Systems and methods of fulfilling orders with stacked container based storage

Abstract

Some embodiments provide a system of automated order fulfillment, comprising: a plurality of totes; a storage area having stacks of totes comprising one or more of the plurality of totes being vertically stacked; and a mobile robot configured to transport a set of one or more retrieved totes, of the stacks of totes, through the storage area, the mobile robot comprising: a robot control circuit; a transport system to self-propel the mobile robot through the storage area; and a frame comprising a storage portion and a tote handling portion, the storage portion storing a frame tote stack of retrieved totes vertically stacked on one another, and the tote handling portion comprising one or more tote handling systems that perform a tote retrieval sequence.

Description

SYSTEMS AND METHODS OF FULFILLING ORDERS WITH STACKEDCONTAINER BASED STORAGECROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application Number 63 / 610,331, filed December 14, 2023, which is incorporated herein by reference in its entirety.TECHNICAL FIELD

[0002] This invention relates generally to robotic control of inventory.BACKGROUND

[0003] Some automated order fulfillment systems used retain products retrieved to fulfill product orders. In some such systems, containers can be used to store items and the containers can be retained in a multi-level storage structure with vertical and horizontal arrays of storage spaces. Mobile robots may be used to move the containers. Improvements to fulfillment facilities would be beneficial.BRIEF DESCRIPTION OF DRAWINGS

[0004] Disclosed herein are embodiments of systems, apparatuses and methods pertaining to order fulfillment. This description includes drawings, wherein:

[0005] FIG. 1A illustrates a simplified perspective view of a portion of an exemplary automated fulfillment system at a fulfillment facility with multiple rows of stacks or sets of one or more totes, which are stacked without a storage structure, in accordance with some embodiments.

[0006] FIG. IB illustrates a simplified overhead view of an exemplary automated fulfillment system, in accordance with some embodiments.

[0007] FIG. 2 illustrates a side view of an exemplary portion of an automated storage system with multiple stacks of totes, and a mobile robot to retrieve and / or return totes, in accordance with some embodiments.

[0008] FIG. 3 illustrates a simplified block diagram of an exemplary mobile robot positioned within an exemplary aisle between two exemplary rows of stacks of exemplary totes, in accordance with some embodiments.

[0009] FIGS. 4A-4B illustrate simplified perspective views of exemplary totes, in accordance with some embodiments.

[0010] FIG. 4C illustrates a plane view of a set of exemplary totes stacked one atop the other, in accordance with some embodiments.

[0011] FIG. 5 illustrates a simplified perspective view of an exemplary mobile robot, in accordance with some embodiments.

[0012] FIG. 6A illustrates a simplified perspective view of an exemplary tote handling system comprising a single exemplary tote engaging system in a retracted position or state, in accordance with some embodiments.

[0013] FIG. 6B illustrates a simplified perspective view of an exemplary tote handling system comprising multiple exemplary tote engaging systems in retracted positions or states, in accordance with some embodiments.

[0014] FIG. 7 illustrates a simplified perspective view of a portion of an exemplary mobile robot comprising the exemplary tote handling system of FIG. 6B with the exemplary multiple tote engaging systems each in exemplary extended positions or states, in accordance with some embodiments.

[0015] FIG. 8A illustrates a simplified perspective view of a portion of an exemplary mobile robot with an exemplary upper tote handling system comprising an exemplary tote engaging system in a retracted position or state, in accordance with some embodiments.

[0016] FIG. 8B illustrates a simplified perspective view of a portion of an exemplary mobile robot with the exemplary upper tote handling system of FIG. 8A with the exemplary tote engaging system in exemplary extended position or state, in accordance with some embodiments.

[0017] FIG. 9A illustrates a simplified perspective view of a portion of an exemplary mobile robot with the exemplary upper tote handling system of FIG. 8A with an exemplary tote securely engaged and retracted into the tote handling portions by the tote engaging system, in accordance with some embodiments.

[0018] FIG. 9B illustrates a simplified perspective view of a portion of an exemplary mobile robot with the exemplary upper tote handling system with an exemplary tote securely engaged by the tote engaging system, in accordance with some embodiments.

[0019] FIGS. 10A-10G illustrate simplified perspective views of an exemplary mobile robot or a zoomed in portion of an exemplary mobile robot controlling one or more exemplary tote handling systems in implementing an exemplary tote retrieval sequence or process, in accordance with some embodiments.

[0020] FIGS. 11A-11F illustrate simplified perspective views of an exemplary mobile robot or a zoomed in portion of an exemplary mobile robot controlling one or more exemplary tote handling systems in implementing an exemplary tote collation sequence or process, in accordance with some embodiments.

[0021] FIGS. 12A-12F illustrate simplified perspective views of an exemplary mobile robot or a zoomed in portion of an exemplary mobile robot controlling one or more exemplary tote handling systems in implementing an exemplary return tote staging sequence or process, in accordance with some embodiments.

[0022] FIGS. 13A-13D illustrate simplified perspective views of an exemplary mobile robot or zoomed in portions of an exemplary mobile robot controlling one or more exemplary tote handling systems in implementing an exemplary tote return sequence or process, in accordance with some embodiments.

[0023] FIGS. 14A-14I illustrate simplified perspective views of an exemplary mobile robot or zoomed in portions of an exemplary mobile robot controlling one or more exemplary tote handling systems in implementing an exemplary tote return sequence or process as part of a tote retrieval sequence or process retrieving one or more totes from an external storage stack, in accordance with some embodiments.

[0024] FIGS. ISA-151 illustrate simplified perspective views of an exemplary mobile robot or zoomed in portions of an exemplary mobile robot controlling two exemplary tote handling systems in implementing a positioning of a first retrieved tote into the frame tote stack at an intended vertical position, and implementing a tote return staging sequence or process, in accordance with some embodiments.

[0025] FIG. 16 illustrates a simplified perspective view of an exemplary mobile robot simultaneously moving each of exemplary totes of an exemplary frame tote stack, in accordance with some embodiments.

[0026] FIG. 17 illustrates a simplified side view of a portion of an exemplary automated fulfillment system, in accordance with some embodiments.

[0027] FIG. 18 illustrates a simplified perspective view of an exemplary workstation with a mobile robot cooperated with the workstation in delivering a frame tote stack to the workstation and / or retrieving a stack of totes from the workstation, in accordance with some embodiments.

[0028] FIG. 19A illustrates a simplified overhead view of an exemplary workstation with a mobile robot cooperated with the workstation in delivering a frame tote stack to the workstation and / or retrieving a stack of totes from the workstation, in accordance with some embodiments.

[0029] FIG. 19B illustrates a simplified overhead view of an exemplary workstation comprising and / or cooperated with one or more storage buffers, and further illustrates a mobile robot cooperated with a tote storage buffer tower of the workstation, in accordance with some embodiments.

[0030] FIG. 20 illustrates a simplified flow diagram of an exemplary process of managing totes in automatically fulfilling orders, in accordance with some embodiments.

[0031] FIG. 21 illustrates a simplified flow diagram of an exemplary tote return process to return one or more totes to an external stack of totes, in accordance with some embodiments.

[0032] FIG. 22 illustrates a simplified flow diagram of an exemplary tote return process to return one or more totes to an external stack of totes, in accordance with some embodiments.

[0033] FIG. 23 illustrates a simplified flow diagram of an exemplary tote return process to return one or more totes to an external stack of totes, in accordance with some embodiments.

[0034] FIG. 24 illustrates a simplified flow diagram of an exemplary process of routing a stack of totes to a workstation, in accordance with some embodiments.

[0035] FIG. 25 illustrates a simplified flow diagram of an exemplary process of inserting a tote into the frame tote stack in accordance with some embodiments.

[0036] FIG. 26 illustrates a simplified flow diagram of an exemplary process of moving a frame tote stack out of robot in forming an external stack and / or incorporating with an already existing external stack, in accordance with some embodiments.

[0037] FIG. 27 illustrate a simplified flow diagram of an exemplary process of managing totes, the transport of totes and the stacking of totes within a fulfillment facility, in accordance with some embodiments.

[0038] FIG. 28 illustrates a simplified flow diagram of an exemplary process of acquiring a return tote, in accordance with some embodiments.

[0039] FIGS. 29A-29B illustrate a simplified flow diagram of an exemplary process of managing stacked totes, in accordance with some embodiments.

[0040] FIG. 30 illustrates an exemplary system for use in implementing methods, techniques, devices, apparatuses, systems, servers, sources and providing order fulfillment through organization of stacked container based storage, in accordance with some embodiments.

[0041] Elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions and / or relative positioning of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of various embodiments of the present invention. Also, common but well- understood elements that are useful or necessary in a commercially feasible embodiment are often not depicted in order to facilitate a less obstructed view of these various embodiments of the present invention. Certain actions and / or steps may be described or depicted in a particular order of occurrence while those skilled in the art will understand that such specificity with respect to sequence is not actually required. The terms and expressions used herein have the ordinary technical meaning as is accorded to such terms and expressions by persons skilled in the technical field as set forth above except where different specific meanings have otherwise been set forth herein.DETAILED DESCRIPTION

[0042] The following description is not to be taken in a limiting sense, but is made merely for the purpose of describing the general principles of exemplary embodiments. Reference throughout this specification to "one embodiment," "an embodiment," "some embodiments", "an implementation", "some implementations", "some applications”, or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases "in one embodiment," "in an embodiment," "in some embodiments", "in some implementations", and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment.

[0043] Some order fulfillment facilities and / or systems are used in supplying one or more items to requesting entities (e.g., customers, manufacturing divisions of one or more manufacturing facilities, repair personnel, retail stores, retail fulfillment centers, etc.). Often such fulfillment facilities and / or systems can be use in supply chains, for example in retail supply chains, and may fulfill orders for individual items, product units and / or goods. Some fulfillment systems may transfer totes and / or other containers, which can include inventory placed into the tote, using mobile robots through the facility, such as between a storage area and one or more picking workstations where orders are processed, typically sequentially picking from inventory or product totes and placed into respective order totes, bags, cartons, etc., that contain eaches picked making up a given order. The storage area, in many fulfillment facilities, includes one or morestorage structures that can be constructed of vertical and horizontal structural beams and other securing and supporting hardware to provide multiple levels of shelves that each provide numerous tote storage locations. Such support structures can be large, expensive, heavy and are typically fixed in a particular location. Additionally, support structures addition must support the weight of the totes and the payloads within the totes. Still further, the support structure must be constructed with sufficient stability to support and react to seismic loading, inadvertent contact by equipment moving through the facility and / or other such safety features. These support structures can be costly to build and often are implemented on a very large scale. In many instances, these support structures may not be feasible and / or practical in many facilities and / or implemented throughout an entire facility. It is beneficial in many facilities, such as smaller facilities and / or in portions of a fulfillment facility to provide alternate modes of storing and arranging totes that do not require such extensive storage structures.

[0044] FIG. 1A illustrates a simplified perspective view of a portion of an exemplary order automated fulfillment system 100 at a fulfillment facility with multiple rows 102 of stacks 104 or sets of one or more totes 106, which are stacked without a storage structure, shelves, framing or other structures into which the totes are placed, in accordance with some embodiments. Instead, the totes 106 can be stacked, in some embodiments, directly on top of each other without any external intervening structure. This can greatly reduce the time to get a facility up and running because of the lack of time needed to install a storage structure, can allow for relatively smaller spaces to quickly be utilized as storage areas, can greatly reduce the cost of implementing a fulfillment system in part due to the lack of purchase and assembly of the storage structure, can allow a facility that may include a storage structure to utilize one or more portions of the facility that are not occupied by the storage structure to additionally be used to store totes, and / or other such benefits.

[0045] One or more mobile robots 110 can move through the fulfillment facility to transport sets of one or more totes 106 to and from the stacks of totes. The stacks can be arranged in the rows 102 with gaps or aisles 112 established between the rows 102 that are sized, in some embodiments, to allow one or more of the mobile robots 110 to move along the length of the rows 102 to a position along the row to retrieve and / or return one or more totes 106 to a stack. In some embodiments, the mobile robots 110 can retrieve and / or return totes to either side of the aisle 112 allowing a greater concentration of rows 102.

[0046] FIG. IB illustrates a simplified overhead view of an exemplary automated fulfillment system 100, in accordance with some embodiments. The fulfillment system 100 includes one or more storage structures 150 including a number of bays or container storage locations 154. The storage structure is assembled from multiple horizontal and vertical beams, booms, joists, spans, posts and / or other such structural support components secured together providing the matrix of storage locations extending along the structure aisles 158. The storage structure 150 further includes horizontal and / or vertical tracks, decks, transit plans and / or other structure utilized by robots in moving through the storage structure. In some embodiments, the fulfillment system 100 can include one or more additional storage areas that include one or more rows 102 of stacks 104 of totes that are stacked directly on top of each other without any external intervening structure and / or without additional separate support structures. The storage locations 154 of the storage structure can each include a y-z array of storage locations 154 in horizontal rows and level changing towers along the rows which in embodiments may be vertical towers. Mobile robots 110 and / or low profile mobile robots 152 may travel between storage levels in the z-direction within the level changing towers to acquire and / or return totes 106 to different storage locations 154 within the storage structure 150. In some implementations, the storage locations extend along the structure aisles 158 with opposing pairs of storage locations 154 arranged to face each other separated by structure aisles 158. A structure aisle 158 may have a width such that a low profile mobile robot 152 traveling within an aisle 158 may transfer totes or other containers to the storage locations 154 on either side of the structure aisle 158. In some embodiments, the fulfillment system 100 includes one or more workstations 170. The mobile robots 110 and / or low profile mobile robots 152 can transport totes 106 from the storage areas, stacks of totes 104, storage structure 150 and / or other areas of the fulfillment facility. The storage structure 150, low profile robots 152, the cooperation and / or movement of robots through the storage structure, exemplary workstations and / or other aspects of the fulfillment system 100 can be similar to and / or include aspects of such systems and components as described in one or more of U.S. Patent Nos. 9,139,363, 10,435,241, and 11,142,398, and U.S. Patent Application Publication Nos. 2019 / 0270591, 2021 / 0229271, and 2023 / 0095494, each of which is incorporated herein by reference in its entirety.

[0047] FIG. 2 illustrates a side view of an exemplary portion of an automated storage system 100 with multiple stacks 104 of totes 106, and a mobile robot 110 that self-propels itself through the facility to retrieve and / or return totes 106, in accordance with some embodiments. FIG. 3illustrates a simplified block diagram of an exemplary mobile robot 110 positioned within an exemplary aisle 112 between two exemplary rows of stacks 104 of exemplary totes 106, in accordance with some embodiments. Referring to FIGS. 1A-3, a fulfillment system 100, in some embodiments, can have one or more storage areas where stacks 104 of totes 106 can be positioned. Each stack 104 can comprise one or more of the plurality of totes 106 being vertically stacked on one another, and typically without any additional structure to maintain the vertical stability of the stacks 104. In some embodiments, some or all of the stacks 104 are assembled without any structure positioned between the totes and / or without any additional structure along lateral sides of the stacks 104. In some embodiments, one or more of the totes 106 can include one or more alignment structures that aid in aligning the totes within the stacks 104 and / or increasing the stability of the stacks 104 of totes. In some embodiments, the stacks 104 of totes 106 of a row 102 can be positioned on risers 204, lifts, bases or other such structures to position a bottom most tote at a predefined height 206 above a floor 208 or other surface along which the mobile robots 110 traverse. In some embodiments, the risers 204 provide some protection for the stacks 104. For example, the risers can elevate the stacks and have a sufficient width to limit and / or avoid the robots 110, other mobile robots, human operated vehicle or system (e.g., forklift systems, man lift system, and / or other such systems operated by workers), and / or other such equipment from inadvertent contact, and providing protection to such systems and workers to reduce or prevent the risk of totes falling. As one non-limiting example, the risers 204 can additionally limit and / or prevent the mobile robots 110 from driving into the stacked totes. Additionally, the risers 204 can provide a level foundation upon which the stack of totes can be positioned and / or built.

[0048] FIGS. 4A-4B illustrate simplified perspective views of exemplary totes 106, in accordance with some embodiments. FIG. 4C illustrates a plane view of a set of exemplary totes 106 stacked one atop the other, in accordance with some embodiments. Referring to FIGS. 1A-4C, the totes 106 comprise a body 402 that can include one or more sides. In some embodiments, the totes 106 are generally rectangular cuboid shaped having lateral sides 404 cooperated at edges 408, seams and / or corners with ends 406 or faces. Other totes may have other shapes. The lateral sides 404, in some implementations, can have a length that is longer than a length of the ends 406, while in other embodiments the length of the ends may be the same as or longer than the length of the lateral sides. The totes 106 provides a cavity 410 defined by the lateral sides 404 and ends 406, which can be configured to receive the one or more items. In some embodiments, thetotes 106 can include one or more aligning and / or stabilizing stacking features 412, 414. For example, some totes can include one or more upper stacking features 412 positioned proximate and / or along upper edges of the totes, and / or one or more bottom stacking features 414 positioned proximate to and / or defining a lower edge of some or all of the tote. For example, an upper stacking feature can comprise one or more ridges 412 that can be tapered, arched and / or have other specific shape that readily mates with a corresponding reciprocal or mirrored shaped bottom stacking features 414 of another tote. The bottom stacking features can, in some embodiments, include a receiving recess 414 configured to mate with respective ridges 412 of another tote upon which the tote is stacked and / or cooperated. Each of the bottom stacking feature 414, in some embodiments, can be configured to align with and slidingly engage one or more upper stacking features 412 of another tote of the plurality of totes establishing vertical and lateral alignment of stacked totes. One or more of the stacking features may include additional structures that can help guide and / or mate the stacking features of two separate totes. In some embodiments, for example, one or more of the lower stacking features 414 may include an angling or tapering 416 from an end 406 of the tote toward a center of the tote and / or one or more upper stacking features may include similar aspects to aid in the engaging. The interior cavity of the totes, in some embodiments, can be configured to receive sub-container or sub totes and / or dividers. The stacking features (e.g., ridge, recess, etc.) do not inhibit the possibility of containers positioned on a flat surface (e.g., for use in operations such as but not limited to decanting), and / or stacked.

[0049] In some implementations, for example, the ridge 412 can comprise a triangular cross- sectional shape, elongated pyramid shape, elongated semi-circle and / or other such shapes. The receiving recess 414 can have a corresponding shape or other shape that can cooperate with one or more different types of ridges 412. The cooperation between the ridges 412 and the respective receiving recesses 414, in some embodiments, enables two totes 106 to readily be slide one atop the other in stacking the two totes. The elongated ridges 412 and elongated receiving recesses 414 operate different than posts, protrusions, apertures and other such structures, in part, by allowing the cooperation and separation of stacked totes without having to lift the upper tote. Instead, an upper one or more totes can merely be slid laterally to move the upper one or more totes from one or more lower stacked totes.

[0050] The totes 106, in some embodiments, can include one or more engaging structural components 420 on one or more external and / or internal sides and / or bottom of the totes thatcan be utilized in moving, transporting, positioning and / or otherwise engaging with the totes. FIG. 4A shows an exemplary tote including one or more engaging structural components 420 on the lateral sides 404, and an engaging structural component 420 on a front end or face 406. It will be appreciated that totes can include substantially any number of engaging structural components and / or no engaging structural components on one or more surfaces of the tote.

[0051] FIG. 5 illustrates a simplified perspective view of an exemplary mobile robot 110, in accordance with some embodiments. Referring to FIGS. 1A-5, the mobile robots 110 can, in some embodiments, be configured to transport a set of one or more retrieved totes 106a to and / or from the one or more stacks 104 of totes 106, and through one or more storage areas of the facility. Further, the mobile robots 110 can typically be operated to retrieve multiple totes 106 and simultaneously transport the multiple totes 106 through the facility. The mobile robot 110 typically includes one or more robot control circuits 502 comprising one or more processors, microprocessors, computer memory, computers and / or other such systems that provide control over the operation of the mobile robot. Further, the mobile robots include a transport system 504 coupled with the robot control circuit 502. The transport system is configured to self-propel the mobile robot through one or more storage areas of the facility based on location identifications, instructions and / or commands from the robot control circuit and / or one or more remote control systems (e.g., a central fulfillment control circuit, remote servers, etc.). The transport system 504 can include one or more drive systems 506 and / or motors that each drive and control one or more axles 508 and / or wheels 510 of the mobile robot to induce movement and / or control steering of the mobile robot 110. The transport systems 504 can be similar to and / or include aspects of transport systems and / or horizontal drive systems of mobile robots described in one or more of U.S. Patent Nos. 9,139,363, 10,435,241, and 11,142,398, and U.S. Patent Application Publication Nos. 2019 / 0270591, 2021 / 0229271, and 2023 / 0095494, each of which is incorporated herein by reference in its entirety.

[0052] In some embodiments, as described above and further below, a mobile robot 110 is configured to simultaneously transport multiple totes 106. The mobile robots 110, in some implementations, can include a frame 120, one or more tote storage portions 122 and one or more tote handling portions 124. The one or more tote handling portions 124 can comprise one or more tote handling systems 130-131 that can be communicatively coupled with the robot control circuit 502 and controlled by the robot control circuit. One or more of the tote handling systems 130-131 can, in some embodiments, further include climbing systems cooperated withthe frame 120 enabling one or more of the respective tote handling systems 130-131 to vertically move within the frame 120. For example, the climbing systems can comprise one or more motors coupled with and configured to drive one or more gears, pinions, belts, cables, pullies, wheels and / or other such components that engage one or more tracks, guides, teeth, cables, chains and / or other structures cooperated with the frame 120 enabling climbing within the frame 120. The climbing systems and / or tracks can be implemented similar to one or more vertical movement systems described in U.S. Application Publication Nos.: 2012 / 0197431; 2014 / 0277692; 2014 / 0288696; 2016 / 0075512; 2016 / 0355337; 2016 / 0207710; 2017 / 0010608; 2017 / 0137223; 2017 / 0137222; 2017 / 0313514; 2017 / 0369243; 2018 / 0134492; and 2018 / 0150793, each of which is incorporated in its entirety herein by references. In other embodiments, the climbing system includes one or more climbing wheels that exert forces against the frame 120 and enable the drive system to activate the climbing wheels to vertically move the respective tote handling system.

[0053] The one or more tote handling systems 130-131, in some embodiments, can include one or more tote engaging systems 302 that are configured to engage with totes 106 to be moved into and / or out of the frame 120 of the mobile robot 110. In part, for example, the one or more tote handling systems 130-131 can be controlled by the robot control circuit to perform one or more tote movement sequences and / or tote retrieval sequences to retrieve one or more totes 106 from a stack 104 of totes 106 are instructed to be removed from the stack and move one or more retrieved totes 106a into the frame 120. In some embodiments, the external storage stacks 104 of totes are positioned to be accessed perpendicular to a direction of travel of the mobile robots 110 and the mobile robots 110 move along an aisle 112.

[0054] The storage portion 122 can be configured to receive and temporarily store a set of one or more retrieved totes 106a that can be vertically stacked one on top of another within the storage portion 122 defining a frame tote stack 202 of the set of one or more retrieved totes 106a. In some embodiments, one or more of the tote handling systems 130-131 can maneuver one or more totes 106 into the storage portion 122 to be incorporated into the frame tote stack 202, and out of the frame tote stack 202. The tote handling systems 130-131 can, in some embodiments, take advantage of the one or more stacking features 412, 414 of the plurality of totes 106 to help align and slidingly engage stacking features of two totes establishing vertical and / or lateral alignment of the set of totes 106a within the frame tote stack 202. In other embodiments, one or more of the mobile robots 110 can include sets of multiple supports, shelves, racks secured with and / or formed as part of the frame of the stooge portion 122. One or more tote handling systems130-131 can be controlled by the robot control circuit to position retrieved totes into a different one of the shelves. The totes stored within the mobile robot may be placed on the support shelves, which may allow random access to the totes. It is noted, however, that the operation of one or more of the tote handling systems 130-131 may similarly provide random access to the totes stacked one atop the other without the support shelves through the pulling of a sub-stack into the tote handling portion 124, adjusting the vertical position of the sub-stack and returning one or more non-desired totes back into the frame tote stack 202. Some embodiments include support shelves consistent with and / or similar to those described in International Patent Application No. PCT / US2023 / 032416, which is incorporated herein by reference in its entirety. Similarly, the facility may include one or more storage racks with one or more shelves, slots, guides, tracks, etc., and the mobile robots 110 can be configured to move totes into these storage racks for storage, and retrieve totes from these storage racks.

[0055] The tote engaging systems 302 are configured to contact and engage one or more totes 106 to move the engaged tote 106 into, out of and / or within the frame 120 of the mobile robot 110. In some embodiments, one or more of the tote engaging systems 302 are configured to extend from the tote handling portions 124 into the tote storage portions 122 to insert and / or remove retrieved totes 106a into and / or from the frame tote stack 202. Additionally or alternatively, in some embodiments, the tote engaging systems 302 can extend from the tote handling portions 124 exterior to the frame 120 to move a tote 106 into the frame 120 and / or move a tote out of the frame (e.g., returning a tote to an external stack 104 of totes). For example, a lower tote handling system 130 can be configured to activate one or more tote engaging systems 302 to extend from the frame 120 to engage one or more totes 106 in an external stack 104 of totes, retrieve at least one tote 106 from the external stack 104 of totes, and retract and move the retrieved tote 106 into the frame 120. The lower tote handling system 130, in some embodiments, can further be configured to move the retrieved tote into the frame tote stack 202 during a tote retrieval sequence. In some embodiments, the mobile robot 110 can further include a second or upper tote handling system 131 can includes one or more tote engaging systems 302 that can at least hold one or more totes 106 in organizing totes, positioning totes within the frame tote stack 202 and / or hold one or more totes to be returned to one or more external stacks 104 of totes 106 during a tote retrieval sequence and / or a tote return sequence.

[0056] FIG. 6A illustrates a simplified perspective view of an exemplary tote handling system 130 comprising a single exemplary tote engaging system 302 in a retracted position or state, inaccordance with some embodiments. FIG. 6B illustrates a simplified perspective view of an exemplary tote handling system 130 comprising multiple exemplary tote engaging systems 302a- 302b in retracted positions or states, in accordance with some embodiments. FIG. 7 illustrates a simplified perspective view of a portion of an exemplary mobile robot 110 comprising the exemplary tote handling system 130 of FIG. 6B with the exemplary multiple tote engaging systems 302a-302b each in exemplary extended positions or states, in accordance with some embodiments. In some embodiments, the multiple tote engaging systems 302a-302b of a single tote handling system (e.g., tote handling system 130) can be operated independently, while in other instances, they are operated in concert.

[0057] Referring to FIGS. 1A-7, in some embodiments, the one or more tote engaging systems 302 of one or more of the tote handling systems 130-131 can include one or more tote engaging control circuits 702 that can provide at least some of the control over the one or more tote engaging systems 302. Further, the tote engaging systems 302, in some embodiments, can include one or more tote engaging motors 704, pullies, drive systems and / or other components that can be controlled to extend and retract the tote engaging system 302 and / or implement other actions to engage and / or disengage one or more totes 106. In some embodiments, one or more of the tote engaging systems 302 can comprise one or more tote engaging features 602, components and / or structures configured engage an intended tote, and in some implementations engage one or more recesses, posts, handles, ridges, shoulders, apertures, other such engaging structural components 420 of the totes 106 or a combination of two or more of such engaging structural components 420. Similarly, the engaging structural components can have substantially any relevant shape to provide an intended engagement and / or cooperation with the tote handling systems 130-131 and / or other systems of the fulfillment system. One or more of the engaging structural components can be positioned on one or more of a front end or face of the tote that is facing a mobile robot when in the storage stacks, a back end or face opposite to the front face, and / or lateral sides that are generally perpendicular to the front face. In some embodiments, for example, one or more tote engaging systems can be controlled to extend from the frame 120 to position one or more tote engaging features 602, engage an intended tote, and move the intended tote into or out of the frame by sliding the intended tote off of a tote upon which the intended tote is supported and stacked, or from an other support structure of the facility.

[0058] In some embodiments, one or more of the tote handling systems 130-131 can include one or more tote handling control circuits 706 that can provide at least some of the control over theone or more tote engaging systems 302, one or more tote handling motors, pullies, drive systems and / or other components that can be controlled vertically move one or more tote handling systems 130 within the tote handling portion 124. The tote engaging control circuits 702 and / or tote handling control circuits 706 can be communicatively coupled with the robot control circuit 502 and / or external control circuits and / or systems to receive control instructions to be implemented in retrieving, moving and / or depositing one or more totes into and / or out of the mobile robot 110. In other embodiments, the tote engaging system 302 and / or the tote handling system 130 does not include an engaging control circuit 702 and / or a tote handling control circuit 706, and the robot control circuit 502 controls the operation of the tote handling system and / or tote engaging systems.

[0059] Typically, the tote engaging systems 302 activate one or more tote engaging motors 704 to extend some or all of the engaging system (e.g., one or more tote engaging features 602) between the retracted position and one or more extended positions, and to engage one or more totes 106. For example, the tote engaging systems can comprise telescoping arms with multiple sections that extend and retract, with tote engaging features 602 that are configured to engage with one or more totes. The engaging features can comprise protrusions and / or extensions configured to mate with recesses of the tote, recesses configured to mate with protrusions of the tote, magnets, biasing, hooks, latches, other such engaging mechanisms, or a combination of two or more of such mechanisms that aid in the engagement between the tote engaging systems and the totes. In some embodiments, the tote engaging system may engage the totes with biasing of ends of the tote engaging systems to provide a clamping force, one or more motors to move the ends of the tote engaging systems to partially close and / or partially open to clamp on the totes and / or unclamp the tote, magnetic systems to couple with magnetic materials on the totes, engage one or more features of the totes, other such actions or a combination of two or more of such actions. Additionally or alternatively, the engaging systems may provide enough rigidity to maintain the engagement between one or more tote engaging features 602 and one or more engaging structural components 420 of a tote 106.

[0060] The tote handling systems 130-131 that include multiple tote engaging systems 302a- 302b, in some embodiments, are configured to vertically move up or down one or more totes between the upper tote engaging system 302a and the lower tote engaging system 302b. For example, a lower tote engaging system 302b may engage a set of one or more lower engaging structural components 420, and move the tote vertically to enable an upper tote engaging system302a to engage an upper set of one or more engaging structural components 420. Additionally or alternatively, the tote engaging systems 302a-302b may be vertically spaced and / or the vertical separation between the tote engaging systems 302a-302b adjusted to both engage a single tote, or operated to each engage a separate tote (e.g., two totes stacked upon each other). Similarly, the one or more tote engaging systems 302a-302b of a lower tote handling system 130 may vertically move a tote to enable one or more tote engaging systems of an upper tote handling system 131 to engage and retain the tote (e.g., a returning tote). Still further, in some embodiments, the vertical movement by the tote engaging systems 302a-302b may allow one or more totes in an external stack to be elevated. For example, a lower engaging system 302b may extend to engage a desired tote, while an upper engaging system 302a engages a tote supported by the desired tote. The upper engaging system 302a may vertically lift the upper supported tote enabling the lower tote engaging system 302b to pull the desired tote into the tote handling portion without pulling in totes from the stack above the desired tote. The tote engaging systems 302a-302b may include two, four, six, eight or other numbers of tote engaging features 602. Similarly, in some embodiments, each of the upper and lower tote engaging systems 302a-302b may include two, four or more arms or other systems to engage and move totes into and out of the mobile robot.

[0061] In some embodiments, one or more of the tote handling systems 130-131 may include a tote engaging base 604 positioned relative to one of the tote engaging systems 302. The tote engaging base 604 can be configured to support one or more tote 106 while maintained by the tote handling system 130-131 and / or moved within the frame. In some embodiments, the tote engaging system can slide one or more totes into the tote handling system and on to the tote engaging base 604 to support the weight of the tote or totes being slid into the mobile robot. The tote engaging base 604 may, in some embodiments, include one or more tote stacking features 412 (not shown) to engage corresponding stacking features 414 of a tote. Further, in some embodiments, portions of the tote engaging system 130-131 may move along some or an entire length of the tote engaging base 604 as a tote is moved out of and / or into the tote handling system. In other embodiments, the tote engaging base 604 moves as the tote engaging system extends and / or retracts to pull one or more totes into and / or push one or more totes out of the tote handling portion 124.

[0062] One or more of the tote handling systems 130-131 can in some embodiments further include one or more climbing systems 708 that cooperate with the frame 120 enabling the totehandling system 130-131 to vertically move within the tote handling portions 124 within the frame 120. For example, the climbing systems can comprise one or more climbing motors coupled with and configured to drive one or more gears, pinions, belts, cables, pullies, wheels and / or other such components that engage one or more tracks, guides, teeth, cables, chains and / or other structures cooperated with the frame 120 enabling climbing within the frame 120.

[0063] In some embodiments, the tote handling system 130 includes one or more orientation and / or rotation motors 710 cooperated with a rotation system 712 that can control a rotational orientation of the one or more tote engaging system 302. The orientation and / or rotation motors 710 can be controlled by the tote engaging control circuits 702, the tote handling control circuits 706 and / or the robot control circuit 502, and can engage one or more shafts, axles, gears, cables, pullies, belts, other such mechanical systems or a combination of two or more of such mechanical systems that can couple with and control the rotation of the rotation system 712. The rotation enables the tote engaging systems 302 to rotate and align with an external stack 104 of totes 106, and the frame tote stack 202 within the storage portion 122. In some embodiments, rotation system and / or other parts of the tote handling system may be implemented similar to systems described in International Patent Application No. PCT / US2023 / 032416, and U.S. Provisional Application No. 63 / 406,534, each of which is incorporated herein by reference in its entirety.

[0064] FIG. 8A illustrates a simplified perspective view of a portion of an exemplary mobile robot 110 with an exemplary upper tote handling system 131 comprising an exemplary tote engaging system 302c in a retracted position or state, in accordance with some embodiments. FIG. 8B illustrates a simplified perspective view of a portion of an exemplary mobile robot 110 with the exemplary upper tote handling system 131 of FIG. 8A with the exemplary tote engaging system 302c in exemplary extended position or state, in accordance with some embodiments. FIG. 9A illustrates a simplified perspective view of a portion of an exemplary mobile robot 110 with the exemplary upper tote handling system 131 of FIG. 8A with an exemplary tote 106 securely engaged and retracted into the tote handling portions 124 by the tote engaging system 302c, in accordance with some embodiments. FIG. 9B illustrates a simplified perspective view of a portion of an exemplary mobile robot 110 with the exemplary upper tote handling system 131 with an exemplary tote 106 securely engaged by the tote engaging system 302d, in accordance with some embodiments.

[0065] Referring to FIGS. 1A-9B, in some embodiments, the tote engaging systems 302c of an upper tote handling system 131 can include one or more tote engaging control circuits 702 thatcan provide at least some of the control over the one or more tote engaging systems 302c. Further, the tote engaging systems 302c, in some embodiments, can include one or more tote engaging motors 704, pullies, drive systems and / or other components that can be controlled to extend and retract the tote engaging system 302c and / or implement other actions to engage and / or disengage one or more totes 106. In some embodiments, the tote engaging system 302c comprise one or more tote engaging features 602 configured to engage an intended tote, and in some implementations engage one or more engaging structural components 420 (e.g., recesses, posts, shoulders, apertures and / or other such structural components) of the totes 106. In some embodiments, for example, the tote engaging system 302c can engage a tote to be returned to an external stack, be extended to an extended position moving the returning tote from the frame 120, and position the returning tote onto a tote of the external stack (e.g., by sliding one or more bottom stacking features 414 onto a respective one of one or more upper stacking features 412 of the tote on the external stack.

[0066] In some embodiments, the upper tote handling system 131 can include one or more tote handling control circuits 706 that can provide at least some of the control over the one or more tote engaging systems 302c, one or more tote handling motors, pullies, drive systems and / or other components that can be controlled vertically move one or more tote handling systems 130 within the tote handling portion 124. The tote engaging control circuit 702 and / or tote handling control circuits 706 can be communicatively coupled with the robot control circuit 502 and / or external control circuits and / or systems to receive control instructions to be implemented in retrieving, moving and / or depositing one or more totes into and / or out of the mobile robot 110. In other embodiments, the tote engaging system 302 and / or the tote handling system 130 does not include an engaging control circuit 702 and / or a tote handling control circuit 706, and the robot control circuit 502 controls the operation of the tote handling system and / or tote engaging systems.

[0067] In some embodiments, the tote engaging system 302c activates one or more tote engaging motors 704 to extend one or more potions of the engaging system (e.g., one or more tote engaging features 602 between the retracted position and / or or more extended positions, and to engage one or more totes 106 (e.g., through biasing of ends of the tote engaging systems to provide a clamping force, one or more motors to move the ends of the tote engaging systems to partially close and / or partially open to clamp on the totes and / or unclamp the a tote, magnetic systems to couple with magnetic materials on the totes, engage one or more features of the totes,other such actions or a combination of two or more of such actions). For example, one or more of the tote engaging systems can comprise telescoping arms with multiple sections that extend and retract, with tote engaging features 602 that are configured to engage with one or more totes. The engaging features can comprise protrusions and / or extensions configured to mate with recesses of the tote, recesses configured to mate with protrusions of the tote, magnets, biasing, hooks, latches, other such engaging mechanisms, or a combination of two or more of such mechanisms.

[0068] The upper tote handling system 131 can in some embodiments further include one or more climbing systems 708 that cooperate with the frame 120 enabling the upper tote handling systems 131 to vertically move within the tote handling portions 124 within the frame 120. For example, the climbing system can comprise one or more climbing motors coupled with and configured to drive one or more gears, pinions, belts, cables, pullies, wheels and / or other such components that engage one or more tracks, guides, teeth, cables, chains and / or other structures cooperated with the frame 120 enabling climbing within the frame 120.

[0069] In some embodiments, the upper tote handling system 131 includes one or more rotation motors 710 cooperated with a rotation system 712 that can control a rotational orientation of at least the one or more tote engaging system 302c. The rotation motor 710 can be controlled by the tote engaging control circuit 702, the tote handling control circuit 706 and / or the robot control circuit 502, and can engage one or more axles, shafts, gears, cables, pullies, belts, other such mechanical systems or a combination of two or more of such mechanical systems that can couple with and control the rotation of the rotation system 712. The rotation enables the tote engaging system 302 to rotate and align with an external stack 104 of totes 106, the frame tote stack 202 within the storage portion 122, and / or other such orientations.

[0070] FIG. 8C illustrates a simplified perspective view of a portion of an exemplary mobile robot 110 with an exemplary upper tote handling system 131n comprising an exemplary tote engaging system 302n, in accordance with some embodiments. The tote engaging system 302n can include one or more tote engaging features 602 that are configured to engage and cooperate with an exterior of a tote and / or one or more engaging structural components 420 of a tote. The upper tote handling system 131n, in some embodiments, does not extend or retract, and further does not include a tote engaging base 604 or other lower structure. This allows totes to be moved vertically up into the upper tote handling system 131 (e.g., from the lower tote handling system 130) and vertically down out of the upper tote handling system 131 (e.g., to the lower totehandling system 130). The tote handling system 131n may include a rotation system or alternatively may be fixed without the ability to rotate.

[0071] FIG. 8D illustrates a simplified perspective view of a portion of an exemplary mobile robot 110 with the exemplary upper tote handling system 131m comprising an exemplary tote engaging system 302m, in accordance with some embodiments. The tote engaging system 302m can include one or more tote engaging features 602 that are configured to engage and cooperate with an exterior of a tote and / or one or more engaging structural components 420 of a tote. In some embodiments, the upper tote handling system 131m does not include a tote engaging base 604 or other lower structure, which in part enables totes to be moved vertically up into the upper tote handling system 131m (e.g., from the lower tote handling system 130) and vertically down out of the upper tote handling system 131 (e.g., placing a tote onto an engaged sub-stack). The tote engaging system 302m, in some embodiments, can include one or more extendible arms 802. FIG. 8D shows the exemplary arms 802 in an extended position or state, in accordance with some embodiments. While the embodiments of FIGS. 8A-8D show the upper tote handling system with a single tote engaging system 302c, it is contemplated that in some embodiments, the upper tote handling system 131 may include multiple tote engaging systems. For example, the upper tote handling system may include a lower tote engaging system 302b and upper tote engaging system 302a, similar to that illustrated in FIG. 7. Similarly, in some embodiments, the lower tote handling system 130 may be implemented without a tote engaging base 604. For example, some embodiments utilize four or more tote engaging features 602 to engage a single tote providing stable support for the tote without the need for the tote engaging base 604.

[0072] Again, FIG. 9B illustrates a simplified perspective view of a portion of an exemplary mobile robot 110 with the exemplary upper tote handling system 131 with an exemplary tote 106 securely engaged by the tote engaging system 302d, in accordance with some embodiments. The upper tote handling system 131 in this embodiment does not include a rotation system 712 and does not include a tote engaging base 604. The tote engaging system 302d may be a static system that does not extend and retract, and instead includes one or more tote engaging features 602 (not shown in FIG. 9B) that engage a tote when the lower tote handling system 130 raises a tote to contact and be engaged by the upper tote handling system 131.

[0073] Still referring to FIGS. 1A-9B, the tote handling systems 130-131 that include multiple tote engaging systems 302a-302c, in some embodiments, can be configured to vertically move one or more totes up or down between the upper tote engaging system 302a and the lower toteengaging system 302b. Additionally or alternatively, the tote engaging systems 302a-302b may be vertically spaced and / or the vertical separation adjusted to both engage a single tote, or operated to each engage a separate tote (e.g., two totes stacked upon each other). Still further, in some embodiments, the vertical movement by the tote engaging systems 302a-302b may allow one or more totes in an external stack to be elevated. For example, a lower engaging system 302b may extend to engage a desired tote, while an upper engaging system 302a engages a tote supported by the desired tote. The upper engaging system 302a may vertically lift the upper supported tote enabling the lower tote engaging system 302b to pull the desired tote into the tote handling portion without pulling in totes from the stack above the desired tote. The tote engaging systems 302a-302b may include two, four, six, eight or other numbers of tote engaging features 602. Similarly, in some embodiments, each of the upper and lower tote engaging systems 302a-302b may include two, four or more arms or other systems to engage and move totes into and out of the mobile robot.

[0074] FIGS. 10A-10G illustrate simplified perspective views of an exemplary mobile robot 110 or a zoomed in portion of an exemplary mobile robot controlling one or more exemplary tote handling systems 130-131 in implementing an exemplary tote retrieval sequence or process, in accordance with some embodiments. Referring to FIGS. 10A-10G, a mobile robot 110 can move along an aisle 112 between rows 102 of stacks 104 of totes, and approaching an intended stack 104a to retrieve an intended tote 106a, in accordance with some embodiments. The mobile robot 110 can align with the external intended stack 104a (e.g., see FIG. 10B) from which one or more totes are to be retrieved and / or one or more totes are to be returned. The tote handling control circuit 706 can control the vertical movement of one or more tote handling systems (e.g., a lower tote handling system 130) to vertically align with the intended tote 106a to be retrieved (e.g., see FIG. 10C), and can extend one or more tote engaging systems 302 to engage the intended tote 106a. The tote engaging system 302, in some implementations, can include one or more tote engaging features 602 configured to be extended from the frame 120, engage one or more intended totes 106a, and move the one or more intended totes into the frame (e.g., by sliding the intended tote off of a lower tote 106b upon which the intended tote is supported and stacked in the intended stack 104a). In some embodiments, the tote engaging system 302 may engage more than one tote of the intended stack 104a, including the intended tote 106a.

[0075] The tote engaging system 302 and / or lower tote handling system 130 can retract sliding the intended tote 106a off of the lower tote 106b previously supporting the intended tote 106a,and into the tote handling portion 124 of the mobile robot 110 (e.g., see FIG. 10D). In some embodiments a base structure 714 and / or a restraining structure 716 of the tote handling system can inhibit movement of a lower tote 106b below the intended tote 106a as the intended tote 106a is slid from the storage stack 104 (e.g., based on contact of the lower tote 106b with a base structure 714, restraining structure 716, protrusion, secondary tote engaging system, etc.). In some embodiments, the restraining structure 716 is fixed, while in other embodiments the tote handling control circuit 706 can activate the restraining structure 716 to extend from the base structure 714 to contact the lower tote 106b and aid in maintaining a position of the lower tote 106b as the intended tote 106a is pulled from the external stack to inhibit movement of the lower tote toward the mobile robot, and subsequently can be retracted (e.g., see FIGS. 7 and 10C-10D). The restraining structure 716, in some embodiments may engage one or more engaging structural components 420 of the tote (e.g., a front handle), while in other embodiments the restraining structure 716 merely contacts a face of the tote. In some embodiments, the totes 106c-106d supported by the intended tote 106a are further pulled into the tote handling portion 124 along with the intended tote 106a based on the intended tote supporting the totes 106c-106d above the intended tote 106a (e.g., see FIG. 10C-10D) as an engaged sub-stack 1002. One or more tote engaging systems 302, in some embodiments, can be configured to move the intended tote 106a and one or more additional totes 106c-106d, which are in the intended stack 104a of totes and that are stacked upon and supported by the intended tote 106a at the time of retrieving the intended tote 106, into the frame as an engaged sub-stack 1002.

[0076] In some embodiments, the upper tote handling system 131 may support a return tote 106e that is scheduled to be returned to the intended stack 104a. In in some embodiments, the tote handling control circuit 706 can control the lower tote handling system 130 to self-propel vertically within the frame 120 until an upper tote (e.g., tote 106d) in a sub-stack 1002 supported by the lower tote handling system 130 contacts the return tote 106e being supported by the upper tote handling system 131. For example, one or more of the upper stacking features 412 of the top most tote 106d of the sub-stack 1002 can cooperate with and / or engage one or more bottom stacking features 414 of the return tote 106e (e.g., see FIG. 10E). In some embodiments, the upper tote handling system 131 can release the return tote 106e when cooperated with the top most tote 106d of the sub-stack 1002, and the return tote 106e becomes the upper most tote in the sub-stack 1002 supported by the lower tote handling system (e.g., see FIG. 10F).

[0077] In some embodiments, one or more totes 106c-106e of the sub-stack 1002 supported by the lower tote handling system 130 are to be returned to the intended stack 104a or another stack 104 in the same or a different row 102. The lower tote handling system 130 can in some instances align the lowest most oriented tote of the sub-stack 1002 to be returned to the intended stack 104a, which typically results in the retrieved intended tote 106a being below a currently highest most tote 106b of the intended stack 104a (e.g., see FIG. 10F). In some embodiments, the robot control circuit 502 and / or the tote handling control circuit 706 can be configured to control one or more tote engaging systems 302 to move the engaged sub-stack downward within the frame and align a tote, of the engaged sub-stack and positioned above and supported by the intended tote, relative to the top most tote 106b of the intended stack 104a of totes, and slide the totes above the intended tote 106a onto the top most tote of the intended stack 104a.

[0078] The lower tote handling system 130 can activate one or more tote engaging systems 302a (e.g., upper tote engaging system 302a of the lower tote handling system 130) to move those totes 106c-106e of the sub-stack 1002 that are not intended to be retrieved and / or are being returned onto the external stack 104a to move those totes 106c-106e of the sub-stack back to the external stack, while retaining the intended tote 106a (e.g., in the lower tote engaging system 302b of the lower tote handling system 130). In some embodiments, the upper tote engaging system 302a slides the lowest most tote 106c not intended to be retained of the sub-stack onto the current top most tote 106b of the external intended stack 104a, where one or more bottom stacking features 414 of the lowest most tote 106c of the sub-stack 1002 to be returned can each cooperate with and sliding along one or more of the upper stacking features 412 of the top most tote 106b of the intended external stack 104a (e.g., see FIG. 10G). In some embodiments, the returning tote 106e is retrieved and positioned with the upper tote handling system 131 while the mobile robot 110 travels to a next tote retrieval location, a workstation, etc. In some embodiments, the tote handling system raises the engaged sub-stack 1002 to position the returning tote 106e onto the engaged sub-stack to be returned prior to lowering the engaged substack and the sliding of the non-desired totes back to the external stack, thereby enabling a tote swap in one retrieval and return of the tote stack. This fast swap can greatly increase the efficiency and throughput of the mobile robot and tote retrieval and / or return processes.

[0079] FIGS. 11A-11F illustrate simplified perspective views of an exemplary mobile robot 110 or a zoomed in portion of an exemplary mobile robot controlling one or more exemplary tote handling systems 130-131 in implementing an exemplary tote collation sequence or process, inaccordance with some embodiments. Referring to FIGS. 11A-11F, often the retrieved totes are organized within a frame tote stack 202 to collate the retrieved totes based on a subsequent intended tote utilization and / or predetermined tote sequencing. Following the retrieval of a retrieved tote 106a (e.g., retrieved in accordance with the retrieval sequence of FIGS. 10A-10G), the robot control circuit 502 and / or the tote handling control circuit 706 can control a tote handling system (e.g., lower tote handling system 130) to rotate and orient the one or more retrieved totes 106a to be consistent with an orientation of one or more totes of the frame tote stack 202 positioned within the storage portion 122 of the mobile robot 110 (e.g., see FIGS. 11A- 11B).

[0080] The robot control circuit 502 and / or the tote handling control circuit 706 can control the first tote engaging system to vertically move within the frame, and vertically position one or more retrieved totes 106a at a predetermined position and slide the retrieved tote onto a top most tote of the frame tote stack when the intended position of the retrieved tote is higher than the current top most tote. In other instances, the predefined order or sequence of the retrieved tote may dictate a predetermined position within the frame tote stack between two previously acquired totes stored within the frame tote stack 202. Accordingly, some embodiments control the lower tote handling system 130 to vertically move within the frame and align the retrieved tote 106a with an intended supporting tote 106_2 that was previously retrieved and is intended to support the retrieved tote 106a within the frame tote stack 202. This results in the retrieved tote 106a being below an intended vertical position within the frame tote stack, such as adjacent to a tote 106_2 intended to support the retrieved tote 106a and / or below the intended vertical position equal to the height of the retrieved tote 106a or below an intended vertical position equal to a height of a total of the retrieved totes when multiple totes are retrieved from the external stack. In some embodiments, robot control circuit 502 and / or the tote handling control circuit 706 can be configured to control the tote handling system 130 and / or tote engaging system 302 to engage at least a second tote 106_3 of the retrieved totes currently at the selected position within the frame tote stack 202 where the retrieved tote 106a is intended to be positioned. One or more other totes supported by the second tote 106_3 may, in some implementations, additionally be engaged by one or more tote engaging system.

[0081] The robot control circuits 502 and / or the tote handling control circuit 706 can activate the tote engaging system 302 to transition from an extended position to a retracted position moving the second tote 106_3, and potentially one or more other totes supported by andpositioned above the second tote 106_3, from the frame tote stack 202 and onto the retrieved tote 106a in the tote handling portion 124 of the frame 120 to form a combined stack 1104. The combined stack can comprise the retrieved tote 106a, the second tote 106_3, and any additional retrieved totes (e.g., 106_4-106_6) stacked on top of the second tote 106_3 (e.g., see FIG. 11C). In some embodiments, the second tote 106_3 is slid onto and directly supported by the retrieved tote 106a (or onto a top most retrieved tote when multiple totes are retrieved from the external stack) without an external intervening support structure between the second tote 106_3 and the retrieved tote 106a (or top most retrieved tote). In some embodiments, the tote engaging system 302 can retract one or more arms and / or other structures engaging one or more engaging features of one or more totes. Further, the moving of the second tote 106_3 onto the retrieved tote 106a can include sliding the second tote 106_3 from the intended supporting tote 106_2, which is below and supporting the second tote_3 in the frame tote stack 202, and onto the retrieved tote 106a. The sliding can in some implementations include cooperating and / or engaging one or more bottom stacking features 414 of the second tote 106_3 with one or more upper stacking features 412 of the retrieved tote 106a (e.g., see FIG. 11C). Further, some embodiments interact with the lower supporting tote 106_2 supporting the second tote 106_3 as the second tote 106_3 is pulled onto the intended tote 106a. For example, the base structure 714 and / or a restraining structure 716 of the lower tote handling system 130 can engage the supporting tote 106_2 as the second tote 106_3 and totes supported by the second tote are pulled into the tote handling portion 124 to inhibit movement of the supporting tote 106_2 toward the lower tote handling system 130. Similarly, the frame 120 and / or the lower tote handling system may engage the supporting tote 106_2 as the intended combined stack 1104 is slid onto the supporting tote 106_2 to inhibit movement of the supporting tote 106_2 away from the lower tote handling system.

[0082] The tote handling system 130 can, in some embodiments, vertically move and orient the retrieved tote 106a and / or the combined stack (the one or more totes slid onto and now supported by the retrieved tote 106a) to a vertical height 1102 to at the selected vertical position and aligned with a top of the intended supporting tote 106_2 (e.g., see FIG. 11D). The tote handling control circuit 706 and / or lower tote handling system 130 can activate the tote engaging system 302 to transition from the retracted position to the extended position moving the retrieved tote 106a or combined stack (retrieved tote and totes supported by the retrieved tote (e.g., second tote 106_3 and other totes supported on the second tote)), to move the combinedstack (including the retrieved tote 106a and totes supported by the retrieved totes) from the tote handling portion 124 into the frame tote stack of the mobile robot 110 and onto the intended supporting tote 106_2 with the retrieved tote 106a positioned at the selected vertical position. In some embodiments, the tote engaging system 302 extends one or more arms and / or other structures to slide the retrieved tote 106a onto the intended supporting tote 106_2 into the frame tote stack 202 at a selected vertical position onto and directly supported by the intended supporting tote 106_2 of the retrieved totes within the frame tote stack 202 without an external intervening support structure between the retrieved tote 106a and the intended supporting tote 106_2. Further, in some embodiments, the moving of the retrieved tote 106a into the frame tote stack 202 can include cooperating and / or engaging one or more bottom stacking features 414 of the retrieved tote 106a with one or more upper stacking features 412 of the intended supporting 106_2 (e.g., see FIG. HE). This positions the retrieved tote 106a within the frame tote stack 202 at a predetermined vertical tote position of the one or more of the frame tote stack based on a predetermined sequencing (e.g., see FIG. 11F). Enabling the positioning of a tote at a desired position within the frame tote stack allows the retrieval of totes in any order, and typically at an optimal order based on a current position of the mobile robot 110 relative to the stacked positions of the one or more totes to be retrieved by that tote and / or the intended destination of the one or more retrieved totes, while still having the retrieved totes ordered within the frame tote stack 202 according to the predefined sequence and / or expected order of use of the retrieved totes. In some embodiments, the insertion of the retrieved tote 106a into the frame tote stack can occur while the mobile robot 110 moves through the facility (e.g., moving to a subsequent external stack, a workstation, etc.).

[0083] FIGS. 12A-12F illustrate simplified perspective views of an exemplary mobile robot 110 or a zoomed in portion of an exemplary mobile robot controlling one or more exemplary tote handling systems 130-131 in implementing an exemplary return tote staging sequence or process, in accordance with some embodiments. Referring to FIGS. 12A-12F, the mobile robots 110 can be utilized to return totes 106 back to one or more external tote storage stacks 104 in the one or more storage area of a fulfillment system 100. Further, the returning of a tote, in some instances, can be implemented while retrieving one or more totes from an external stack. In some embodiments, one of the tote handling systems 130-131 (e.g., a lower tote handling system 130) can be controlled move within the frame 120 to be vertically positions at a vertical level aligned to retrieve an intended return tote 106x of the frame tote stack 202 within the tote storageportion 122 of the mobile robot 110. The intended return tote can be positioned in any vertical position within the frame tote stack 202. In the exemplary embodiments illustrated in FIGS. 12A- 12F, the return tote 106x is at a current top vertical position within the frame tote stack 202. It will be appreciated by those skilled in the art, however, that a return tote can be retrieved from any position within the frame tote stack, similar to the positioning sequence, by retrieving the return tote 106x along with one or more totes currently supported by the return tote, moving the sub-stack vertically down and moving one or more of the remainder of the sub-stack to be maintained within the frame tote stack back onto the frame tote stack. This retrieval can occur while the mobile robot continues to move through the facility.

[0084] The robot control circuit 502 and / or the tote handling control circuit 706 can be configured to control one of the one or more tote handling systems (e.g., lower tote handling system 130) to move to the vertical position of the return tote 106x and rotate to orient the tote engaging system 302 with the intended return tote 106x (e.g., see FIG. 12A). The tote engaging system 302 can be controlled to engage the return tote 106x and slide the return tote 106x from the frame tote stack 202 to the tote engaging system and into the tote handling portion 124 (e.g., see FIG. 12B). In some implementations, the retrieval of the return tote 106x is implemented separate from a retrieval sequence (e.g., after a retrieved tote is positioned at a selected vertical position within the frame tote stack 202).

[0085] In some embodiments, the lower tote handling system 130 can rotate the return tote 106x to align with the upper tote handling system 131 and / or an orientation of an external stack 104 to which the return tote is intended to be returned (e.g., see FIGS. 12C-12D). The lower tote handling system 130 can be controlled to move the return tote 106x into engagement with the upper tote handling system 131, which in some instances includes vertically positioning the return tote 106x at a vertical position to enable the upper tote handling system 131 to engage the return tote 106x (e.g., see FIG12E, where the lower tote handling system 130 has lifted the return tote into the upper tote handling system 131). The upper tote handling system 131 can be controlled to engage the return tote 106x and retain the return tote in preparation for returning to an external stack, enabling the lower tote handling system to be vertically moved within the frame to implement one or more other tasks while the return tote 106x is staged to be returned to an external stack (e.g., see FIG. 12F). The movement of the return tote 106x to the upper tote handling system 131, in some embodiments, can occur while the mobile robot is in transit to another external stack, a workstation, and / or other such location. In some embodiments, one ormore tote handling systems 130-131 can be operated independent of the control of the transport system of the mobile robot to perform one or more operations, such as but not limited to inserting a retrieved tote into the frame tote stack, moving a tote to the upper tote handling system, reordering one or more totes of the frame tote stack, other such operations, or a combination of two or more of such operations. This can improve an efficiency of the fulfillment system by, in part, reducing tote retrieval and / or return timing.

[0086] FIGS. 13A-13D illustrate simplified perspective views of an exemplary mobile robot 110 or zoomed in portions of an exemplary mobile robot controlling one or more exemplary tote handling systems 130-131 in implementing an exemplary tote return sequence or process, in accordance with some embodiments. In some embodiments, the upper tote handling system 131 obtains the returning tote 106x, such as in a return staging process (e.g., see FIGS. 12A-12F). For example, the lower tote handling system 130 may retrieve a returning tote 106x from the frame tote stack, vertically move the returning tote to engage with the upper tote handling system 131. As another example, the upper tote handling system 131, in some embodiments, vertically moves to align with the returning tote 106x within the frame tote stack, and engages and retrieves the returning tote 106x. In other embodiments, the lower tote handling system 130 can retrieve the returning tote 106x from the frame tote stack 202 and implement the return to an external return stack 104a of one or more totes (e.g., totes 106_10-106_20) without the use of the upper tote handling system 131. Referring to FIGS. 13A-13D, the mobile robots 110 can be directed to return one or more returning totes 106x to one or more external tote storage stacks 104 in the one or more storage areas of a fulfillment system 100. In some embodiments, the mobile robot 110 receives location information, and self-propels and autonomously controls movement of the mobile robot through the facility to an intended return storage stack 104a. For example, FIG. 13A illustrates a simplified perspective view of a mobile robot 110 moving along an aisle 112 adjacent one or more rows 102 of storage stacks 104 of totes, which may be positioned on risers 204, toward an intended return storage stack 104a. In other embodiments, an external control system may provide some or all the directions to the mobile robot 110 to route to the return storage stack 104a (e.g., in the event of congestion, an obstruction, a route to enable one or more other totes to be retrieved prior to returning the returning tote 106x, other such factors, or a combination of two or more factors).

[0087] The mobile robot 110 can travel along the surface 208 to align with the intended return storage stack 104a (e.g., see FIG. 13B). In some embodiments, one or more of the tote handlingsystems 130-131 (e.g., an upper tote handling system 131) can be controlled to position the returning tote 106x at a vertical level aligned with an upper most tote 106_20 of the external return storage stack 104a (e.g., see FIG. 13B with the upper tote handling system 131 positioning the returning tote 106x relative to an upper most tote 106_20 of the intended return storage stack 104a). A tote engaging system 302 of the upper tote handling system 131 can be controlled by the robot control circuit 502 and / or the tote handling control circuit 706 to extend moving the returning tote 106x out of the frame 120 and on to the top most tote 106_20 on the return storage stack 104a (e.g., see FIG. 13C). This movement of the returning tote 106x, in some embodiments, can comprise moving the returning tote 106x to cause a cooperation between one or more bottom stacking features 414 of the returning tote 106x with one or more upper stacking features 412 of the upper most tote 106_20 as the returning tote 106x is slid onto the upper most tote 106_20. The tote engaging system 302 can release from the returning tote 106x (e.g., retract) enabling the mobile robot 110 to be free from the returning tote 106x and the return storage stack 104a such that the mobile robot 110 can move off to perform one or more other tasks (e.g., see FIG. 13D).

[0088] FIGS. 14A-14I illustrate simplified perspective views of an exemplary mobile robot 110 or zoomed in portions of an exemplary mobile robot controlling one or more exemplary tote handling systems 130-131 in implementing an exemplary tote return sequence or process as part of a tote retrieval sequence or process retrieving one or more totes from an external storage stack 104a, in accordance with some embodiments. As such, in some embodiments, a second tote handling system (e.g., upper tote handling system 131), of the one or more tote handling systems, which can be communicatively coupled with the robot control circuit, can be controlled by the robot control circuit 502 and / or the tote handling control circuit 706 to position a returning tote 106x onto an engaged sub-stack 1402 before an unwanted tote (e.g., tote 106_17) is returned to the return storage stack 104a of totes so that the returning tote 106x is also returned to the return storage stack 104a of totes when the one or more unwanted totes (e.g., totes 106_17-106_20) are returned to the return storage stack 104a. Referring to FIGS. 14A-14I, the mobile robots 110 can be directed to return one or more return totes 106x to one or more tote external storage stacks 104a in the one or more storage area of a fulfillment system 100. For example, FIG. 14A illustrates a simplified perspective view of a mobile robot 110 moving along an aisle 112 toward an intended return storage stack 104a.

[0089] The mobile robot 110 can align with the intended return storage stack 104a (e.g., see FIG. 14B). In some embodiments, one or more of the tote handling systems 130-131 (e.g., an upper tote handling system 131) can be controlled to position the return tote 106x at a vertical level aligned with an upper most tote 106_20 of the external return storage stack 104a (e.g., see FIG. 14B with the upper tote handling system 131 positioning the return tote 106x relative to an upper most tote 106_20). One or more tote engaging systems 302c of the upper tote handling system 131 can be controlled by the robot control circuit 502 and / or the tote handling control circuit 706 to extend moving the return tote 106x out of the frame 120 and on to the top most tote 106_20 on the return storage stack 104a (e.g., see FIG. 14C), such as slidably engaging one or more bottom stacking features 414 of the return tote 106x with one or more upper stacking features 412 of the upper most tote 106_20 as the return tote 106x is slid onto the upper most tote 106_20.

[0090] In some embodiments, in retrieving one or more totes from the external return storage stack 104a, the robot control circuit 502 and / or the tote handling control circuit 706 can control the lower tote handling system 130 to vertically move to align with an intended retrieve tote (e.g., intended retrieve tote 106_16) within the return storage stack 104a (e.g., see FIG. 14C-14D). Further, the robot control circuit 502 and / or the tote handling control circuit 706 can control one or more tote engaging system 302a-302b of the lower tote handling system 130 to engage one or more totes of the return storage stack 104a. For example, a first or lower tote engaging system 302b of the lower tote handling system 130 can be extended to engage the intended retrieve tote 106_16. Some embodiments may optionally further engage one or more other totes in the storage stack 104a, for example in stabilizing a retrieve or engaged sub-stack 1402 to be pulled into the mobile robot by controlling a second or upper tote engaging system 302a, of the lower tote handling system 130, to engage one or more additional totes above the intended retrieve tote (e.g., see FIG. 14D, with upper engaging system 302a engaging a tote 106_17 positioned on the retrieve tote 106_16). The one or more lower tote engaging system 302b and upper tote engaging system 302a of the lower tote handling system 130 and the tote engaging system 302c of the upper tote handling system 131 can be cooperatively controlled to move the intended retrieve tote 106_16 into the frame 120. This can include moving one or more totes 106_17-106x that are stacked upon the intended retrieve tote 106_16 into the frame as a retrieve or engaged sub-stack 1402 (e.g., see FIG. 14E). As illustrated above, in some embodiments, a returning tote 106x may be cooperated with the return stack 104a prior to an intended retrieve tote 106_16 is retrieved. The robot control circuit 502 and / or the tote handling control circuit 706 can beconfigured to control the upper tote handling system 131 to slide the returning tote 106x onto a top most tote 106_20 of the return stack 104a before the lower tote handling system 130 slides the intended retrieve tote 106_16 into the frame.

[0091] The lower tote handling system 130 can, in some embodiments, vertically move and orient the retrieved tote 106_16 and / or the engaged sub-stack 1402 (the one or more totes supported by the retrieved tote 106_16) to a vertical height 1404 to align a tote above the intended retrieved tote 106_16 with an upper surface of the top most remaining tote 106_15 on the external return storage stack 104a. FIG. 14F shows the lower tote handling system 130 having moved the engaged sub-stack 1402 down (relative to the position illustrated din FIG. 14E) with the tote 106_17 supported by the retrieved tote 106_16 aligned at the level or height 1404 with the current top most tote 106_15 remaining in the return storage stack 104a, while the retrieved tote 106_16 is below the level of the upper surface of the top most tote of the return storage stack 104a. While FIG. 14F illustrates the tote 106_17 directly above and on the retrieved tote 106_16, it will be appreciated that two or more totes may be intended to be retrieved totes and can be positioned below the vertical height 1404. Further, in some embodiments, the upper tote handling system 131 vertically moves in cooperation with the lower tote handling system 130 and / or the retrieved and engaged sub-stack 1402, which in some embodiments further maintains stability of the engaged sub-stack 1402. In other embodiments, the upper tote handling system 131 disengages from the top most tote 106x of the engaged sub-stack 1402 prior to the lower tote handling system 130 vertically moving the engaged sub-stack 1402.

[0092] In some embodiments, prior to returning the unwanted totes of the engaged sub-stack 1402, the lower tote engaging system 302b and / or other tote stabilizing feature can engage the current upper most tote 106_15 of the return storage stack 104a (e.g., see FIG. 141). This can stabilize the return storage stack 104a as one or more unwanted totes (e.g., totes 106_17 - 106x) of the sub-stack 1402 are returned to the return storage stack 104a. The tote handling control circuit 706 and / or lower tote handling system 130 can, in some embodiments, activate one or more of the tote engaging systems 302a-302c of the upper and / or lower tote handling systems 130-131 to transition from the retracted position to the extended position moving the one or more totes of the engaged sub-stack 1402 that are to be returned to the return storage stack 104a (e.g., totes 106_17 - 106x of the engaged sub-stack 1402), to move the remainder of the totes of the engaged sub-stack from the tote handling portion 124 and back onto the return storage stack 104a. into the frame tote stack of the mobile robot 110 and onto the intended supporting tote106_2 with the retrieved tote 106a positioned at the selected vertical position. FIG. 14H illustrates the upper tote engaging system 302a, of the lower tote handling system 130, and the tote engaging system 302c, of the upper tote handling system 131, transitioned to the extended position moving the unwanted totes of the engaged sub-stack back onto the return storage stack 104a. The cooperative operation of multiple tote engaging systems 302 can help stabilize the return storage stack 104a and / or the unwanted totes of the engaged sub-stack 1402. The unwanted totes of the engaged sub-stack 1402 can, in some implementations, be moved such that the lowest most oriented unwanted tote 106_17 is slid directly onto the current top most tote 106_15 of the return storage stack 104a (e.g., engaging one or more bottom stacking features 414 of the retrieved tote 106a with one or more upper stacking features 412 of the intended supporting 106_2) (e.g., see FIG. 14H), while the lower tote handling system 130 retains the intended retrieved tote 106_16 (e.g., see FIGS. 14H-14I). In some embodiments, the tote engaging systems 302 can extend one or more arms and / or other structures to slide the unwanted totes 106_17-106x onto the intended supporting tote 106_15 to become part of the return storage stack 104a. As such, some embodiments enable a tote swap in one retrieval and return sequence with the tote stack. The mobile robot 110 may activate one or more sensors to capture identifying information of the return storage stack 104a and / or the one or more returned unwanted totes 106_17-106x, and communicate that identifying formation and / or a correlation between the returned unwanted totes and the location of the return storage stack 104a, which can enable accurate tracking of the locations of the totes 106, and products within the totes, within the storage facility. In other embodiments, one or more of the tote engaging systems may enable vertical movement of one or more totes, which can be utilized in retrieving an intended retrieve tote 106_16. For example, an upper tote engaging system 302a may engage an unwanted tote 106_17 in the external stack and supported by the intended tote 106_16, vertically raise the supported unwanted tote 106_17 (and any totes supported by the unwanted tote 106_17). Some embodiments may further utilize one or more tote engaging systems of the upper tote handling system 131 to stabilize the stack. A lower tote engaging system 302b of the lower tote handling system 130 can engage the intended retrieve tote 106_16, and pull the intended retrieve tote 106_16 into the mobile robot while the upper tote engaging system 302a is lifting the unwanted tote 106_17. Once the intended retrieve tote 106_16 is acquired, the upper tote engaging system 302b of the lower tote handling system 130 can then be controlled to lower the unwanted substack back onto the remaining totes of the external stack.

[0093] FIGS. 15A-15I illustrate simplified perspective views of an exemplary mobile robot 110 or zoomed in portions of an exemplary mobile robot controlling two exemplary tote handling systems 130-131 in implementing a positioning of a first retrieved tote 106a into the frame tote stack 202 at an intended vertical position, and implementing a tote return staging sequence or process, in accordance with some embodiments. As such, in some embodiments, a second tote handling system (e.g., upper tote handling system 131), of the one or more tote handling systems, which can be communicatively coupled with the robot control circuit, can be controlled by the robot control circuit 502 and / or the tote handling control circuit 706 to vertically move within the tote handling portion 124 to a vertical position aligned with one or more intended returning totes 106x (e.g., see FIG. 15A). In some embodiments, a rotation system 712 can be controlled to orient one or more tote engaging systems 302c relative to the intended returning tote 106x and align one or more tote engaging systems with the returning tote 106x.

[0094] In some embodiments, the lower tote handling system 130 can be activated at the time the upper tote handling system 131 is aligning with the returning tote 106x. In some embodiments, the lower tote handling system 130 can be controlled to operate independent of the operation of the operation of the upper tote handling system 131, except in those instances where the lower tote handling system 130 is intended to engage and / or cooperate with the upper tote handling system 131. As such, the lower tote handling system 130 can have a first retrieved tote 106a that was previously retrieved from an external storage stack 104 or other source of totes. The lower tote handling system 130 can be controlled by the robot control circuit 502 and / or the tote handling control circuit 706 to vertically move within the tote handling portion 124 to a vertical position aligned with an intended position within the frame tote stack 202 (e.g., see FIG. 15A). The robot control circuit 502 and / or the tote handling control circuit 706 can control the orientation of a rotation system 712 to orient one or more tote engaging systems 302a-302b of the lower tote handling system 130 to orient the first retrieved tote 106a relative to the frame tote stack 202 (e.g., see FIGS. 15B-15C).

[0095] The robot control circuit 502 and / or the tote handling control circuit 706 can be configured to control the upper tote handling system 131 to vertically move within the tote handling portion 124 and engage and slide a current top retrieved tote from the frame tote stack into the tote handling portion, wherein the top retrieved tote is a returning tote to be returned to one of the stacks of totes during a next performance of the tote retrieval sequence

[0096] The robot control circuit 502 and / or the tote handling control circuit 706 can be configured to control the upper tote handling system 131 to activate one or more tote engaging systems to engage with and retract the one or more return totes 106x from the frame tote stack 202 and into the upper tote handling system 131 (e.g., see FIG. 15D). While FIG. 15D illustrates the retrieval of one returning tote 106x, it will be appreciated that in some embodiments, the upper tote handling system may simultaneously retrieve two or more returning totes. In some embodiments, the one or more returning totes 106x are the top most totes of the frame tote stack 202, while in other embodiments the upper tote handling system and the lower tote handling system can cooperatively operate to retrieve from within the frame tote stack and intended returning tote. Once the returning tote 106x is obtained, the upper tote handling system 131 can be configured to rotate to orient the returning tote 106x (e.g., see FIG. 15E) in an orientation to be moved to an external storage stack 104 of totes 106. In some embodiments, the upper tote handling system 131 engages and slides the returning tote 106x from a supporting tote 106_30 of the frame tote stack 202 and into the tote handling portion 124 where the returning tote 106x can be returned to one of the external storage stacks 104 of totes during a next performance of a tote return sequence and / or a tote retrieval sequence.

[0097] A predefined order of the retrieved totes may define that a first retrieved tote 106a is to be positioned between two previously acquired totes (e.g., a lower retrieved tote 106_31, and an upper retrieved tote 106_32) stored within the frame tote stack 202. Accordingly, in some embodiments, the robot control circuit 502 and / or the tote handling control circuit 706 can control the lower tote handling system 130 to vertically move within the frame 120 and align one or more tote engaging systems (e.g., an upper tote engaging system 302a) of the lower tote handling system 130 with the upper retrieved tote 106_32 and activate the tote engaging system 302a to engage the upper retrieved tote 106_32 (e.g., see FIG. 15F). In some embodiments, the retrieved tote 106a is positioned below an intended vertical position within the frame tote stack 202, such as adjacent to the lower retrieved tote 106_31 intended to support the retrieved tote 106a. The tote engaging system 302a can further be controlled to slide the upper retrieved tote 106_32, and other retrieved totes of the frame tote stack 202 being supported by the upper retrieved tote 106_32 when present. This movement of the upper retrieved tote 106_32 can include sliding the upper retrieved tote 106_32 off of the lower retrieved tote 106_31 and sliding the upper retrieved tote 106_32 onto the retrieved tote 106a, establishing a retrieved combined stack 1104 (e.g., see FIG. 15G).

[0098] The lower tote handling system 130 can, in some embodiments, vertically move and orient the retrieved tote 106a and / or the combined stack 1104 to align the retrieved tote 106a with a top of the intended supporting lower retrieved tote 106_31 (e.g., see FIG. 15H). The robot control circuit 502 and / or the tote handling control circuit 706 can activate one or more of the tote engaging systems 302 of the lower tote handling system 130 to transition from the retracted position to the extended position moving the retrieved tote 106a or combined stack 1104 from the tote handling portion 124 into the frame tote stack 202 and onto the intended supporting lower tote 106_31 with the retrieved tote 106a positioned at the selected vertical position (e.g., see FIG. 151).

[0099] Some embodiments enable the simultaneously removal of all the retrieved totes of the frame tote stack 202 from the mobile robot 110. FIG. 16 illustrates a simplified perspective view of an exemplary mobile robot 110 simultaneously moving each of exemplary totes of an exemplary frame tote stack 202, in accordance with some embodiments. The robot control circuit 502 and / or the tote handling control circuit 706 can be configured, in some embodiments, to control at least one of the tote handling systems (e.g., a lower tote handling system 130) to vertically move within the frame and align one or more tote engaging systems of the lower tote handling system with a lowest oriented retrieved tote 106_50 of the frame tote stack 202. The tote engaging system can be activated to extend to engage the lowest most oriented retrieved tote 106_50 and subsequently retract the tote engaging system, while engaged with the lowest oriented retrieved tote 106_50. Some embodiments further control the upper tote handling system 131 optionally to vertically move within the frame and align one or more tote engaging systems with one or more tote above the lowest most tote 106_50 of the frame tote stack 202, such as a top or upper most oriented tote 106_51. The tote engaging system can be activated to extend to engage the upper most oriented retrieved tote 106_50 and subsequently retract the tote engaging system in sequence and / or simultaneously with the retracting of the engaging system of the lower tote handling system 130, while the upper tote handling system 131 engages with the upper most oriented retrieved tote 106_51. Some embodiments further simultaneously rotate the lower tote handling system 130 and the upper tote handling system 131 to orient the totes for removal from the mobile robot 110. The lower tote handling system 130 and the upper tote handling system 131 can similarly be simultaneously activated to extend one or more respective tote engaging systems to move the totes of the frame tote stack 202 out of the mobile robot 110 (e.g., see FIG. 16). This enables simultaneously depositing, as a stack, each of theretrieved totes of the frame tote stack 202 at a deposit location. A similar process can be performed to simultaneous control the lower tote handling system 130 and upper tote handling system 131 to extend one or more respective tote engaging systems to engage one or more totes of an external stack 104 of totes, and simultaneously retract the tote engaging systems to simultaneously move an entire stack of totes into the mobile robot 110.

[0100] FIG. 17 illustrates a simplified side view of a portion of an exemplary automated fulfillment system 100, in accordance with some embodiments. The fulfillment system 100 can include one or more workstations 170. One or more mobile robots 110 can travel through the fulfillment facility between one or more storage areas 1706, where rows of stacks 104 of totes 106 are positioned, and the one or more workstations 170, in delivery stacks of one or more totes 106 to the workstation 170 and / or in retrieving stacks of totes from the workstation 170. FIG. 18 illustrates a simplified perspective view of an exemplary workstation 170 with a mobile robot 110 cooperated with the workstation in delivering a frame tote stack 202 to the workstation and / or retrieving a stack of totes from the workstation, in accordance with some embodiments. FIG. 19A illustrates a simplified overhead view of an exemplary workstation 170 with a mobile robot 110 cooperated with the workstation in delivering a frame tote stack 202 to the workstation and / or retrieving a stack of totes from the workstation, in accordance with some embodiments. FIG. 19B illustrates a simplified overhead view of an exemplary workstation 170 comprising and / or cooperated with one or more storage buffers, and further illustrates a mobile robot 110 cooperated with a tote storage buffer tower 1702 of the workstation 170, in accordance with some embodiments.

[0101] Referring to FIGS. 1A-3 and 17-19B, in some embodiments, totes 106 are transported to the workstations where a worker 1704, picking robot, other such systems, or combination of two or more of such picking can retrieve one or more items from the delivered totes in fulfilling at least part of orders for one or more items. The retrieved items can be placed into order totes, bags, boxes, on a conveyor system to be packaged and / or routed for delivery, other such actions, or a combination of such actions. The picking and / or fulfillment of orders can be similar order fulfillment described in one or more of U.S. Patent Nos. 9,139,363, 10,435,241, and 11,142,398, and U.S. Patent Application Publication Nos. 2019 / 0270591, 2021 / 0229271, and 2023 / 0095494, each of which is incorporated herein by reference in its entirety.

[0102] The robot control circuit 502 can control the transport system 504 to transport and move the mobile robot 110 between one or more storage areas 1706 and the one or more workstations170. In some embodiments, the control circuit 502 and / or one or more tote handling control circuits 706 can control one or more of the tote handling systems 130-131 to move the retrieved totes 106 in the frame tote stack 202 from the mobile robot to the workstation 170. The transfer of the totes 106 can, in some instances, be individual totes transferred one at a time, while in other instances, multiple totes may be simultaneously transferred to and / or from the workstation 170. In some embodiments, a workstation may comprise one or more picking conveyors 1712, deck, bays and / or other such systems along which totes 106 can be moved to allow picking by a worker 1704, picking robot and / or other such system. Further, in some embodiments, one or more picking conveyors 1712, deck, bays and / or other such systems can move totes 106 away from the picking area after processing at the workstation (e.g., one or more item removed from a tote in fulfilling an order, one or more items added to the tote acting as an order tote in which ordered items of an order can be consolidated, one or more items added to the tote in decanting a collection (e.g., case, pallet, etc.) of items to be moved into the storage areas (e.g., into stacks 104 and / or the storage structure 150)) and move these processed totes to one of one or more buffer towers 1702 in staging these processed totes to be returned to the storage area and / or to another workstation. The routing to a particular buffer tower can be controlled by a central control system providing directions to a workstation control circuit and / or a conveyor control circuit.

[0103] In some embodiments, one or more tote handling systems 130-131 can vertically move within the frame 120 and sequentially retrieve individual totes 106 in accordance with a predetermined sequencing based on the sequence that the retrieved totes are processed through the workstation 170 in fulfilling orders. For example, a mobile robot 110 can be positioned adjacent to a workstation, and repeatedly feed one tote at a time to a conveyor system 1712 (e.g., see FIG. 19A). In other embodiments, one or more of the tote handling systems 130-131 can be controlled to retrieve multiple totes 106 and transfer multiple totes simultaneously to a buffer tower 1702 that are configured to receive and retain multiple totes. One or more of the buffers towers 1702 can include one or more lift and / or elevator systems 1708 that can be configured to move totes 106 vertically within the respective buffer tower 1702. Additionally or alternatively, in some embodiments one or more buffers towers 1702 can include one or more tote handling systems similar to or the same as the tote handling systems 130-131 of the mobile robots, that can be controlled to retrieve totes from the mobile robots, move totes within the buffer towers and / or move totes to and / or from the workstation picking conveyors 1712, deck, bays or the like.

[0104] The mobile robots 110, in some embodiments, can bring the retrieved totes 106 to the workstations and transfer one or more, and typically each of the totes of a frame tote stack 202 to a receiving buffer tower 1702. This frees up the mobile robot to return to the storage areas to again acquire sets of totes to be transferred to a workstation and / or perform other tasks. The robot control circuit 502 and / or the engaging control circuit 702 can control one or more of the tote handling systems 130-131 of the mobile robot 110 to simultaneously move the retrieved totes in the frame tote stack 202 into a buffer tower 1702 at the workstation 170. Additionally or alternatively, a mobile robot 110 can move to a buffer tower 1702 that has retrieved totes already processed in fulling one or more orders and is awaiting return to a storage area. The mobile robot 110 can align with the buffer tower 1702 and one or more tote handling systems 130-131 of the mobile robot and / or buffer tower can slide one or more totes, and typically simultaneously slide multiple totes into the tote handling portion 124 of the mobile robot, which can then transport the retrieved totes back to a storage area to one or more stacks and / or to create a new stack, to one or more other workstations, or other routing as dictated, for example, by a central control system. For example, a frame tote stack can be retrieved from a buffer tower 1702, transported to a storage area and the entire frame tote stack transferred from the mobile robot to a riser 204 establishing a new stack within the storage area. The risers 204 can, in some embodiments, include one or more aligning and / or stabilizing stacking features 412 (e.g., see FIG. 2) spaced along one or more portions of or the entire length of the risers, and that can cooperate with respective stabilizing stacking features 414 of the totes 106.

[0105] FIG. 20 illustrates a simplified flow diagram of an exemplary process 2000 of managing totes in automatically fulfilling orders, in accordance with some embodiments. In step 2002, a mobile robot control circuit 502 can control a transport system 504 of the mobile robot 110 to self-propel through one or more storage areas 1706 having stacks 104 of totes 106. Each stack 104 can comprise one or more totes 106 being vertically stacked on one another. In step 2004, the mobile robot positions itself proximate to an external intended stack 104 of totes. In step, 2006 one or more tote handling systems 130-131 of the mobile robot 110 can be activated. In step 2008, the one or more tote handling systems 130-131 engage at least an intended tote 106 of the external stack 104 that is instructed to be removed from the external stack. In some embodiments, one or more tote engaging systems, of the one or more tote handling systems, can be extended from a frame 120 of the mobile robot 110. The engaging of the tote 106 can comprise, in some embodiments, a cooperation of tote engaging features 602 of the one or moretote engaging system with one or more engaging structural components 420 (e.g., recesses, posts, handles, ridges, shoulders, apertures, other such engaging structural components or combination of two or more of such engaging structural components) of the tote 106.

[0106] In step 2010, at least the intended one or more totes are retrieved by at least one tote handling system 130 in implementing a tote retrieval sequence from the intended external stack 104 of totes, and moved into the frame of the mobile robot 110 (e.g., into a tote handling portion 124). Prior to the retrieval, some embodiments may control one or more tote handling systems (e.g., an upper tote handling system 131) to position a returning tote onto a top most tote of the external stack of totes before the tote handling system slides the intended tote into the frame. In some embodiments, the retrieval of the intended tote comprises retracting, following the engaging of the intended tote, at least one tote engaging system 302 and sliding the intended tote 106a off of a second tote, of the external stack 104 of totes, upon which the intended tote is supported and stacked. The retrieval of the intended one or more totes, in some embodiments, includes the retrieval of one or more additional totes (e.g., including at least one tote directly on top of the intended tote) that were above and supported within the external stack by the intended tote. As such, the sliding of the intended tote from the external stack may include sliding the intended tote and one or more totes which are in the external stack and that are stacked upon and supported by the intended tote at the time of retrieving the intended tote including a third tote stacked directly on top of the intended tote, into the frame as an engaged sub-stack supported by the intended tote.

[0107] In some embodiments, the process 2000 includes optional step 2012 where one or more return totes are positioned on top of the engaged sub-stack in preparation for return to the external stack (or another external stack). This can include controlling one or more of the tote handling systems (e.g., upper tote handling system 131) to obtain a returning tote (e.g., from the frame tote stack 202) from the in preparation for placement onto the engaged sub-stack and return to the external stack of totes during a subsequent performance of the tote retrieval sequence at another external stack.

[0108] In step 2014, the one or more additional totes (which may include one or more returning totes) supported by the intended tote and not intended to be retrieved are returned to the external stack. The returning of the one or more additional totes, in some embodiments, can include activating one or more one or more tote handling systems 130-131 to vertically move the engaged sub-stack to align the lowest tote intended to be returned with the upper most tote ofthe external stack, and moving the one or more totes being returned from the frame. For example, the lower tote handling system 130 can be controlled to move the engaged sub-stack downward within the frame and align the lowest most tote that is not to be retained, of the engaged substack and positioned above and directly in contact with and supported by the retrieved tote, relative to a top most tote of the external stack of totes, and move the one or more totes out and onto the external stack, typically without an external intervening support structure between the lowered returning tote and the tote of the external stack that was the top most tote until the one or more returning totes were moved onto the external stack. This movement out of the frame, in some implementations, can comprise sliding the additional totes from the mobile robot to slidingly engage one or more bottom stacking features 414 of a lowest positioned tote, of the additional totes, with one or more upper stacking features 412 of a top most positioned tote remaining in the external stack in automatically aligning the additional totes with the one or more totes of the instructed external stack in vertically and laterally aligning the one or more additional totes with the external intended stack. The retrieved intended tote can be retained by a tote handling system 130 (e.g., a lower tote handling system). The engaging of one or more bottom stacking features of a bottom most returning tote of the one or more totes to be returned with upper stacking features of a top most tote of the external stack can provide automatic alignment of the bottom most returning tote (and those stacked upon the bottom most returning tote) with the top most tote of the external stack (and thus vertical alignment with the external stack) by slidingly engaging the bottom stacking features of the bottom most returning tote with the upper stacking features of the top most tote of the external stack in vertically and laterally aligning the bottom most returning tote with the external stack.

[0109] In step 2016, the retrieved intended tote is positioned within a storage portion 122 of the mobile robot 110 as part of a frame tote stack 202 of a set of one or more retrieved totes vertically stacked on one another, typically without an external intervening structure, within the storage portion 122 and supported by the mobile robot. The storage of the retrieved tote can include vertically positioning (e.g., by the lower tote handling system 130) the retrieved tote at a selected vertical position, relative to the frame tote stack, such as above a top most tote within the frame tote stack. The tote handling system can then be controlled to slide the retrieved tote into the frame tote stack onto and directly supported by the top most tote of the retrieved totes within the frame tote stack without an external intervening support structure between the retrieved tote and the top most tote previously incorporated into the frame tote stack. Additionally oralternatively, in some embodiments, vertically move one or more of the tote handling systems 130-131 within the frame, and vertically positioning the retrieved tote at a selected vertical position relative to the frame tote stack, and slide the retrieved tote into the frame tote stack onto and directly supported by one of the totes of the retrieved totes within the frame tote stack without an external intervening support structure between the retrieved tote and the one of the totes within the frame tote stack. In some embodiments, the positioning of the retrieved tote within the storage portion of the mobile robot as part of the frame tote stack comprises engaging bottom stacking features 414 of the retrieved tote with upper stacking features 412 of a previously retrieved tote within the frame tote stack and automatically aligning the retrieved tote with the previously retrieved tote by slidingly engaging the bottom stacking features of the retrieved tote with the upper stacking features of the previously retrieved tote in the frame tote stack in vertically and laterally aligning the retrieved tote with the frame tote stack.

[0110] FIG. 21 illustrates a simplified flow diagram of an exemplary tote return process 2100 to return one or more totes to an external stack 104 of totes, in accordance with some embodiments. Some implementations include step 2102 where one or more tote handling systems (e.g., a lower tote handling system 130) is controlled to engage a returning tote while positioned with the frame tote stack 202. In step 2104, the returning tote is slid from the frame tote stack. The removing of the returning tote from the frame tote stack, in some embodiments, can occur prior to being positioned onto an engaged sub-stack 1002. In step 2106, the lower tote handling system 130 can vertically move the returning tote into engagement with the upper tote handling system 131. This engagement of the returning tote with the upper tote handling system 131 can enable the returning tote to be staged in preparation to be positioned onto one or more totes of an engaged sub-stack 1002 prior to returning the returning tote and any totes of an engaged sub-stack that are to be returned to an external stack.

[0111] FIG. 22 illustrates a simplified flow diagram of an exemplary tote return process 2200 to return one or more totes to an external stack 104 of totes, in accordance with some embodiments. In step 2202, a lower tote handling system 130 is controlled to vertically align with and to engage a top previously retrieved tote from the frame tote stack 202. In step 2204, the lower tote handling system 130 slides the top retrieved tote into the tote handling portion after an intended retrieved tote has been retrieved and is positioned at the selected vertical position aligning the intended retrieved tote or a top most tote of an engaged sub-stack with a lower portion of the previously retrieved tote. Some embodiments include optional step 2206, wherethe lower tote handling system 130 moves the top retrieved tote into engagement with the upper tote handling system 131 of the mobile robot, wherein the top retrieved tote is a returning tote to be returned to one of the external stacks of totes.

[0112] FIG. 23 illustrates a simplified flow diagram of an exemplary tote return process 2300 to return one or more totes to an external stack 104 of totes, in accordance with some embodiments. In step 2302, the upper tote handling system is vertically moved within the frame to align with a lowest most tote of one or more totes within the frame tote stack to be returned. In step 2304, the upper tote handling system is controlled to engage the lowest most tote to be returned. In step 2306, the upper tote handling system slides the one or more totes to be returned from the frame tote stack and into the tote handling portions 124 in obtaining one or more returning totes to be returned to an external stack of totes during a subsequent tote retrieval sequence or independent of a subsequent tote retrieval sequence.

[0113] FIG. 24 illustrates a simplified flow diagram of an exemplary process 2400 of routing a stack of totes to a workstation, in accordance with some embodiments. In step 2402, the robot control circuit receives an identification of a workstation to receive a stack of totes. In some embodiments, the identification is accompanied by routing instructions. The received routing, in some implementations, can be provided by a central control system that can take into consideration a shorted route, congestion, whether one or more additional totes are to be retrieved in route to the workstation, other such factors, or a combination of two or more of such factors. In other embodiments, the identification is used by the robot control circuit to determine a routing to the intended workstation.

[0114] In step 2404, the robot control circuit controls one or more propulsion systems of the robot to self-propel through the storage area to a workstation. In step 2406, one or more of the tote handling systems 130-131 are vertically positioned within the frame to align with a bottom most tote of the frame tote stack 202. In step 2408, the one or more tote handling systems retrieve the retrieved totes in the frame tote stack. In some embodiments, the one or more tote handling systems 130-131 may rotate the retrieved tote stack while in the tote handling portion 124 of the robot to orient the stack of totes relative to the workstation and / or a buffer tower associated with the workstation. In step 2410, one or more of the tote handling systems 130-131 move the totes of the frame tote stack out from the mobile robot to be accessible at the workstation. In some embodiments, the movement of the totes from the mobile robot can include the simultaneous movement of the retrieved totes from the frame tote stack into a buffer tower1702 at the workstation 170. A similar process can be implemented in reverse to retrieve a stack of totes from a buffer tower and / or the workstation, and return the stack to the storage area.

[0115] FIG. 25 illustrates a simplified flow diagram of an exemplary process 2500 of inserting a tote into the frame tote stack in accordance with some embodiments. In step 2502, one or more of the tote handling systems 130-131 vertically position the retrieved tote at the selected vertical position relative to the frame tote stack aligning the retrieved tote handling system (e.g., the lower tote handling system 130) with the frame tote stack adjacent the selected vertical position. In step 2504, one or more of the tote handling systems engages a previously retrieved tote, of the retrieved totes within the frame tote stack, at the selected vertical position. In step 2506, the previously retrieved tote is slid onto the retrieved tote (or on a top most tote when one or more totes are on top of a retrieved tote that are also to be inserted into the frame tote stack) in the tote handling portion of the frame of the mobile robot, forming a combined stack 1104. The combined stack can comprises the intended retrieved tote, the previously retrieved tote, and any additional previously retrieved totes stacked on top of the previously tote of the frame tote stack. In step 2508, the one or more tote handling systems are controlled to vertically move the combined stack 1104 relative to the selected vertical position to align the intended retrieved tote with a top most remaining tote of the frame tote stack. In step 2510, the combined stack is slide into the frame tote stack with the intended retrieved tote positioned at the selected vertical position.

[0116] FIG. 26 illustrates a simplified flow diagram of an exemplary process 2600 of moving a frame tote stack 202 out of robot in forming an external stack and / or incorporating with an already existing external stack, in accordance with some embodiments. In step 2602, the mobile robot receives an instructed deposit location. In step 2604, the mobile robot self-propels to the intended deposit location. In step 2606, one or more of the tote handling systems 130-131 is controlled to vertically align a tote engaging system of at least one of the tote handling systems with a lowest oriented retrieved tote of the frame tote stack 202. In step 2608, the tote engaging system is extended and engages the lowest oriented retrieved tote. In step 2610, the one or more tote engaging systems can be retracted while engaged with the lowest oriented retrieved tote and simultaneously move each of the retrieved totes of the frame tote stack 202 from the storage portion 122 and into the tote handling portion 124. Some embodiments include optional step 2612 where the one or more tote handling systems rotate the frame tote stack to an intended orientation based on an intended placement of the stack. In step 2614, the one or mote totehandling systems move the totes of the frame tote stack out of the frame and simultaneously deposit, as a stack, each of the retrieved totes of the frame tote stack at the intended deposit location.

[0117] FIG. 27 illustrate a simplified flow diagram of an exemplary process 2700 of managing totes, the transport of totes and the stacking of totes within a fulfillment facility, in accordance with some embodiments. In step 2702 a mobile robot is activated and instructed to move to an intended external stack 104 of totes. In step 2704, the mobile robot self-propels along one or more aisles to approach the target external stack for tote placement. In step 2706, the mobile robot aligns adjacent to the target external stack. In step 2708, one or more tote handling system 130-131 engage an intended tote 106. In some embodiments, one or more tote engaging systems 302, which may include for example one or more extendable arms, to engage with a partial target stack of the external stack at a designated tote level of the intended tote.

[0118] In step 2710, one or more of the tote handling systems 130-131 retrieve the intended tote. In some embodiments, the tote engaging system(s) 302 retracts to pull in by sliding the engaged part of the external stack into the frame 120. In step 2712, one or more of the tote handling systems lift the intended tote to engage with one or more returning totes. For example, a lower tote handling system 130 can lift the intended tote and any totes supported on the intended tote to a level to engage a return tote retained by the upper tote handling system 131. In step 2714, the one or more tote handling system 130-131 vertically move to align one or more totes to be returned (e.g., tote handling system aligns to enable slidably move the combine stack from in the frame to the external stack).

[0119] In step 2716, an upper tote engaging system 302 of the lower tote handling system 130 slides the one or more return totes to the external stack, while in step 2718 retaining the retrieved tote (e.g., lower tote engaging system 302 of the lower tote handling system 130 maintains engagement of the retrieved tote, which can be a bottom most tote while and after transferring the sub-stack onto the external stack). In step 2720, the one or more return totes are positioned on the external stack. In step 2722, one or more tote engaging system 302 are disengaged from the one or more return totes positioned on the external stack, and retracted, while in step 2724 the retrieved tote continues to be retained in the tote handling system.

[0120] In step 2726, one or more of the tote handling system 130-131 rotates the retrieved tote and vertically aligns the retrieved tote relative to the frame tote stack within the frame 120. In step 2728, one or more totes may be moved from frame tote stack above intended position. Forexample, one or more tote engaging systems may be extended engage to slidably receive a partial tote stack from the frame tote stack above an intended placement location and the retrieved tote within the tote handling system. In step 2730, some embodiments totes from the frame tote stack are cooperated with the one or more intended totes supported by the tote handling system 130 establishing a combined stack 1104. In step 2732, the combined stack is transferred by one or more tote handling system onto the frame tote stack (e.g., tote engaging system can extend one or more arms to place the combined tote stack onto the frame tote stack). Some embodiments include step 2734 where one or more return totes are retrieved in anticipation of returning the one or more totes to one or more external stacks.

[0121] FIG. 28 illustrates a simplified flow diagram of an exemplary process 2800 of acquiring a return tote, in accordance with some embodiments. In step 2802, a lower tote handling system 130 retrieves a return tote from frame tote stack. The tote handling system can align with the return tote to obtain the return tote (e.g., which may be on top of the frame tote stack). In step 2804, the lower tote handling system 130 slidably receives return tote. In step 2806, the lower tote handling system vertically moves to position the return tote to engage with the upper tote handling system 131 in preparation for subsequent return to an external stack.

[0122] FIGS. 29A-29B illustrate a simplified flow diagram of an exemplary process 2900 of managing stacked totes, in accordance with some embodiments. In step 2902, a mobile robot 110 self-propels to an intended external stack. The mobile robot can include tote handling systems 130-131. In step 2904, the mobile robot aligns with the instructed external stack. In step 2906, one or more tote handling systems (e.g., a lower tote handling system 130 and an upper tote handling system 131) rotate to an orientation to engage one or more totes of the external stack when the tote handling systems are not in the desired orientation. In step 2908, tote engaging systems 302 from both the upper and lower tote handling systems 131-130 can be extended toward one or more totes of the external stack. In step 2910, some embodiments control a tote engaging system of the upper tote handling system 131 to extend and engage a top most tote of the external stack. In step 2912, some embodiments control a tote engaging system of the lower tote handling system 130 to extend and engage at least one intended tote that is intended to be retrieved and moved into the frame.

[0123] In step 2914, the one or more tote engaging systems can cooperatively operate to retract. In step 2916, a sub-stack of one or more totes can be moved (e.g., slid) from the external stack and moved into the frame by retracting the tote engaging systems. In step 2918, someembodiments cooperatively lower the lower tote handling system 130 and upper tote handling system 131 toward a base of the robot. In step 2920, the vertical movement vertically aligns one or more totes of the sub-stack that are to be returned to the external stack with a current top most tote of the external stack. In step 2922, some embodiments retain and / or block the one or more intended totes by the lower tote handling system.

[0124] In step 2924, the tote engaging systems of the upper and lower tote handling systems can be activated to transfer one or more non-intended totes (e.g., a partial tote stack) from the frame and onto the external stack (e.g., on to a current top most tote of the external stack), while in step 2926 retaining the one or more intended totes that are intended to be retrieved and transported by the mobile robot.

[0125] In step 2928, some embodiments retract the one or more tote engaging system, and the mobile robot may begin to move away from the external stack (e.g., move to another external stack, toward a workstation, etc.). In step 2930, some embodiments orient one or more of the tote handling systems (e.g., upper and lower tote handling systems) to interact with the frame tote stack. In step 2932, some embodiments vertically align the upper tote handling system to align with a return tote intended to be returned to an external stack (e.g., a top most tote in the frame tote stack, a second to the top most tote when two totes are to be returned, etc.). In step 2934, the lower tote handling system 130, in some embodiments, retains the retrieved tote.

[0126] In step 2936, the lower tote handling system vertically aligns the retrieved tote below an intended position within the frame tote stack, and an upper tote engaging system of the lower tote handling system 130 engages with one of the totes of the frame tote stack at a vertical level above a level where the previously retrieved tote is to be positioned within the frame tote stack. In step 2938, the upper tote engaging system of the lower tote handling system 130 transfers one or more totes (e.g., partial tote stack) of the frame tote stack out of the frame tote stack and onto the retrieved tote. In step 2940, the partial tote stack is slid onto the retrieved tote maintained within the lower tote handling system 130, typically without any external intervening structure other than the engaging features of the totes. In step 2942, the lower tote handling system 130 vertically elevates the retrieved totes (and any totes from the frame tote stack moved onto the retrieved tote) to align with an intended vertical position within the frame tote stack (e.g., providing clearance for the intended tote, which often can be a lowest tote in a combined stack). In step 2944, one or more tote engaging systems 302 of the lower tote handling system 130 are activated to transfer the retrieved tote and any totes supported by the retrieved tote (e.g., acombined stack of two or more totes) onto a current top most tote of the frame tote stack. In step 2945, one or more tote engaging systems 302 of the lower tote handling system 130 are retracted, and may rotate to orient and / or align with an upper tote handling system 131, while in step 2948 the upper tote handling system may retain one or more totes intended to be returned.

[0127] Further, the circuits, circuitry, systems, devices, processes, methods, techniques, functionality, services, servers, sources and the like described herein may be utilized, implemented and / or run on many different types of devices and / or systems. FIG. 30 illustrates an exemplary system 3000 that may be used for implementing any of the components, circuits, circuitry, systems, functionality, apparatuses, processes, or devices of the automated fulfillment system 100, mobile robots 110, low profile mobile robots 152, tote handling systems 130-131, robot control circuits 502, tote engaging systems 302, transport systems 504, drive systems 505, tote engaging control circuits 702, tote handling control circuits 706, storage buffers 1702, the workstation 170, picking conveyors 1712, and / or other above or below mentioned systems or devices, or parts of such circuits, circuitry, functionality, systems, apparatuses, processes, or devices. However, the use of the system 3000 or any portion thereof is certainly not required.

[0128] By way of example, the system 3000 may comprise one or more control circuits or processor modules 3012, one or more memory 3014, and one or more communication links, paths, buses or the like 3018. Some embodiments may include one or more user interfaces 3015, and / or one or more internal and / or external power sources or supplies 3040. The control circuit 3012 can be implemented through one or more processors, microprocessors, central processing unit, logic, local digital storage, firmware, software, and / or other control hardware and / or software, and may be used to execute or assist in executing the steps of the processes, methods, functionality and techniques described herein, and control various communications, decisions, programs, content, listings, services, interfaces, logging, reporting, etc. Further, in some embodiments, the control circuit 3012 can be part of control circuitry and / or a control system 3010, which may be implemented through one or more processors with access to one or more memory 3014 that can store instructions, code and the like that is implemented by the control circuit and / or processors to implement intended functionality. In some applications, the control circuit and / or memory may be distributed over a communications network (e.g., LAN, WAN, Internet) providing distributed and / or redundant processing and functionality. Again, the system 3000 may be used to implement one or more of the above or below, or parts of, components, circuits, systems, processes and the like.

[0129] The user interface 3016 can allow a user to interact with the system 3000 and receive information through the system. In some instances, the user interface 3016 includes a display 3022 and / or one or more user inputs 3024, such as buttons, touch screen, track ball, keyboard, mouse, etc., which can be part of or wired or wirelessly coupled with the system 3000. Typically, the system 3000 further includes one or more communication interfaces, ports, transceivers 3020 and the like allowing the system 3000 to communicate over a communication bus, a distributed computer and / or communication network (e.g., a local area network (LAN), the Internet, wide area network (WAN), etc.), communication link 3018, other networks or communication channels with other devices and / or other such communications or combination of two or more of such communication methods. Further the transceiver 3020 can be configured for wired, wireless, optical, fiber optical cable, satellite, or other such communication configurations or combinations of two or more of such communications. Some embodiments include one or more input / output (I / O) ports 3034 that allow one or more devices to couple with the system 3000. The I / O ports can be substantially any relevant port or combinations of ports, such as but not limited to USB, Ethernet, or other such ports. The I / O interface 3034 can be configured to allow wired and / or wireless communication coupling to external components. For example, the I / O interface can provide wired communication and / or wireless communication (e.g., Wi-Fi, Bluetooth, cellular, RF, and / or other such wireless communication), and in some instances may include any known wired and / or wireless interfacing device, circuit and / or connecting device, such as but not limited to one or more transmitters, receivers, transceivers, or combination of two or more of such devices.

[0130] In some embodiments, the system may include one or more sensors 3026 to provide information to the system and / or sensor information that is communicated to another component, such as the central control system, a delivery vehicle, etc. The sensors can include substantially any relevant sensor, such as distance measurement sensors (e.g., optical units, sound / ultrasound units, etc.), optical-based scanning sensors to sense and read optical patterns (e.g., bar codes), radio frequency identification (RFID) tag reader sensors capable of reading RFID tags in proximity to the sensor, motion sensors, cameras, accelerometers, gyroscopes, inertial sensors, and other such sensors. The foregoing examples are intended to be illustrative and are not intended to convey an exhaustive listing of all possible sensors. Instead, it will be understood that these teachings will accommodate sensing any of a wide variety of circumstances in a given application setting.

[0131] The system 3000 comprises an example of a control and / or processor-based system with the control circuit 3012. Again, the control circuit 3012 can be implemented through one or more processors, controllers, central processing units, logic, software and the like. Further, in some implementations the control circuit 3012 may provide multiprocessor functionality.

[0132] The memory 3014, which can be accessed by the control circuit 3012, typically includes one or more processor-readable and / or computer-readable media accessed by at least the control circuit 3012, and can include volatile and / or nonvolatile media, such as RAM, ROM, EEPROM, flash memory and / or other memory technology. Further, the memory 3014 is shown as internal to the control system 3010; however, the memory 3014 can be internal, external or a combination of internal and external memory. Similarly, some or all of the memory 3014 can be internal, external or a combination of internal and external memory of the control circuit 3012. The external memory can be substantially any relevant memory such as, but not limited to, solid- state storage devices or drives, hard drive, one or more of universal serial bus (USB) stick or drive, flash memory secure digital (SD) card, other memory cards, and other such memory or combinations of two or more of such memory, and some or all of the memory may be distributed at multiple locations over the computer network. The memory 3014 can store code, software, executables, scripts, data, content, lists, programming, programs, log or history data, user information, customer information, product information, and the like. While FIG. 30 illustrates the various components being coupled together via a bus, it is understood that the various components may actually be coupled to the control circuit and / or one or more other components directly.

[0133] Some embodiments provide systems, apparatuses and corresponding methods of providing automated order fulfillment, comprising: a plurality of totes; a storage area having stacks of totes, each stack comprising one or more of the plurality of totes being vertically stacked on one another; and a mobile robot configured to transport a set of one or more retrieved totes, of the stacks of totes, through the storage area, the mobile robot comprising: a robot control circuit; a transport system coupled with the robot control circuit, wherein the transport system is configured to self-propel the mobile robot through the storage area based on commands from the robot control circuit; and a frame comprising a storage portion and a tote handling portion, the storage portion storing a frame tote stack of the set of one or more retrieved totes vertically stacked on one another, and the tote handling portion comprising one or more tote handling systems controlled by the robot control circuit to perform a tote retrieval sequence to retrieve afirst tote from a first stack of totes, of the stacks of totes, that is instructed to be removed from the first stack of totes.

[0134] Some embodiments provide methods of automatically fulfilling orders, comprising: controlling, through a mobile robot control circuit of a mobile robot, a transport system of the mobile robot to self-propel through a storage area having stacks of totes, each stack comprising one or more of the plurality of totes being vertically stacked on one another, and positioning the mobile robot proximate a first stack of totes, of the stacks of totes; engaging, by a first tote handling system cooperated with a storage portion of the mobile robot, a first tote of the first stack of totes that is instructed to be removed from the first stack of totes; retrieving, by the first tote handling system in implementing a tote retrieval sequence, the first tote from the first stack of totes; and positioning the first tote within a storage portion of the mobile robot as part of a frame tote stack of a set of one or more retrieved totes vertically stacked on one another within the storage portion and supported by the mobile robot.

[0135] Those skilled in the art will recognize that a wide variety of other modifications, alterations, and combinations can also be made with respect to the above described embodiments without departing from the scope of the invention, and that such modifications, alterations, and combinations are to be viewed as being within the ambit of the inventive concept. Numerous alternative embodiments of the present invention will be apparent to those skilled in the art in view of the foregoing description. Accordingly, this description is to be construed as illustrative only and is for the purpose of teaching those skilled in the art the best mode for carrying out the present invention. Details of the structure may vary substantially without departing from the spirit of the present invention, and exclusive use of all modifications that come within the scope of the appended claims is reserved. Within this specification embodiments have been described in a way which enables a clear and concise specification to be written and illustrated, but it is intended and will be appreciated that embodiments and relevant portions of embodiments may be variously combined or separated without parting from the invention. It is intended that the present invention be limited only to the extent required by the appended claims and the applicable rules of law.

Claims

Claims1. An automated order fulfillment system, comprising: a plurality of totes; a storage area having stacks of totes, each stack comprising one or more of the plurality of totes being vertically stacked on one another; and a mobile robot configured to transport a set of one or more retrieved totes, of the stacks of totes, through the storage area, the mobile robot comprising: a robot control circuit; a transport system coupled with the robot control circuit, wherein the transport system is configured to self-propel the mobile robot through the storage area based on commands from the robot control circuit; and a frame comprising a storage portion and a tote handling portion, wherein the storage portion configured to store a frame tote stack of the set of one or more retrieved totes vertically stacked on one another, and wherein the tote handling portion comprises one or more tote handling systems controlled by the robot control circuit and configured to perform a tote retrieval sequence to retrieve a first tote from a first stack of totes, of the stacks of totes, that is instructed to be removed from the first stack of totes.

2. The automated order fulfillment system of claim 1, wherein the mobile robot comprises: a first tote handling system of the one or more tote handling systems configured to retrieve the first tote from the first stack of totes and insert the first tote in the frame tote stack during the tote retrieval sequence; and a second tote handling system of the one or more tote handling systems configured to hold a returning tote to be returned to the first stack of totes during the tote retrieval sequence.

3. The automated order fulfillment system of claim 1, wherein a first tote handling system, of the one or more tote handling systems, comprises: a first tote engaging system configured to extend from the frame, engage the first tote, and move the first tote into the frame by sliding the first tote off of a second tote, of the first stack of totes, upon which the first tote is supported and stacked.

4. The automated order fulfillment system of claim 3, wherein the robot control circuit is configured to control the first tote handling system, in moving the first tote into the frame, to move the first tote and one or more additional totes, which are in the first stack of totes and that are stacked upon and supported by the first tote at the time of retrieving the first tote, into the frame as an engaged substack.

5. The automated order fulfillment system of claim 4, wherein the robot control circuit is configured to control the first tote handling system to move the engaged sub-stack downward within the frame and align a third tote, of the engaged sub-stack and positioned above and supported by the first tote, relative to the second tote of the first stack of totes, and slide the third tote onto the second tote.

6. The automated order fulfillment system of claim 5, wherein the mobile robot further comprises a second tote handling system, of the one or more tote handling systems, communicatively coupled with the robot control circuit, wherein the robot control circuit is configured to control the second tote handling system to position a returning tote onto the engaged sub-stack before the third tote is returned to the first stack of totes so that the returning tote is also returned to the first stack of totes when the third tote is returned to the first stack of totes.

7. The automated order fulfillment system of claim 6, wherein the robot control circuit is configured to control the first tote handling system to vertically position and slide the first tote into the frame tote stack at a selected vertical position onto and directly supported by a fourth tote of the retrieved totes within the frame tote stack without an intervening support structure between the first tote and the fourth tote.

8. The automated order fulfillment system of claim 6, wherein the robot control circuit is configured to control the first tote handling system to engage and slide the returning tote from the frame tote stack prior to being positioned onto the engaged sub-stack, and move the returning tote into engagement with the second tote handling system.

9. The automated order fulfillment system of claim 5, wherein the mobile robot further comprises a second tote handling system of the one or more tote handling systems, communicatively coupled with the robot control circuit, wherein the robot control circuit is configured to control the secondtote handling system to slide a returning tote onto a top most tote of the first stack of totes before the first tote handling system slides the first tote into the frame.

10. The automated order fulfillment system of claim 1, wherein the one or more tote handling systems comprises a first tote handling system communicatively coupled with the robot control circuit, wherein the robot control circuit is configured to control the first tote handling system to vertically move within the frame, and vertically position and slide the first tote into the frame tote stack, at a selected vertical position of the frame tote stack, onto and directly supported by a second tote of the retrieved totes within the frame tote stack without an intervening support structure between the first tote and the second tote, wherein the selected vertical position is based on a predetermined sequencing of the retrieved totes in the frame tote stack.

11. The automated order fulfillment system of claim 10, further comprising: a workstation; wherein the robot control circuit is configured to control the transport system to transport the mobile robot between the storage area and the workstation, and control the first tote handling system to move the retrieved totes in the frame tote stack from the mobile robot to the workstation and the predetermined sequencing of the retrieved totes is based on a sequence for the retrieved totes to be processed through the workstation.

12. The automated order fulfillment system of claim 11, further comprising: a buffer tower cooperated with the workstation; wherein the robot control circuit, in controlling the first tote handling system to move the retrieved totes, is configured to control the first tote handling system to simultaneously move the retrieved totes in the frame tote stack into the buffer tower at the workstation.

13. The automated order fulfillment system of claim 10, wherein the robot control circuit, in controlling the first tote handling system when inserting the first tote into the frame tote stack at the selected vertical position of the frame tote stack, is configured to control the first tote handling system to: align with the frame tote stack adjacent the selected vertical position; engage a fourth tote, of the retrieved totes, at the selected vertical position;slide the fourth tote onto the first tote in the tote handling portion of the frame to form a combined stack, the combined stack comprising the first tote; and vertically move the combined stack relative to the selected vertical position and slide the combined stack into the frame tote stack with the first tote positioned at the selected vertical position.

14. The automated order fulfillment system of claim 13, wherein the robot control circuit is configured to control the first tote handling system to engage and slide a top retrieved tote from the frame tote stack into the tote handling portion after the first tote is positioned at the selected vertical position, move the top retrieved tote into engagement with a second tote handling system of the one or more tote handling systems, wherein the top retrieved tote is a returning tote to be returned to one of the stacks of totes.

15. The automated order fulfillment system of claim 13, wherein the one or more tote handling systems comprises a second tote handling system communicatively coupled with the robot control circuit, wherein the robot control circuit is configured to control the second tote handling system to vertically move within the tote handling portion and engage and slide a top retrieved tote from the frame tote stack into the tote handling portion, wherein the top retrieved tote is a returning tote to be returned to one of the stacks of totes during a next performance of the tote retrieval sequence.

16. The automated order fulfillment system of claim 1, comprising a first tote handling system of the one or more tote handling systems, wherein the robot control circuit is configured to control the first tote handling system to: vertically align a first tote engaging system of the first tote handling system with a lowest oriented retrieved tote of the frame tote stack; extend the first tote engaging system of the first tote handling system and engage the lowest oriented retrieved tote; retract the first tote engaging system, while engaged with the lowest oriented retrieved tote, and simultaneously move each of the retrieved totes of the frame tote stack from the storage portion; and simultaneously deposit, as a stack, each of the retrieved totes of the frame tote stack at a deposit location.

17. The automated order fulfillment system of claim 1, wherein each of the plurality of totes comprises upper stacking features and bottom stacking features, wherein the bottom stacking features are configured to align with and slidingly engage the upper stacking features of another tote of the plurality of totes establishing vertical and lateral alignment of the frame tote stack.

18. A method for automatic order fulfillment, comprising: controlling, through a robot control circuit of a mobile robot, a transport system of the mobile robot to self-propel through a storage area having stacks of totes, each stack comprising one or more of totes being vertically stacked on one another, and positioning the mobile robot proximate a first stack of totes, of the stacks of totes; engaging, by a first tote handling system cooperated with a storage portion of the mobile robot, a first tote of the first stack of totes that is instructed to be removed from the first stack of totes; retrieving, by the first tote handling system in implementing a tote retrieval sequence, the first tote from the first stack of totes; and positioning the first tote within the storage portion of the mobile robot as part of a frame tote stack of a set of one or more retrieved totes vertically stacked on one another within the storage portion and supported by the mobile robot.

19. The method of claim 18, further comprising: obtaining, by a second tote handling system of the mobile robot, a returning tote to be returned to the first stack of totes during the tote retrieval sequence.

20. The method of claim 18, wherein the retrieving the first tote from the first stack of totes comprises: extending a first tote engaging system, of the first tote handling system, from a frame of the mobile robot; retracting, following the engaging the first tote, the first tote engaging system and sliding the first tote off of a second tote, of the first stack of totes, upon which the first tote is supported and stacked; and moving the first tote into the frame.

21. The method of claim 20, wherein the sliding the first tote off of the second tote comprises:sliding the first tote and one or more additional totes, in the first stack of totes, that are stacked upon and supported by the first tote at the time of retrieving the first tote, including a third tote stacked directly on top of the first tote; and moving the one or more additional totes along with the first tote, as an engaged sub-stack.

22. The method of claim 21, further comprising: moving, via the first tote handling system, the engaged sub-stack downward within the frame and align the third tote, of the engaged sub-stack and positioned above and supported by the first tote, relative to the second tote of the first stack of totes; and sliding the third tote onto the second tote.

23. The method of claim 22, further comprising: positioning, by a second tote handling system, a returning tote onto the engaged sub-stack before the third tote is returned to the first stack of totes wherein the returning tote is returned to the first stack of totes when the third tote is returned to the first stack of totes.

24. The method of claim 23, further comprising: vertically positioning, by the first tote handling system, the first tote at a selected vertical position, relative to the frame tote stack; and sliding the first tote into the frame tote stack onto and directly supported by a fourth tote of the retrieved totes within the frame tote stack without an intervening support structure between the first tote and the fourth tote.

25. The method of claim 23, further comprising: engaging, by the first tote handling system, the returning tote while positioned with the frame tote stack; sliding the returning tote from the frame tote stack prior to being positioned onto the engaged sub-stack; and moving the returning tote into engagement with the second tote handling system.

26. The method of claim 22, further comprising:sliding, by a second tote handling system of the mobile robot, a returning tote onto a top most tote of the first stack of totes before the first tote handling system slides the first tote into the frame.

27. The method of claim 18, further comprising: vertically moving the first tote handling system within a frame of the mobile robot, and vertically positioning the first tote at a selected vertical position relative to the frame tote stack; and sliding the first tote into the frame tote stack onto and directly supported by a second tote of the retrieved totes within the frame tote stack without an intervening support structure between the first tote and the second tote.

28. The method of claim 27, further comprising: self-propelling, by the mobile robot, through the storage area to a workstation; and moving, by the first tote handling system, the retrieved totes in the frame tote stack from the mobile robot to the workstation.

29. The method of claim 28, wherein the moving the retrieved totes to the workstation comprises: simultaneously moving the retrieved totes in the frame tote stack into a buffer tower at the workstation.

30. The method of claim 27, wherein the vertically positioning the first tote at the selected vertical position relative to the frame tote stack comprises: aligning the first tote handling system with the frame tote stack adjacent the selected vertical position; engaging a fourth tote, of the retrieved totes, at the selected vertical position; sliding the fourth tote onto the first tote in a tote handling portion of the frame of the mobile robot and forming a combined stack, the combined stack comprising the first tote, the fourth tote; and vertically moving the combined stack relative to the selected vertical position and sliding the combined stack into the frame tote stack with the first tote positioned at the selected vertical position.

31. The method of claim 30, further comprising: engaging, by the first tote handling system, a top retrieved tote from the frame tote stack;sliding the top retrieved tote into the tote handling portion after the first tote is positioned at the selected vertical position; and moving the top retrieved tote into engagement with a second tote handling system of the mobile robot, wherein the top retrieved tote is a returning tote to be returned to one of the stacks of totes.

32. The method of claim 30, further comprising: vertically moving a second tote handling system within the tote handling portion to align with a top retrieved tote of the frame tote stack; engaging and sliding the top retrieved tote from the frame tote stack into the tote handling portion; and returning the top retrieved tote to one of the stacks of totes during a subsequent tote retrieval sequence.

33. The method of claim 18, further comprising: vertically aligning a first tote engaging system of the first tote handling system with a lowest oriented retrieved tote of the frame tote stack; extending the first tote engaging system of the first tote handling system and engaging the lowest oriented retrieved tote; retracting the first tote engaging system, while engaged with the lowest oriented retrieved tote, and simultaneously move each of the retrieved totes of the frame tote stack from the storage portion; and simultaneously depositing, as a stack, each of the retrieved totes of the frame tote stack at a deposit location.

34. The method of claim 18, wherein the positioning the first tote within the storage portion of the mobile robot as part of the frame tote stack comprises engaging bottom stacking features of the first tote with upper stacking features of a first retrieved tote of the frame tote stack and automatically aligning the first tote with the first retrieved tote by slidingly engaging the bottom stacking features of the first tote with the upper stacking features of the first retrieved tote in vertically and laterally aligning the first tote with the frame tote stack.

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