in accordance with aspects of the present disclosure.

[0076] FIG. 5G is a diagram illustrating an exemplary cell grabber in accordance with aspects of the present disclosure.

[0077] FIG. 5H is a diagram illustrating an exemplary cell grabber in accordance with aspects of the present disclosure.

[0078] FIG. 51 is a diagram illustrating an exemplary cell grabber in accordance with aspects of the present disclosure.

[0079] FIG. 5J is a diagram illustrating an exemplary cell grabber in accordance with aspects of the present disclosure.

[0080] FIG. 5K is a diagram illustrating an exemplary cell grabber in accordance with aspects of the present disclosure.

[0081] FIG. 5L is a diagram illustrating an exemplary cell grabber in accordance with aspects of the present disclosure.

[0082] FIG. 5M is a diagram illustrating an exemplary cell grabber in accordance with aspects of the present disclosure.

[0083] FIG. 5N is a diagram illustrating an exemplary cell grabber in accordance with aspects of the present disclosure.

[0084] FIG. 50 is a diagram illustrating an exemplary cell grabber in accordance with aspects of the present disclosure.

[0085] FIG. 5P is a diagram illustrating an exemplary cell grabber in accordance with aspects of the present disclosure.

[0086] FIG. 5Q is a diagram illustrating an exemplary cell grabber performing indirect hooking of product cells in accordance with aspects of the present disclosure.

[0087] FIG. 5R is a diagram illustrating an exemplary product cell loading / unloading in accordance with aspects of the present disclosure.

[0088] FIG. 5S is a diagram illustrating an exemplary product cell loading / unloading in accordance with aspects of the present disclosure.

[0089] FIG. 5T is a diagram illustrating an exemplary synchronous product cell loading / unloading in accordance with aspects of the present disclosure.

[0090] FIG. 5U is a diagram illustrating an exemplary synchronous multi-width product cell loading / unloading in accordance with aspects of the present disclosure.

[0091] FIG. 6A is a diagram illustrating an exemplary retrieval robot platform in accordance with aspects of the present disclosure.

[0092] FIG. 6B is a diagram illustrating an exemplary retrieval robot platform in accordance with aspects of the present disclosure.

[0093] FIG. 6C is a diagram illustrating an exemplary retrieval robot platform in accordance with aspects of the present disclosure.

[0094] FIG. 6D is a diagram illustrating an exemplary retrieval robot platform in accordance with aspects of the present disclosure.

[0095] FIG. 6E is a diagram illustrating an exemplary retrieval robot platform in accordance with aspects of the present disclosure.

[0096] FIG. 7A is a diagram illustrating an exemplary inbound loading station in accordance with aspects of the present disclosure.

[0097] FIG. 7B is a diagram illustrating an exemplary delivery station in accordance with aspects of the present disclosure.

[0098] FIG. 7C is a diagram illustrating an exemplary delivery station in accordance with aspects of the present disclosure.

[0099] FIG. 7D is a diagram illustrating an exemplary delivery station in accordance with aspects of the present disclosure.

[0100] FIG. 7E is a diagram illustrating an exemplary delivery station in accordance with aspects of the present disclosure.

[0101] FIG. 8A is a flow chart illustrating an exemplary method that may be performed in accordance with some embodiments.

[0102] FIG. 8B is a flow chart illustrating an exemplary method that may be performed in accordance with some embodiments.

[0103] FIG. 9 is a diagram illustrating an exemplary computer / control system that may perform processing in some embodiments and in accordance with aspects of the present disclosure.DETAILED DESCRIPTION

[0104] In this specification, reference is made in detail to specific embodiments of the invention. Some of the embodiments or their aspects are illustrated in the drawings.

[0105] For clarity in explanation, the invention has been described with reference to specific embodiments, however it should be understood that the invention is not limited to the described embodiments. On the contrary, the invention covers alternatives, modifications, and equivalents as may be included within its scope as defined by any patent claims. The following embodiments of the invention are set forth without any loss of generality to, and without imposing limitations on, the claimed invention. In the following description,specific details are set forth in order to provide a thorough understanding of the present invention. The present invention may be practiced without some or all of these specific details. In addition, well known features may not have been described in detail to avoid unnecessarily obscuring the invention.

[0106] In addition, it should be understood that steps of the exemplary methods set forth in this exemplary patent can be performed in different orders than the order presented in this specification. Furthermore, some steps of the exemplary methods may be performed in parallel rather than being performed sequentially. Also, the steps of the exemplary methods may be performed in a network environment in which some steps are performed by different computers in the networked environment.

[0107] Some embodiments are implemented by a computer system. A computer system may include a processor, a memory, and a non-transitory computer-readable medium. The memory and non-transitory medium may store instructions for performing methods and steps described herein.

[0108] The following generally relates to a system and methods for automated warehouse fulfillment. The automated fulfillment system offers a comprehensive solution that enhances warehouse operations' efficiency, accuracy, and scalability by combining robotics, artificial intelligence, sensor networks, and data analytics. Therefore, the automated warehouse system is configured to eliminate inefficiencies by creating a seamlessly integrated ecosystem where various components work harmoniously to achieve high automation and operational excellence.

[0109] The automated warehouse fulfillment system may be used to significantly improve order fulfillment speed, accuracy, and cost-effectiveness by harnessing the potential of robotics, Al, sensors, and data analytics.

[0110] The automated warehouse fulfillment system may be configured for storing, picking, and packing independent product items. The system may include containers for storing individual product items and compartments for storing linked containers. One or more retrieval robots may be used to load, unload, and move containers throughout the warehouse 3D space. The one or more retrieval robots may be Autonomous Mobile Robots (AMR).[OHl] In some embodiments, a network of rails for robots to move horizontally along the rack shelves may be used. The robots may be moved vertically between the floor and different levels by one or more robot lifts. One or more servers may be configured to perform realtime warehouse inventory management and tasks scheduling as well as handling internal inventory optimization requests. The retrieval robots may have one or more sets of sensors that allow the robot to localize and move in a warehouse space, adapt to changes in the environment, and perform tasks without human intervention.

[0112] The system may also include modular storage units and cell compartments that integrate with existing warehouse infrastructure. The cell compartments may be configured to hold a plurality of product cells for storing inventory / product. The product cells may be purpose- built product containers designed to store individual product items and connect with other product cells.

[0113] In some embodiments, a bottomless product cell construction may be used to help automate the order packing process. For example, an outbound station can utilize the bottomless cell structure so that outbound products are dropped out of the product cell directly to a destination bin or package.

[0114] In some embodiments, loading of product cells may be improved by using bottomless product cells. A bottomless product cell may be placed over and around a product as opposed to having the product being placed in the cell. This may reduce the powerconsumption needed for inbound loading as heavier products do not need to be lifted to be loaded.

[0115] FIG. l is a diagram illustrating an exemplary automated warehouse fulfillment system 100 in which some embodiments may operate. The automated warehouse fulfillment system 100 may comprise one or more retrieval robots 105, one or more robot lifts 110, one or more storage racks 115, one or more modular storage units 120, one or more loading stations 125, one or more delivery stations 130, one ormore client devices 135, one or more servers 140, one or more data stores 145 and one or more networks 150.

[0116] The one or more retrieval robots 105 may be autonomous mobile robots (AMR) configured to load, unload, and move containers throughout a warehouse 3D space. The retrieval robots 105 may further be configured to navigate on ground, over a network of rails or combination of both. In some embodiments, the one or more retrieval robots 105 may comprise specialized wheels configured to engage one or more rails that run horizontally along shelves of storage racks 115. In some embodiments, the specialized wheels may be dual purpose wheels, wherein the wheels allow for navigation on the ground as well as on the network of rails. In some embodiments, the one or more retrieval robots 105 may be configured with both ground wheels and rail wheels.

[0117] In some embodiments, the one or more retrieval robots 105 may be configured to communicate directly with one another or over network 150. The one or more retrieval robots 105 may further be configured to communicated with the one or more robot lifts 110, the one or more loading stations 125, the one or more delivery stations 130, the one or more client devices 135, the one or more servers 140 and the one or more data stores 145 over network 150.

[0118] In some embodiments, the one or more retrieval robots 105 may comprise a set of sensors that allow the robots to localize and move in the warehouse space, adapt to changes in the environment, and perform tasks without human intervention.

[0119] The one or more robot lifts 110 may be configured to move the one or more retrieval robots 105 vertically between the floor and different shelf levels of the one or more storage racks 115. In some embodiments, the one or more robot lifts 110 may be static lifting stations, dynamic lifting stations or a combination of the two.

[0120] In some embodiments, static robot lifts may serve a fixed warehouse aisle, moving vertically to transport the retrieval robot 105 from the floor to a specific shelf level of the storage rack or vice versa.

[0121] In some embodiments, dynamic robot lifts may be configured to move horizontally along the warehouse rows in addition to vertical movement. The dynamic nature allows a single unit to serve multiple aisles and increases flexibility in robot movement and task execution.

[0122] In some embodiments, each of the one or more storage racks 115 may comprise a plurality of shelves wherein each shelf may comprise one or more rails and hold one or more modular storage units 120. In some embodiments, each of the one or more modular storage units 120 may further comprise one or more cell compartments each loaded with one or more product cells. The product cells may be configured to hold one or more products.

[0123] In some embodiments, the one or more rails may be specialized rails integrated with the storage rack shelves to enable the movement of the retrieval robots 105. These rails may be configured to provide a pathway for the retrieval robots 105 to move horizontally along the shelves to access the one or more modular storage units 120 and the corresponding product cells held in them. In some embodiments, the one or more retrievalrobots 105 may further comprise one or more grabber units configured to load and / or unload product cells from the one or more modular storage units 120.

[0124] The one or more loading stations 125 may be configured as dedicated zones within the warehouse for manipulating inbound products. The loading stations 125 may be responsible for inputting products into the product cells and loading said product cells onto the one or more retrieval robot 105. The one or more retrieval robots 105 may then perform a product cell stocking procedure, wherein the one or more product cells are deposited in specified cell compartment of a specified modular storage unit 120. The loading stations 125 may be configured to ensure that incoming products are efficiently and accurately placed inside appropriate product cells for storage and future order fulfillment. The inbound process may be an automated or manual process. In some embodiments, the inbound process may also be semi-automated.

[0125] The one or more delivery stations 130 may be configured as outbound stations overseeing the collection and packing of ordered products. In some embodiments, the delivery stations 130 may be configured to ensure that products are efficiently retrieved from the product cells and prepared to dispatch. In some embodiments, the outbound process may forward collected product cells to the next stage of a last-mile fulfillment pipeline, eliminating the process of manually picking each item by a dedicated warehouse worker.

[0126] The client devices 135 may be any computing device capable of communicating over network 150. The client devices 135 may be integrated into a notebook computer, smartphone, personal digital assistant, desktop computer, tablet computer, or other computing device.

[0127] The servers 140 may be one or more physical or virtual machines configured to communicate with the one or more retrieval robots 105, one or more robot lifts 110, one ormore loading stations 125, one or more delivery stations 130, one or more client devices135, and one or more data stores 145 over network 150.

[0128] The one or more servers 140 may be configured as a distributed computing infrastructure. Servers 140 may be configured to communicate with the one or more retrieval robots 105 either directly or indirectly. The communication may include the receiving of sensor data and status information as well as transmission of control commands.

[0129] Datastores 145 may communicate with one another over network 150. Datastores 145 may be any storage device capable of storing data for processing or as a result of processing information at the one or more retrieval robots 105, the one or more robot lifts 110, the one or more loading stations 125, the one or more delivery stations 130, the one or more client devices 135 and / or the one or more servers 140. The datastores 145 may be a separate device or the same device as server 140. The datastores 145 may be located in the same location as that of servers 120, or at separate locations.

[0130] Network 150 may be an intranet, internet, mesh, LTE, GSM, peer-to-peer or other communication network that allows the one or more retrieval robots 105, the one or more robot lifts 110, the one or more loading stations 125, the one or more delivery stations 130, the one or more client devices 135, the one or more servers 140 and / or one or more data stores 145 to communicate with one another.

[0131] In some embodiments, the automated warehouse fulfillment system 100 may operate as standalone units. For example, a standalone system may be configured to automate existing retail supermarket facilities. A standalone system may be deployed by retrofitting shelves with modular storage units 120 so they can store product cells. Loading stations 125 and delivery stations 130 may be installed at the location. Standalone systems may not require lifts and rails to be installed.

[0132] FIG. 2A is a diagram illustrating an exemplary retrieval robot 105 in accordance with aspects of the present disclosure. Retrieval robot 105 may comprise network module 201, datastore module 202, robot control module 203, robot drive module 204, grabber module205, retrieval platform 210 and sensor array 213.

[0133] Network module 201 may transmit and receive data from other computing systems via a network such as network 150 as described above with regard to FIG. 1. In some embodiments, the network module 201 may enable transmitting and receiving data from the Internet, Intranet, peer-to-peer network, ad hoc network or other forms of communication. Data received by the network module 201 may be used by the other modules. The modules may transmit data through the network module 201.

[0134] The datastore module 202 may be configured to store information generated by the one or more modules operating on the retrieval robot 105. The one or more modules operating on retrieval robot 105 may also retrieve information from the datastore module 202. Datastore module 202 may also be configured to receive and store information received over network module 201.

[0135] The robot control module 203 may be configured to enable the retrieval robot 105 to operate autonomously and efficiently within the warehouse environment. It may serve as the brain of the robotic system, providing the necessary intelligence and decision-making capabilities to perform tasks without human intervention.

[0136] In some embodiments, the robot control module 203 may receive data from sensor array 213. Sensor array 213 may comprise one or more high-resolution cameras, LiDAR sensors, and / or proximity detectors. Information received from these sensors may be used by the robot control module 203 to give the retrieval robot 105 a real-time understanding of its surroundings. In some embodiments, the sensor data may be used to make intelligent decisions about path planning, obstacle avoidance, and manipulation tasks.

[0137] In some embodiments, the robot control module 203 may be configured to encompass various high-level modules and low-level embedded components to facilitate one or more key functions. The one or more key functions may include localization, motion planning, perception and object recognition, task execution and safety collision avoidance.

[0138] In some embodiments, the localization function, performed by the robot control module 203, may use sensor data (e.g., camera, lidar, and odometry data) from camera module 209 and / or the sensor array 213, to localize the retrieval robot 105 within the warehouse. The localization procedure may be configured to determine the robot’s position, orientation, and environmental surroundings.

[0139] In some embodiments, the robot control module 203 may be configured to localize and stop with a specified grabber module 205 in front of a requested cell compartment of a specified modular storage unit 120. In some embodiments, every cell compartment of the modular storage unit 120 may have a special place for a label containing a set of the same QR codes. Each QR code may store a unique ID corresponding to the selected cell compartment. The QR codes may be used to help eliminate a displacement error of the retrieval robot 105 when it moves along the rails using only odometry (wheels) localization data. In some embodiments, each QR code of the set of QR codes may be of a different size, orientation and / or relative positions to a reference point. In some embodiments, the set of QR codes may include 3 or more QR codes. The factor of three may be used to help make scanning by camera module 209 more robust to various external environment scenarios, such as light conditions. In some embodiments, the set of QR codes may be different than one another.

[0140] In some embodiments, the motion planning function, performed by the robot control module 203, may determine the optimal paths and trajectories for the retrieval robot 105to move within the warehouse. The motion plan may correspond to the most efficient routes to reach the desired locations for order fulfillment.

[0141] In some embodiments, the perception and object recognition function, performed by the robot control module 203, may be configured to incorporate image processing, artificial intelligence (Al) algorithms, machine learning (ML) algorithms and / or computer vision algorithms to recognize and identify product cells, modular storage units, QR codes and / or other objects in the warehouse. The perception and object recognition function may be used to facilitate accurate locating and interacting with the product cells by the retrieval robot 105.

[0142] In some embodiments, the task execution function may be configured to receive tasks assigned by the server 140 and execute various actions based on said assigned tasks. In some embodiments, the assigned tasks may include moving the retrieval robot 105 by the floor, along the rack shelf rails and / or loading and unloading product cells.

[0143] In some embodiments, the safety and collision avoidance function, performed by the robot control module 203, may include safety protocols and collision avoidance mechanisms to prevent accidents and ensure the safe operation of the retrieval robot 105 within the warehouse, even in dynamic and crowded environments.

[0144] In some embodiments, the robot control module 203 may be configured to determine an absolute distance between a current position of the retrieval robot 105 and a required target cell compartment.

[0145] The robot drive module 204 may be configured to convert the determined absolute distance into a number of wheel revolutions. The robot drive module 204 may then move the retrieval robot 105, by controlling one or more motors connected to one or more wheels of the retrieval robot, using the previously determined number of wheel revolutions.

[0146] In some embodiments, after stopping at a final position, the robot control module 203 may use the camera module 209 to scan the label (QR codes) of the target cell compartment and calculate a pixel offset between the target cell compartment and the grabber module 205. The robot control module 203 may then compare the received pixel offset with a precomputed value and determine which direction and distance to move and transform the pixel value to the number of wheel revolutions. The robot drive module 204 may then move the retrieval robot 105 based on the determined number of wheel revolutions.

[0147] The robot control module 203 may then iteratively check the position of the retrieval robot calculating the pixel offset after every move is completed until the pixel offset is within a predetermined threshold of the precomputed value.

[0148] In some embodiments, after arriving at the location in front of the desired cell compartment, the grabber module 205 may initiate a pulling or pushing procedure for pulling or pushing a specified number of product cells.

[0149] In some embodiments, the pulling procedure may comprise checking that there is enough space on the specified cell channel module 206 to accommodate the requested number of product cells. If not, the requested operation cannot be completed.

[0150] The retrieval robot may then be moved so as to position the cell channel module 206 in front of the desired stack / chain of product cells in the cell compartment. The front product cell of the stack may then be identified for pulling. In some embodiments, the grabber module 205 may be seated onto / into a grabber carriage unit 212 of a retrieval platform 210. The grabber carriage unit 212 may be moved in a vertical direction (z-axis) by a z-axis motion module 211. The retrieval platform 210 may change the grabber module 205 height to a preparatory position by vertically moving the grabber carriage unit 212.

[0151] From the preparatory position, a manipulator module 207 of the cell channel module206 may be moved by linear motion module 208. When the cell channel module 206 isempty, a linking mechanism of the manipulator module 207 may be moved into a connecting position, wherein the connecting position is either above or below a corresponding front linking mechanism of the target product cell. The front linking mechanism may also be referred to as a front side linking mechanism, front end linking mechanism, rack side linking mechanism or rack end linking mechanism and / or described as being a linking mechanism facing away from the rack and towards the manipulator module 207. The height of the grabber module 205 may then be changed to engage the connection between the two linking mechanisms. The direction of height change needed to engage the connection depends on the type of linking mechanism.

[0152] When the manipulator module 207 is already connected to a product cell, a back linking mechanism of the already connected product cell may be moved to the connecting position corresponding to the front linking mechanism of the target product cell. The back linking mechanism of the already connected product cell and the linking mechanism of the manipulator module 207 may be the same or similar shape and engage in the same or similar manner. The back linking mechanism may also be referred to as a back side linking mechanism, back end linking mechanism, grabber side linking mechanism or grabber end linking mechanism.

[0153] When the connection between the manipulator module 207 or already connected product cell and the target product cell has been engaged, the manipulator module 207 may begin to be pulled towards the retrieval robot 105. This results in all the product cells in the cell compartment moving as a single unit. The manipulator module 207 may continue to pull the target product cell until a desired number of product cells has been pulled onto the cell channel module 206. The height of the grabber module 205 may then be adjusted to disengage the connection between the last desired product cell and the remaining product cells in the cell compartment. The connection between the manipulator module 207 and allthe product cells loaded on the cell channel module remain engaged and the retrieval robot105 may then proceed with the next scheduled task.

[0154] The pushing operation is the reverse of the pulling operation. Instead of pulling the target product cell towards the robot and disengaging the connection, a connection is engaged between the already connected product cell and the target product cell. The already connected product cell may then be pushed from the robot into the cell compartment and disconnected from the manipulator module 207 or back linking mechanism of another product cell on the cell channel module 206.

[0155] FIG. 2B is a diagram illustrating an exemplary robot lift 110 in accordance with aspects of the present disclosure. The robot lift 110 may comprise network module 221, datastore module 222, a lift control module 223 and a lifting unit 224.

[0156] Network module 221 and datastore module 222 may be the same or similar to that of network module 201 and datastore module 202 as described above with regard to FIG. 2 A.

[0157] The lift control module 223 may be configured to receive instruction from retrieval robot 105, client device 135 and / or server 140. The instructions may correspond to positioning of the lifting unit 224. In some embodiments, robot lift 110 may include one or more sensors. The one or more sensors may be used to identify retrieval robots 105, locate retrieval robots 105, determine position of the retrieval robots 105, determine the position of lifting unit 224 and confirm successful loading and unloading of a retrieval robot 105 within the robot lift. In some embodiments, the lifting unit 224 may comprise a platform for docking or otherwise parking a retrieval robot and a kinematic system for moving the platform. The kinematic system may be configured to produce vertical and horizontal movement of the platform, both with and without a retrieval robot parked. In some embodiments, the platform may be moved along vertical and horizontal rails or guidance mechanisms. Movement of the platform may be driven by belts, lead screws, ball screwsor other linear motion mechanisms. In some embodiments, the driving mechanism of the lift platform may include motors mounted directly to the platform, motors mounted to a frame of the robot lift 110 or combination thereof.

[0158] FIG. 2C is a diagram illustrating an exemplary loading station 125 in accordance with aspects of the present disclosure. The loading station 125 may comprise network module 231, datastore module 232, a loading control module 233 and a loading unit 234.

[0159] Network module 231 and datastore module 232 may be the same or similar to that of network module 201 and datastore module 202 as described above with regard to FIG. 2 A.

[0160] The loading control module 233 may be used to ensure that incoming products are efficiently and accurately placed inside the appropriate product cells for storage and future order fulfillment. The inbound process may be automated, semi-automated or manual. Operation of loading station 125 is discussed below with regard to FIG. 7A.

[0161] FIG. 2D is a diagram illustrating an exemplary delivery station 130 in accordance with aspects of the present disclosure. The delivery station 130 may comprise network module 241, datastore module 242, a delivery control module 243 and a delivery unit 244.

[0162] Network module 241 and datastore module 242 may be the same or similar to that of network module 201 and datastore module 202 as described above with regard to FIG. 2 A.

[0163] In some embodiments, delivery stations 130 may be dedicated zones for collecting and packing ordered products. These stations play a critical role in the fulfillment process, ensuring that products are efficiently retrieved from the product cells and prepared to be dispatched.

[0164] In some embodiments, the delivery control module 243 may be configured to control one or more delivery units 255, forwarding collected product cells to the next stage of a last-mile fulfillment pipeline, eliminating the process of manually picking each item by adedicated warehouse worker. Operation of loading station 125 is discussed below with regard to FIGS. 7B-7E.

[0165] FIG. 2E is a diagram illustrating an exemplary client device 135 in accordance with aspects of the present disclosure. The client device 135 may comprise network module 251, datastore module 252, user interface module 253 and display module 254.

[0166] Network module 251 and datastore module 252 may be the same or similar to that of network module 201 and datastore module 202 as described above with regard to FIG. 2 A.

[0167] User interface module 253 may generate a user interface (UI) based on information received from server 140. The user interface module 233 may further manage user interactions with the UI and the updating of the UI based at least in part on the user interactions. The UI may comprise one or more interfaces and / or elements of the one or more interfaces. The one or more interfaces may include panels, windows, tabs, containers and / or combination thereof. The one or more interfaces may be any structure or object that organizes and / or displays information graphically. In some embodiments, the user interface module 253 may be configured to manage a UI generated remotely on server 140. The managing may comprise receiving user interactions with the UI, processing the user interactions, updating the UI based on the user interactions and / or information received from server 140, transmitting the user interactions to the server 140 and transmitting information associated with the user interface module 253 processing the user interactions.

[0168] Display module 254 may be any device configured to display graphical representations of information (LCD display, OLED display, DLP display, etc.). Display module 254 may be further configured to display graphical representations of the UI generated or received by the user interface module 253. Display module 254 may further be configured to display interactions of the user with the UI.

[0169] FIG. 2F is a diagram illustrating an exemplary sever 140 in accordance with aspects of the present disclosure. Server 140 may comprise network module 261, datastore module 262, inventory management module 263, task scheduler module 264 and remote monitoring module 265.

[0170] Network module 261 and datastore module 262 may be the same or similar to that of network module 201 and datastore module 202 as described above with regard to FIG. 2 A.

[0171] In some embodiments, inventory management module 263 may be configured as a comprehensive solution designed to streamline and optimize inventory management processes within an automated or manual warehouse environment. The inventory management module 263 may be configured to track, control, and optimize their inventory levels.

[0172] In some embodiments, task scheduler module 264 may be configured with two components: external and internal. The external component may be configured to integrate with a Warehouse Management System (WMS). Specified orders may be transformed into actionable tasks and transferred to one or more retrieval robots. Execution of the task by the retrieval robots may also be tracked by the task scheduler module 264. In some embodiments, the assignment process may use AI / ML models to find the most optimal collection strategy based on a warehouse’s order history and / or layout of the warehouse.

[0173] In some embodiments, the internal component may utilize AI / ML models for real-time inventory management optimizations. Inventory optimization tasks may be intelligently generated by the AI / ML based on analysis of the current state of the warehouse and studying historical order data. The task scheduler model 264 may also be configured to generate a web dashboard with real-time statistics and the state of the whole facility’s operations.

[0174] The remote monitoring module 265 may be configured to provide real-time access to retrieval robot deployments. The remote monitoring module 265 may allow remote supervisors to connect to retrieval robot’s cameras and control specified retrieval robots when manual intervention is needed. This ensures that any unexpected situations can be addressed promptly, minimizing downtime and improving system reliability.

[0175] FIGS. 3A-AA are diagrams illustrating product cells 300 in accordance with some embodiments. In some embodiments, the product cells may be purpose-built product containers designed to store individual product items and connect with other product cells. The product cell may be the fundamental component of the automated fulfillment system, providing the building blocks for storing and moving individual product items. The design of the product cells may be standardized and configured to allow for individual product cells to be connected to one another, making the product cell truly modular and expandable. The standardization and connecting capabilities of the product cells enable efficient and automated operations to be performed, improving warehouse fulfillment efficiency, accuracy, and overall productivity.

[0176] In some embodiments, the product cells may include different linking mechanisms, be of different / variable dimensions and be configured with custom covers.

[0177] FIGS 3A-3B show a first embodiments of a single cell. The cell 300 may comprise one or more side registration features 301, a front end linking mechanism 302 and a grabber end linking mechanism 303. In some embodiments, product cells may include one or more front end linking mechanisms and / or one or more back end linking mechanisms. In some embodiments, the product cell 300 may be omnidirectional or bidirectional. An omnidirectional / bidirectional product cell may comprise one or more front end linking mechanisms 302 and one or more grabber end linking mechanisms 303, where both linking mechanisms are of the same shape. In some embodiments, the linking mechanisms of aproduct cell may comprise two different shaped connectors on each end of the product cell’s body and be configured to interconnect with either end of a second product cell of the same type.

[0178] FIGS. 3C-3D show a second embodiment of a single cell. The second embodiment may comprise one or more side registration features 301, one or more front end linking mechanism 304 and one or more grabber end linking mechanism 305. In some embodiments, a product cell may be configured to have hooks similar to that of the linking mechanisms of FIGS. 3C-3D, but with all of the hooks facing the same direction relative to the end they are disposed on. For example, a product cell oriented in the same manner as shown in FIG. 3D would have both top linking mechanisms facing right while both bottom linking mechanisms facing the left. In other words, the linking mechanism on opposite sides of a product cell may be rotated 180 degrees relative to one another.

[0179] FIGS. 3E-3H show a third embodiment of a single cell. The third embodiment may comprise one or more front end registration features 306A, one or more grabber end registration features 306B, a front end linking mechanism 307 and a grabber end linking mechanism 308.

[0180] FIGS. 3I-3L show the interconnecting of two single cells of the first embodiment type. FIGS. 3M-3N show the interconnecting of two single cells of the second embodiment type. FIGS. 3O-3R show the interconnecting of two single cells of the third embodiment type.

[0181] The linking mechanism of the product cells may be configured with a front and rear hook mechanisms that allow it to connect with neighboring / adjacent product cells physically, forming a cohesive unit (chain) that can move as a single entity. This linking mechanism may be used to enable the stacking of connected product cells on a shelf, streamlining the storage and retrieval process.

[0182] FIGS. 3S-3X show product cells of varying dimensions. Each product cell may be configured for a specific product, eliminating wasted space. In some embodiments, the dimensions of the product cells may be set in one dimension while being variable in other dimensions. For example, a product cell may be configured to be the width of a single grabber cell channel of a retrieval robot, while the length and height of the product cell can be customizable to each product. The length and height dimensions may be based on the overall dimensions of the product to be stored in the product cell. In some embodiments, the width may also be varied by set discreet values. For example, the product cell may be configured to span 1, 2, 3 or more grabber cell channels of the retrieval robot. In some embodiments, the product cells may be standardized with one or multiple product items. In some embodiments, the product cells may also be standardized with one or multiple types, categories or classifications of product items. In some embodiments, the product cells may also be standardized with one or multiple types, categories or classifications of containers / packagings holding the product items. These containers / packagings may be the retail packaging of the product items. The standardization of the product cells allows for the efficient storing, organizing and accessing of product items in a warehouse or retail space.

[0183] The dimensions of a product cell can vary based on the specific application domain and the size of the product items it needs to accommodate. This flexibility allows for customization to suit different product types optimally.

[0184] FIG. 3 Y shows a product cell with a custom cover. The product cell can have a special cover for the improved stability of specific product segments like beverages or health and beauty bottles.

[0185] FIGS. 3Z and 3 AA show a bottomless product cell. In some embodiments, the product cells may be bottomless, allowing for additional capabilities for the product cell over thepreviously described embodiments. The bottomless product cells may be moved, loaded and unloaded in the same manner, while also allowing products to be delivered by dropping into a receptacle or separate handling device.

[0186] In some embodiments, the product cell may have a retractable or moveable bottom panel. In some embodiments, the bottom panel may be controllable by the product cell itself. For example, the product cell may have control over the movement, locking, opening and / or closing of the bottom panel. In some embodiments, the bottom panel may be controllable, either directly or indirectly, through external interactions with other devices or objects.

[0187] In some embodiments, the bottom may be hinged to allow products to be dropped from the product cell. In some embodiments, hinged bottom panels may be opened or closed by the product cell itself. In some embodiments, hinged bottom panels may be opened or closed by the interaction of the bottom panel with another surface or object. For example, the bottom panel may be held in place when in contact with a rail / floor of a grabber channel cell or a cell compartment on shelf. When moved to a position without a floor / rail to maintain contact with the bottom panel, gravity and the mass of the product within the product cell may then force the bottom panel open, dropping the product out of the product cell.

[0188] In some embodiments, the bottom panel may be open by default, and only closed when held in that position by an external object / surface. In some embodiments, the bottom panel may be closed by default. In some embodiments, the hinged bottom panel may use a spring or other mechanism to hold it in a closed position while empty but automatically open (i.e., gravity assisted) when holding a product.

[0189] In some embodiments, the bottom panel may comprise one or more pieces and one or more hinges. In some embodiments, the one or more bottom panel pieces may be connectedto one another or separate. The pieces may be connected by hinges or flexible interfaces / materials. In some embodiments, there may be a combination of connected and separate pieces making up the bottom panel. In some embodiments, the bottom panel configurations may include multiple pieces that may be retracted in an accordion manner, by folding in different directions. In some embodiments, trap door configurations may be used, where no connection is present between pieces on each side of a separating line and each piece is hinged on opposing sides of the product cell from one another.

[0190] FIGS. 4A and 4B are diagrams illustrating an exemplary modular storage unit in accordance with aspects of the present disclosure. The modular storage unit 401 may comprise one or more cell compartments 402, one or more retrieval robot rail supports 403 and one or more product cells 404.

[0191] In some embodiments. The modular storage unit 401 may be configured to store one or more different product cell sets (chains). In some embodiments, the modular storage unit 401 may be installed on a shelf as a typical storage pallet. In some embodiments, the retrieval robot rail supports 403 may alternatively be attached to the shelf / rack where the modular storage unit 401 is installed.

[0192] The modular storage unit 401 plays a critical role in the overall functionality of the automated fulfillment system by providing a structured and organized space for storing products and optimizing the movement of product cells. The modular storage unit’s organized layout and linked product cell chains facilitate smooth operations, enhancing the efficiency of the fulfillment process. The modularity of the storage unit allows for enhanced storage efficiency and flexibility in deployment of operation, ultimately resulting in higher accuracy and overall improved productivity.

[0193] In some embodiments, one or more modular storage units 401 may be stacked or linked together. The modular structure of the storage unit 401 allows it to accommodate differentsets of connected product cells. The modular design of the storage unit 401 allows for flexibility in its dimensions to suit different warehouse configurations and storage needs. The modular storage unit 401 may be dimensioned and configured based on the needs of the warehouse and the products being stored.

[0194] In some embodiments, product cells may be linked within the cell compartments 402 of the storage unit, forming chains of containers that can move as a single entity. This linking mechanism allows for efficient storage and retrieval of product items, as entire stacks of interconnected product cells can be loaded, unloaded, and moved as needed.

[0195] FIGS. 4C and 4D are diagrams illustrating an exemplary storage and retrieval system in accordance with aspects of the present disclosure. As shown, the multiple modular storage units 401 are installed in shelves on a storage rack 405. Also shown is a retrieval robot 407 positioned on two retrieval rails 406 installed on the retrieval robot rail supports 403.

[0196] In some embodiments, the retrieval robot 407 may be configured to move along the retrieval rails 406 to facilitate loading and unloading of product cells from the storage units 401.

[0197] FIGS. 4E and 4G are diagrams illustrating an exemplary cell compartment 402 in accordance with aspects of the present disclosure. Each cell compartment 402 of a storage unit may comprise one or more localization labels 408. The one or more localization labels may contain unique identifiers. The retrieval robot 407 may be equipped with one or more cameras 409. The one or more cameras 409 may be configured to capture one or more images / video of the localization labels 408. Scanning of the localization labels 408, by the retrieval robot, may be used in the navigation and precise localization of the retrieval robot 407 within the rack space, ensuring accurate movements and task execution.

[0198] In some embodiments, the one or more localization labels 408 may be QR codes representing a unique position of a specific cell compartment 402. In some embodiments, each of the one or more localization labels 408 may be of different sizes to help increase robustness in different warehouse environment conditions.

[0199] FIG. 4H is a diagram illustrating an exemplary modular storage rack 405 with modular storage units 401 installed in accordance with aspects of the present disclosure. Storage units 401 may be stacked into sets on shelves of a rack 405, providing a dense storage structure.

[0200] FIG. 41 is a diagram illustrating an exemplary static retrieval robot lift in accordance with aspects of the present disclosure. In some embodiments, static retrieval robot lifts may be mechanical systems integrated into the automated fulfillment system to enable vertical movement of retrieval robots. A static retrieval robot lift may comprise a robot lifting unit 410, a one or more lift mounting units 411 and one or more vertical lift tracks 412. The lifts may transport the retrieval robots between the warehouse floor and different storage levels. In some embodiments, one or more static retrieval robot lift may be installed on each row of racks in a warehouse. In some embodiments, a single static retrieval robot lift may be installed for pairs of adjacent rows of racks.

[0201] FIG. 4J is a diagram illustrating an exemplary dynamic retrieval robot lift in accordance with aspects of the present disclosure. The dynamic retrieval robot lift may comprise a robot lifting unit 410, one or more vertical lift track 412 and one or more horizontal lift track 413.

[0202] The dynamic retrieval robot lift may be configured to move horizontally along warehouse rack rows in addition to vertical movement. The dynamic nature allows a single unit to serve multiple aisles and increases flexibility in robot movement and task execution.

[0203] The one or more retrieval robots may use the lifts to efficiently navigate between different warehouse levels, enabling them to access and interact with product cell stored on various shelves. By utilizing the lifts, the retrieval robots can optimize their travel and perform tasks such as loading and unloading product cells, contributing to the fulfillment process's overall efficiency and accuracy.

[0204] FIG. 4K is a diagram illustrating an exemplary retrieval robot lift transporting a retrieval robot in accordance with aspects of the present disclosure.

[0205] FIGS. 4L-4N are diagrams illustrating an exemplary storage rack 405 with retrieval robot rails 406 installed in accordance with aspects of the present disclosure. The retrieval robot rails 406 may be special rails integrated with the rack shelves to enable the movement of retrieval robot 407. These rails may provide a pathway for the retrieval robots to move horizontally along the shelves, allowing them to access different modular storage units 401 and corresponding product cells.

[0206] In some embodiments, the retrieval robots 407 may be configured to utilize the retrieval robot rails 406 to efficiently navigate through the warehouse space and carry out tasks such as picking up and delivering product cells. By following the designated path along the retrieval robot rails 406, the retrieval robots can access various locations within the warehouse and optimize the movement of products, enhancing the fulfillment process's overall efficiency.

[0207] FIG. 5 A is a diagram illustrating an exemplary empty retrieval robot 500 in accordance with aspects of the present disclosure. The retrieval robot 500 may comprise a chassis body 501 and a grabber assembly 515. The retrieval robot 500 may be configured as an autonomous robot able to move by floor, on the retrieval robot lifts, and along the retrieval robot rails within the warehouse and operate and transport multiple product cells.

[0208] FIG. 5B is a diagram illustrating an exemplary loaded retrieval robot 500 navigating in a in accordance with aspects of the present disclosure.

[0209] FIGS. 5C and 5D are diagrams illustrating an exemplary retrieval robot chassis in accordance with aspects of the present disclosure. The retrieval robot chassis may comprise a chassis frame 502, one or more motor housings 503, a robot control unit 504, one or more drive motors 505, one or more driving pulleys 506, one or more timing belts 507, one or more tensioner pulleys 508, one or more ground wheels 509, one or more rail wheels 510, and one or more driven pulleys 511.

[0210] The retrieval robot chassis forms the robust and reliable foundation of the retrieval robot. In some embodiments, the retrieval robot chassis may be designed to navigate various surfaces seamlessly, such as warehouse floors, lifts, or rail systems. This versatility enables the retrieval robot to efficiently transport goods from inbound stations to storage and from storage to outbound stations and facilitate the movement of product cells throughout the warehouse.

[0211] In some embodiments, the retrieval robot chassis may serve as the moving core of the retrieval robot. In some embodiments, the retrieval robot chassis may be configured as a hybrid mobility system, which combines ground wheels 509 with rail wheels 510. This hybrid approach allows the retrieval robot to move both on the warehouse floor and along specialized retrieval robot rails using the same set of drive motors 505. It enables the robot to navigate the warehouse in three dimensions efficiently, accessing different storage levels for optimal fulfillment operations.

[0212] FIG. 5E is a diagram illustrating an exemplary top-side view of a four set cell grabber assembly 515 in accordance with aspects of the present disclosure. Grabber assembly 515 may comprise one or more linear rails 516, one or more manipulators 517, one or more grabber pulleys 518, one or more grabber belts 519, one or more product cells 520 and oneor more grabber cameras 521. In some embodiments, the grabber assembly 515 may be organized into individual grabber units / cell channels, wherein the grabber units or cell channels each comprise their own linear rail 516, manipulator 517, and grabber cameras521.

[0213] In some embodiments, grabber assembly 515 may be responsible for manipulating product cells from the retrieval robot, including the loading of product cells onto the retrieval robot and unloading the product cells off from the retrieval robot.

[0214] In some embodiments, the grabber assembly 515 may be installed on top of the retrieval robot directly or onto a platform attached to the retrieval robot. In some embodiments, the grabber assembly 515 may be set-up as four equal -width grabber units / cell cannels, but it can vary in number and width. The number and width of each of the grabber units / cell channels may be based on the product cells being handled.

[0215] FIG. 5F is a diagram illustrating an exemplary frontal view of a four set cell grabber assembly 515 in accordance with aspects of the present disclosure. Grabber assembly may further comprise one or more grabber motors 522. The grabber motors 522 may be configured to drive movement of the manipulator 517 along a linear rail 516. In some embodiments, each grabber unit / cell channel may share a grabber motor 522, as shown in FIG 5F. In some embodiments, each grabber unit / cell channel may alternatively have their own grabber motor 522. In some embodiments, the driving of the manipulator 517 may alternatively be driven pneumatically, hydraulically, magnetically and / or electromagnetically. For example, pneumatic actuators, hydraulic actuators, linear magnetic motors and solenoids may be used to generate linear movement of the manipulator 517 along the linear rail 516. In some embodiments, a leadscrew or ball screw may be used to generate the linear movement. As shown in FIGS. 5E-5R, the linear motion of the manipulator 517 may be belt driven.

[0216] FIG. 5G is a diagram illustrating an exemplary top-side view of a two set cell grabber in accordance with aspects of the present disclosure. FIG. 5H is a diagram illustrating an exemplary bottom-side view of a two set cell grabber in accordance with aspects of the present disclosure. FIGS. 5E-5H show grabber assemblies and manipulators configured to connect to product cell through a hook based linking mechanism.

[0217] FIGS. 51-50 show diagrams illustrating grabber assemblies and manipulators configured with a male / female linking mechanism. The male / female linking mechanism forms a hook / loop configuration. In some embodiments, the grabber assembly and linking mechanism may be configured to perform direct hooking of product cells and indirect hooking of product cells. In some embodiments, the grabber assembly may be configured to operate in a grouped mode, synchronized mode or single pull mode.

[0218] FIG. 51 is a diagram illustrating an exemplary top-side view of a two set cell grabber assembly 515 with a single product cell attached to the manipulators 517 in accordance with aspects of the present disclosure.

[0219] FIG. 5J is a diagram illustrating an exemplary top-side view of a two set cell grabber assembly 515 with multiple single product cell in a chain attached to the manipulators 517 in accordance with aspects of the present disclosure.

[0220] FIG. 5K is a diagram illustrating an exemplary top-side view of a four set cell grabber assembly 515 with multiple single product cell in a chain attached to the manipulators 517 in accordance with aspects of the present disclosure.

[0221] FIG. 5L is a diagram illustrating an exemplary top view of a two set cell grabber assembly 515 with a double product cell attached to the manipulators 517 in accordance with aspects of the present disclosure.

[0222] FIG. 5M is a diagram illustrating an exemplary top-side view of a two set cell grabber assembly 515 with a double product cell attached to the manipulators 517 in accordance with aspects of the present disclosure.

[0223] FIG. 5N is a diagram illustrating an exemplary top-side view of a four set cell grabber assembly 515 with multiple double product cell in a chain attached to the manipulators 517 in accordance with aspects of the present disclosure.

[0224] FIG. 50 is a diagram illustrating an exemplary top-side view of a two set cell grabber assembly 515 with multiple single product cells of different lengths in a chain attached to the manipulators 517 in accordance with aspects of the present disclosure.

[0225] FIG. 5P is a diagram illustrating an exemplary cell grabber directly hooking a product cell. The hooking / locking mechanism may be configured to securely and precisely load and unload product cells. In some embodiments, the basic hooking process may be to raise the whole grabber assembly 515, push the manipulator 517, and descend / lower the grabber assembly 515. In some embodiments, for robustness purposes, it can be modified in the following way: push the manipulator 517 a bit further to get a physical touch between the manipulator 517 and the and the product cell 520, then pull back a bit to have a smoother linkage of hooking / linking mechanism of the manipulator 517 with a hooking / linking mechanism of the product cell 520.

[0226] In some embodiments the raising of the whole grabber assembly 515 may be performed by changing the height of the retrieval robot itself. In some embodiments, the retrieval robot may comprise an integrated adjustable height platform configured to raise and lower the grabber assembly 515. In some embodiments, an adjustable height platform may be mounted to the retrieval robot and the grabber assembly 515 may be mounted to a z-axis carriage of the platform. The platform may then change the height of the grabber assembly by driving the z-axis carriage.

[0227] In some embodiments, the hooking process may alternatively comprise lowering the whole grabber assembly 515, pushing the manipulator 517, and raising the grabber assembly 515.

[0228] In some embodiments, the hooking process may alternatively comprise moving the grabber assembly 515 a set horizontal distance away from a centerline of the product cell, pushing the manipulator 517, and moving the grabber assembly 515 to be in line with the centerline of the product cell.

[0229] In some embodiments, the hooking process between the manipulator 517 and the product cell 520 may depend on a gender and / or direction of orientation of the linking mechanisms involved. For example, if the manipulator comprises a male linking mechanism, the first movement of the grabber assembly 515 would be opposite to the direction the linking mechanism is facing, followed by moving the manipulator 517 to a position that is level / even with the female linking mechanism of the product cell, and finally followed by the movement of the grabber assembly in the direction that the male linking mechanism is facing. For example, if the manipulator has a male end facing down, the hooking process would be up / over / down (lift / align / lower). The hooking process would therefore be right / align / left for a left facing male linking mechanism, left / align / right for a right facing male linking mechanism and down / under / up (lower / align / lift) for an upward facing male linking mechanism.

[0230] For a manipulator 517 comprising a female linking mechanism, the first movement of the hooking process would be to move the grabber assembly 515 in the direction the male linking mechanism is facing, followed by moving the manipulator 517 to a position that is level / even with the male linking mechanism of the product cell, and finally followed by the movement of the grabber assembly in the opposite direction of the direction the male linking mechanism is facing. For example, if the manipulator has a female end and theproduct box has a male end facing up, the hooking process would be up / over / down (lift / align / lower). The hooking process would therefore be right / align / left for a right facing male linking mechanism, left / align / right for a left facing male linking mechanism and down / under / up (lower / align / lift) for a downward facing male linking mechanism.

[0231] The unhooking process would just be the same steps in reverse, but where the second step would be to retract the manipulator.

[0232] FIG. 5Q is a diagram illustrating an exemplary cell grabber indirectly hooking product cells. Indirect hooking implies operations with a manipulator 517 that is already connected to a product cell. The main difference with direct hooking is that the hooking occurs with the hooking / linking mechanism of frontmost product cell instead of a manipulator hooking / linking mechanism itself.

[0233] FIGS. 5R and 5S are diagram illustrating an exemplary grouped product cell loading / unloading in accordance with aspects of the present disclosure. Chains of grouped product cells may all be loaded and unloaded as a single entity.

[0234] FIGS. 5T and 5U are diagrams illustrating an exemplary synchronous product cell loading / unloading in accordance with aspects of the present disclosure.

[0235] In some embodiments, each manipulator 517 of the grabber assembly 515 may operate independently or synchronously with other manipulators 517 of the grabber assembly 515. In the latter scenario, multiple adjacent manipulators 517 may work simultaneously, streamlining the process and improving efficiency. FIG. 5 T shows all four manipulators of a grabber assembly 515 operating synchronously when unloading multiple sets of containers (product cells). In some embodiments, synchronous mode may be used for loading / unloading multiple sets of containers (product cells) with multiple manipulators simultaneously. In some embodiments, the synchronous mode may also be used to load and unload multi-width product cells, as shown in FIG. 5 U.

[0236] FIGS. 6A-6E are diagrams illustrating an exemplary retrieval robot platform 600 in accordance with aspects of the present disclosure. The retrieval robot platform 600 may comprise a platform frame 601, a platform brace 602, one or more z-axis motor 603, one or more lead screws 604, a grabber z-axis carriage 605 and an attached grabber assembly 606.

[0237] In some embodiments, the retrieval robot platform 600 may be mounted to a retrieval robot or integrated into the robot itself. The grabber z-axis carriage 605 and attached grabber assembly 606 may be configured to move vertically as a whole unit. In some embodiments, the platform may comprise an array of sensors, including one or more cameras. Information collected by the array of sensors and cameras may be used to perform computer functions for localization, safety, and correctness purposes. The integration of the grabber assembly 606 with the platform enables the loading and unloading of product cells at any at any height.

[0238] The retrieval robot platform 600 can move the grabber z-axis carriage 605 vertically while handling a heavy workload. This vertical movement capability enables the robot to access different storage levels of modular storage units. The ability to drive significant loads ensures that the retrieval robot can handle a wide range of product items, making it versatile and adaptable to different fulfillment needs.

[0239] In some embodiments, the array of sensors and cameras of retrieval robot platform 600 may be configured to provide real-time feedback on its position and orientation. These sensors may be used to help the retrieval robot to accurately position itself for loading and unloading operations, ensuring precision in handling product items. In some embodiments, the retrieval robot platform 600 may incorporate safety and verification features to prevent accidents during the fulfillment process, safeguarding both the retrieval robot and the warehouse environment.

[0240] FIG. 7A is a diagram illustrating an exemplary inbound loading station in accordance with aspects of the present disclosure. The inbound loading stations may be used to ensure that incoming products are efficiently and accurately placed inside the appropriate product cells for storage and future order fulfillment. The inbound process may be automated, semiautomated or manual.

[0241] In some embodiments, the inbound loading station may include a one or more sets of sensors. In an automated inbound process, new products may be unloaded onto a conveyor belt. The sensors of the inbound loading station may be used to determine the product type and dimension using computer vision and Al. A loading control module may be configured to generate tasks for one or more retrieval robots to bring suitable empty product cells to the inbound loading Station. A loading unit may then place products into the received empty product cells. In some embodiments, the loading unit may be a robotic arm or other articulated unit with end effectors capable of picking and placing items.

[0242] For manual inbound processing, an on-site operator may select, through a user interface on a client device, a product they wish to load and an item count. Based on the selection and item count, the loading control module may generate tasks that will bring empty containers to the inbound station. The tasks may be sent to the retrieval robots or other systems capable of delivering the requested number or product cells.

[0243] In some embodiments, the retrieval robots may bring the required empty products to a stack at the inbound loading station and mark it as available for loading items to product cells. The on-site operator may select loading mode on a tablet, scans the QR code of the stack, load the required units, and pushes the “stack loaded” button. Cells in this stack may then be marked as ready to dispatch.

[0244] FIGS. 7B-7E are diagrams illustrating an exemplary delivery station in accordance with aspects of the present disclosure.

[0245] In some embodiments, delivery stations may be dedicated zones for collecting and packing ordered products. These stations play a critical role in the fulfillment process, ensuring that products are efficiently retrieved from the product cells and prepared to be dispatched.

[0246] In some embodiments, the general process comprises forwarding collected product cells to the next stage of a last-mile fulfillment pipeline, eliminating the process of manually picking each item by a dedicated warehouse worker.

[0247] In some embodiments, the outbound process may comprise retrieval robots bringing product cells with ordered items and unloading them to an outbound delivery station table. A delivery control module may be configured to mark each stack as available for processing.

[0248] In some embodiments, a robotic arm may be used to move product cells from the outbound table to the back of a street-facing storage. In this example, the delivery person or end customer may access the products after standard identity verification, for example, by inputting or scanning an order’s unique code.

[0249] In some embodiments, a manual fulfillment process may be used, where an on-site operator at the outbound table unloads items from product cells to pack the order. Empty product cells in unloaded stacks may be marked as ready to return to the automated storage by robots.

[0250] FIG. 8A is a flow chart illustrating an exemplary process flow 800A that may be performed in accordance with some embodiments.

[0251] At step 801, the automated warehouse fulfilment system may be configured to receive, by a server, a first product order for a first product, wherein the first product is stored in a first product cell.

[0252] At step 802, the system may be configured to transform, by a task scheduler module, the first product order into a first actionable task wherein the first actionable task comprises a location of the first product cell corresponding to the first product order, the first product cell location corresponding to a first cell compartment positioned in a first rack at a first rack location.

[0253] At step 803, the system may be configured to assign the first actionable task to a first retrieval robot.

[0254] At step 804, the system may be configured to send, over the network, the first actionable task to the first retrieval robot.

[0255] At step 805, the system may be configured to track the first retrieval robot’s execution of the first actionable task.

[0256] FIG. 8B is a flow chart illustrating an exemplary process flow 800B that may be performed in accordance with some embodiments.

[0257] At step 806, the first retrieval robot of the automated warehouse fulfilment system may be configured to generate an execution plan based on the first actionable task.

[0258] At step 807, the robot may be configured to identify a target location based on the first actionable task.

[0259] At step 808, the robot may be configured to determine a current position and orientation of the first retrieval robot.

[0260] At step 809, the robot may be configured to plan a first path from the current position to the target location.

[0261] At step 810, the robot may be configured to calculate a first distance of the first path.

[0262] At step 811, the robot may be configured to determine a motion plan based on the first path and the first distance.

[0263] At step 812, the robot may be configured to move the first retrieval robot to the target location by controlling the robot drive unit based on the determined motion plan.

[0264] At step 813, the robot may be configured to scan, by the one or more sensor modules, a localization label of the first cell compartment.

[0265] At step 814, the robot may be configured to calculate, based on the scanning, a position offset between the first retrieval robot’s gabber assembly and the first cell compartment.

[0266] At step 815, the robot may be configured to reposition the first retrieval robot based on the position offset.

[0267] At step 816, the robot may be configured to align a first grabber cell channel of the grabber assembly with the first cell compartment.

[0268] At step 817, the system may be configured to move, in-line with the first grabber cell channel, a first manipulator to a first preparatory position.

[0269] At step 818, the system may be configured to interlock, by changing height of the first manipulator, the first manipulator’s grabber side linking mechanism with the first product cell’s rack side linking mechanism.

[0270] At step 819, the system may be configured to pull, by a first linear motion unit, the interlocked first product cell into the first grabber cell channel.

[0271] At step 820, the system may be configured to disengage the first product cell from an interconnected second product cell in the first cell compartment, wherein the disengaging comprises changing height of interconnected first product cell and first manipulator.

[0272] At step 821, the system may be configured to deliver, to a first delivery station, the first product cell.

[0273] FIG. 9 illustrates an example machine of a computer system within which a set of instructions, for causing the machine to perform any one or more of the methodologies discussed herein, may be executed. In alternative implementations, the machine may beconnected (e.g., networked) to other machines in a LAN, an intranet, an extranet, an ad- hoc network, a mesh network, and / or the Internet. The machine may operate in the capacity of a server or a client machine in client-server network environment, as a peer machine in a peer-to-peer (or distributed) network environment, or as a server or a client machine in a cloud computing infrastructure or environment.

[0274] The machine may be a personal computer (PC), a tablet PC, a set-top box (STB), a Personal Digital Assistant (PDA), a cellular telephone, a web appliance, a server, a network router, a switch or bridge, or any machine capable of executing a set of instructions (sequential or otherwise) that specify actions to be taken by that machine. Further, while a single machine is illustrated, the term “machine” shall also be taken to include any collection of machines that individually or jointly execute a set (or multiple sets) of instructions to perform any one or more of the methodologies discussed herein.

[0275] The example computer system 900 includes a processing device 902, a main memory 904 (e.g., read-only memory (ROM), flash memory, dynamic random access memory (DRAM) such as synchronous DRAM (SDRAM) or Rambus DRAM (RDRAM), etc.), a static memory 906 (e.g., flash memory, static random access memory (SRAM), etc.), and a data storage device 918, which communicate with each other via a bus 960.

[0276] Processing device 902 represents one or more general -purpose processing devices such as a microprocessor, a central processing unit, or the like. More particularly, the processing device may be complex instruction set computing (CISC) microprocessor, reduced instruction set computing (RISC) microprocessor, very long instruction word (VLIW) microprocessor, or processor implementing other instruction sets, or processors implementing a combination of instruction sets. Processing device 902 may also be one or more special-purpose processing devices such as an application specific integrated circuit (ASIC), a field programmable gate array (FPGA), a digital signal processor (DSP), networkprocessor, or the like. The processing device 902 is configured to execute instructions 926 for performing the operations and steps discussed herein.

[0277] The computer system 900 may further include a network interface device 908 to communicate over the network 920. The computer system 900 may also include grabber module 930, retrieval platform 935, robot control module 938, robot drive module 939, sensor array module 940, lift control module 941, loading control module 942, delivery control module 943, user interface module 944, display module 945, inventory management module 946, task scheduler module 947 and remote monitoring module 948.

[0278] The grabber module 930 may further comprise cell channel module 931, manipulator module 932, linear motion module 933 and camera module 934.

[0279] The retrieval platform 935 may further comprise z-axis motion module 936 and grabber carriage unit 937.

[0280] Grabber module 930, cell channel module 931, manipulator module 932, linear motion module 933, camera module 934, retrieval platform 935, z-axis motion module 936, grabber carriage unit 937, robot control module 938, robot drive module 939 and sensor array module 940 may be the same or similar to that of grabber module 205, cell channel module 206, manipulator module 207, linear motion module 208, camera module 209, retrieval platform 210, z-axis motion module 211, grabber carriage unit 212, robot control module 203, robot drive module 204 and sensor array module 213 as disclosed in FIG. 2A.

[0281] Lift control module 941 may be the same or similar to that of lift control module 223 as disclosed in FIG. 2B.

[0282] Loading control module 942 may be the same or similar to that of loading control module 233 as disclosed in FIG. 2C.

[0283] Delivery control module 943 may be the same or similar to that of delivery control module 243 as disclosed in FIG. 2D.

[0284] User interface module 944 and display module 945 may be the same or similar to that of user interface module 253 and display module 254 as disclosed in FIG. 2E.

[0285] Inventory management module 946, task scheduler module 947 and remote monitoring module 948 may be the same or similar to that of inventory management module 263, task scheduler module 264 and remote monitoring module 265 as disclosed in FIG. 2F.

[0286] The data storage device 918 may include a machine-readable storage medium 924 (also known as a computer-readable medium) on which is stored one or more sets of instructions or software 926 embodying any one or more of the methodologies or functions described herein. The instructions 926 may also reside, completely or at least partially, within the main memory 904 and / or within the processing device 902 during execution thereof by the computer system 900, the main memory 904 and the processing device 902 also constituting machine-readable storage media. Information, including data used in the processes and methods of the system and the one or more sets of instructions or software, may also be stored in blockchain, as NFTs or other decentralized technologies.

[0287] In one implementation, the instructions 926 include instructions to implement functionality corresponding to the components of a device to perform the disclosure herein. While the machine-readable storage medium 924 is shown in an example implementation to be a single medium, the term “machine-readable storage medium” should be taken to include a single medium or multiple media (e.g., a centralized or distributed database, and / or associated caches and servers) that store the one or more sets of instructions. The term “machine-readable storage medium” shall also be taken to include any medium that is capable of storing or encoding a set of instructions for execution by the machine and that cause the machine to perform any one or more of the methodologies of the present disclosure. The term “machine-readable storage medium” shall accordingly be taken to include, but not be limited to, solid-state memories, optical media and magnetic media.

[0288] It will be appreciated that the present disclosure may include any one and up to all of the following examples.

[0289] Example 1. An automated warehouse fulfillment system, the fulfillment system comprising: a network; one or more servers; one or more storage racks; one or more storage units installed in each of the one or more storage racks and wherein each of the one or more storage units comprises one or more cell compartments; one or more product cells loaded into the one or more cell compartment of each of the one or more storage units; one or more robot lift units; and one or more retrieval robots; and wherein the one or more retrieval robots are configured perform one or more processes corresponding to the one or more product cells, the one or more processes comprising a loading process, an unloading process and a moving process.

[0290] Example 2. The system of Example 1, wherein each of the one or more storage racks comprises one or more rail supports and one or more retrieval rails.

[0291] Example 3. The system of any one of Examples 1-2, wherein each of the one or more robot lift units comprises one or more vertical lift tracks and a lift platform.

[0292] Example 4. The system of any one of Examples 1-3, wherein each of the one or more cell compartments comprises one or more localization labels.

[0293] Example 5. The system of any one of Examples 1-4, wherein each of the one or more product cells comprises a product holding area, a rack side linking mechanism and a grabber side linking mechanism.

[0294] Example 6. The system of any one of Examples 1-5, wherein a first cell compartment is loaded with a plurality of product cells and wherein each of the plurality of product cells is interlocked with adjacent product cells forming a chain of product cells.

[0295] Example 7. The system of any one of Examples 1-6, wherein the interlocking comprises engaging, at an interface between an initiating product cell and a receiving product cell, thegrabber side linking mechanism of the initiating product cell with the rack side linking mechanism of the receiving product cell.

[0296] Example 8. The system of any one of Examples 1-7, wherein the engaging comprises: moving the initiating product cell to a preparatory position, wherein the preparatory position is vertically offset to the receiving product cell and wherein the preparatory position further aligns the grabber side linking mechanism of the initiating product cell with the rack side linking mechanism of the receiving product cell; moving, after reaching the preparatory position, the initiating product cell vertically to a position in which the grabber side linking mechanism of the initiating product cell contacts and forms a physical connection with the rack side linking mechanism of the receiving product cell.

[0297] Example 9. The system of any one of Examples 1-8, wherein each of the one or more retrieval robots comprises: a robot control unit; a robot drive unit; one or more ground wheels; one or more rail wheels; one or more sensor modules; a grabber assembly, wherein the grabber assembly comprises: one or more linear rails; one or more manipulators, wherein the one or more manipulators comprise a grabber side linking mechanism; one or more linear motion units; one or more grabber cell channels; and one or more grabber cameras; and a grabber platform, wherein the grabber platform comprises: a rigid frame; one or more z-axis motion units; and a grabber z-axis carriage.

[0298] Example 10. The system of any one of Examples 1-9, wherein the one or more servers comprise: a task scheduler module, wherein the task scheduler module is configured to: receive a first product order for a first product, wherein the first product is stored in a first product cell; transform the first product order into a first actionable task wherein the first actionable task comprises a location of the first product cell corresponding to the first product order, the first product cell location corresponding to a first cell compartment positioned in a first rack at a first rack location; assign the first actionable task to a firstretrieval robot; send, over the network, the first actionable task to the first retrieval robot; and track the first retrieval robot’s execution of the first actionable task; and wherein the first retrieval robot is configured to: receive, from the task scheduler module, the first actionable task; generate, by the first retrieval robot, an execution plan based on the first actionable task; identifying a target location based on the first actionable task; determining a current position and orientation of the first retrieval robot; planning a first path from the current position to the target location; calculating a first distance of the first path; determining a motion plan based on the first path and the first distance; moving the first retrieval robot to the target location by controlling the robot drive unit based on the determined motion plan; scanning, by the one or more sensor modules, a localization label of the first cell compartment; calculating, based on the scanning, a position offset between the first retrieval robot’s gabber assembly and the first cell compartment; repositioning the first retrieval robot based on the position offset; aligning a first grabber cell channel of the grabber assembly with the first cell compartment; moving, in-line with the first grabber cell channel, a first manipulator to a first preparatory position; interlocking, by changing height of the first manipulator, the first manipulator’s grabber side linking mechanism with the first product cell’s rack side linking mechanism; pulling, by a first linear motion unit, the interlocked first product cell into the first grabber cell channel; disengaging the first product cell from an interconnected second product cell in the first cell compartment, wherein the disengaging comprises changing height of interconnected first product cell and first manipulator; and delivering, to a first delivery station, the first product cell.

[0299] Example 11. A method for autonomously fulfilling product orders, the method comprising: receiving, by a server, a first product order for a first product, wherein the first product is stored in a first product cell; transforming, by a task scheduler module executing on the server, the first product order into a first actionable task wherein the first actionabletask comprises a location of the first product cell corresponding to the first product order, the first product cell location corresponding to a first cell compartment positioned in a first rack at a first rack location; assigning, by the task scheduler module, the first actionable task to a first retrieval robot; sending, from the task scheduler module, the first actionable task to the first retrieval robot; receiving, by the first retrieval robot, the first actionable task; generating, by the first retrieval robot, an execution plan based on the first actionable task; identifying, by the first retrieval robot, a target location based on the first actionable task; determining a current position and orientation of the first retrieval robot; planning a first path from the current position to the target location; calculating a first distance of the first path; determining a motion plan based on the first path and the first distance; moving the first retrieval robot to the target location by controlling a robot drive unit of the retrieval robot based on the determined motion plan; scanning, by one or more sensor modules of the retrieval robot, a localization label of the first cell compartment; calculating, based on the scanning, a position offset between a grabber assembly of the first retrieval and the first cell compartment; repositioning the first retrieval robot based on the position offset; aligning a first grabber cell channel of the grabber assembly with the first cell compartment; moving, in-line with the first grabber cell channel, a first manipulator to a first preparatory position; interlocking, by changing height of the first manipulator, a grabber side linking mechanism of the first manipulator with a rack side linking mechanism of the first product cell; pulling, by a first linear motion unit, the interlocked first product cell into the first grabber cell channel; disengaging the first product cell from an interconnected second product cell in the first cell compartment, wherein the disengaging comprises changing height of interconnected first product cell and first manipulator; and delivering, to a first delivery station, the first product cell.

[0300] Some portions of the preceding detailed descriptions have been presented in terms of algorithms and symbolic representations of operations on data bits within a computer memory. These algorithmic descriptions and representations are the ways used by those skilled in the data processing arts to most effectively convey the substance of their work to others skilled in the art. An algorithm is here, and generally, conceived to be a self- consistent sequence of operations leading to a desired result. The operations are those requiring physical manipulations of physical quantities. Usually, though not necessarily, these quantities take the form of electrical or magnetic signals capable of being stored, combined, compared, and otherwise manipulated. It has proven convenient at times, principally for reasons of common usage, to refer to these signals as bits, values, elements, symbols, characters, terms, numbers, or the like.

[0301] It should be borne in mind, however, that all of these and similar terms are to be associated with the appropriate physical quantities and are merely convenient labels applied to these quantities. Unless specifically stated otherwise as apparent from the above discussion, it is appreciated that throughout the description, discussions utilizing terms such as "identifying" or “determining” or "executing" or “performing” or “collecting” or “creating” or “sending” or the like, refer to the action and processes of a computer system, or similar electronic computing device, that manipulates and transforms data represented as physical (electronic) quantities within the computer system's registers and memories into other data similarly represented as physical quantities within the computer system memories or registers or other such information storage devices.

[0302] The present disclosure also relates to an apparatus for performing the operations herein. This apparatus may be specially constructed for the intended purposes, or it may comprise a general purpose computer selectively activated or reconfigured by a computer program stored in the computer. Such a computer program may be stored in a computer readablestorage medium, such as, but not limited to, any type of disk including floppy disks, optical disks, CD-ROMs, and magnetic-optical disks, read-only memories (ROMs), random access memories (RAMs), EPROMs, EEPROMs, magnetic or optical cards, or any type of media suitable for storing electronic instructions, each coupled to a computer system bus.

[0303] Various general purpose systems may be used with programs in accordance with the teachings herein, or it may prove convenient to construct a more specialized apparatus to perform the method. The structure for a variety of these systems will appear as set forth in the description above. In addition, the present disclosure is not described with reference to any particular programming language. It will be appreciated that a variety of programming languages may be used to implement the teachings of the disclosure as described herein.

[0304] The present disclosure may be provided as a computer program product, or software, that may include a machine-readable medium having stored thereon instructions, which may be used to program a computer system (or other electronic devices) to perform a process according to the present disclosure. A machine-readable medium includes any mechanism for storing information in a form readable by a machine (e.g., a computer). For example, a machine-readable (e.g., computer-readable) medium includes a machine (e.g., a computer) readable storage medium such as a read only memory (“ROM”), random access memory (“RAM”), magnetic disk storage media, optical storage media, flash memory devices, etc.

[0305] In the foregoing disclosure, implementations of the disclosure have been described with reference to specific example implementations thereof. It will be evident that various modifications may be made thereto without departing from the broader spirit and scope of implementations of the disclosure as set forth in the following claims. The disclosure and drawings are, accordingly, to be regarded in an illustrative sense rather than a restrictive sense.

Claims

CLAIMSWHAT IS CLAIMED IS:

1. An automated warehouse fulfillment system, the fulfillment system comprising: a network; one or more servers; one or more storage racks; one or more storage units installed in each of the one or more storage racks and wherein each of the one or more storage units comprises one or more cell compartments; one or more product cells loaded into the one or more cell compartment of each of the one or more storage units; one or more robot lift units; and one or more retrieval robots; and wherein the one or more retrieval robots are configured perform one or more processes corresponding to the one or more product cells, the one or more processes comprising a loading process, an unloading process and a moving process.

2. The system of claim 1, wherein each of the one or more storage racks comprises one or more rail supports and one or more retrieval rails.

3. The system of claim 2, wherein each of the one or more robot lift units comprises one or more vertical lift tracks and a lift platform.

4. The system of claim 3, wherein each of the one or more cell compartments comprises one or more localization labels.

5. The system of claim 4, wherein each of the one or more product cells comprises a product holding area, a rack side linking mechanism and a grabber side linking mechanism.

6. The system of claim 5, wherein a first cell compartment is loaded with a plurality of product cells and wherein each of the plurality of product cells is interlocked with adjacent product cells forming a chain of product cells.

7. The system of claim 6, wherein the interlocking comprises engaging, at an interface between an initiating product cell and a receiving product cell, the grabber side linking mechanism of the initiating product cell with the rack side linking mechanism of the receiving product cell.

8. The system of claim 7, wherein the engaging comprises: moving the initiating product cell to a preparatory position, wherein the preparatory position is vertically offset to the receiving product cell and wherein the preparatory position further aligns the grabber side linking mechanism of the initiating product cell with the rack side linking mechanism of the receiving product cell; moving, after reaching the preparatory position, the initiating product cell vertically to a position in which the grabber side linking mechanism of the initiating product cell contacts and forms a physical connection with the rack side linking mechanism of the receiving product cell.

9. The system of claim 8, wherein each of the one or more retrieval robots comprises: a robot control unit; a robot drive unit; one or more ground wheels;one or more rail wheels; one or more sensor modules; a grabber assembly, wherein the grabber assembly comprises: one or more linear rails; one or more manipulators, wherein the one or more manipulators comprise a grabber side linking mechanism; one or more linear motion units; one or more grabber cell channels; and one or more grabber cameras; and a grabber platform, wherein the grabber platform comprises: a rigid frame; one or more z-axis motion units; and a grabber z-axis carriage.

10. The system of claim 9, wherein the one or more servers comprise: a task scheduler module, wherein the task scheduler module is configured to: receive a first product order for a first product, wherein the first product is stored in a first product cell; transform the first product order into a first actionable task wherein the first actionable task comprises a location of the first product cell corresponding to the first product order, the first product cell location corresponding to a first cell compartment positioned in a first rack at a first rack location;assign the first actionable task to a first retrieval robot; send, over the network, the first actionable task to the first retrieval robot; and track the first retrieval robot’s execution of the first actionable task; and wherein the first retrieval robot is configured to: receive, from the task scheduler module, the first actionable task; generate, by the first retrieval robot, an execution plan based on the first actionable task; identifying a target location based on the first actionable task; determining a current position and orientation of the first retrieval robot; planning a first path from the current position to the target location; calculating a first distance of the first path; determining a motion plan based on the first path and the first distance; moving the first retrieval robot to the target location by controlling the robot drive unit based on the determined motion plan; scanning, by the one or more sensor modules, a localization label of the first cell compartment; calculating, based on the scanning, a position offset between the first retrieval robot’s gabber assembly and the first cell compartment; repositioning the first retrieval robot based on the position offset; aligning a first grabber cell channel of the grabber assembly with the first cell compartment; moving, in-line with the first grabber cell channel, a first manipulator to a first preparatory position;interlocking, by changing height of the first manipulator, the first manipulator’s grabber side linking mechanism with the first product cell’s rack side linking mechanism; pulling, by a first linear motion unit, the interlocked first product cell into the first grabber cell channel; disengaging the first product cell from an interconnected second product cell in the first cell compartment, wherein the disengaging comprises changing height of interconnected first product cell and first manipulator; and delivering, to a first delivery station, the first product cell.

11. A method for autonomously fulfilling product orders, the method comprising: receiving, by a server, a first product order for a first product, wherein the first product is stored in a first product cell; transforming, by a task scheduler module executing on the server, the first product order into a first actionable task wherein the first actionable task comprises a location of the first product cell corresponding to the first product order, the first product cell location corresponding to a first cell compartment positioned in a first rack at a first rack location; assigning, by the task scheduler module, the first actionable task to a first retrieval robot; sending, from the task scheduler module, the first actionable task to the first retrieval robot; receiving, by the first retrieval robot, the first actionable task; generating, by the first retrieval robot, an execution plan based on the first actionable task; identifying, by the first retrieval robot, a target location based on the first actionable task;determining a current position and orientation of the first retrieval robot; planning a first path from the current position to the target location; calculating a first distance of the first path; determining a motion plan based on the first path and the first distance; moving the first retrieval robot to the target location by controlling a robot drive unit of the retrieval robot based on the determined motion plan; scanning, by one or more sensor modules of the retrieval robot, a localization label of the first cell compartment; calculating, based on the scanning, a position offset between a grabber assembly of the first retrieval and the first cell compartment; repositioning the first retrieval robot based on the position offset; aligning a first grabber cell channel of the grabber assembly with the first cell compartment; moving, in-line with the first grabber cell channel, a first manipulator to a first preparatory position; interlocking, by changing height of the first manipulator, a grabber side linking mechanism of the first manipulator with a rack side linking mechanism of the first product cell; pulling, by a first linear motion unit, the interlocked first product cell into the first grabber cell channel; disengaging the first product cell from an interconnected second product cell in the first cell compartment, wherein the disengaging comprises changing height of interconnected first product cell and first manipulator; anddelivering, to a first delivery station, the first product cell.

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