Automated storage and retrieval system with shared pathways for mobile robots and method

Abstract

There are provided systems and methods that involve arrangement of pathways at order fulfillment facilities. In one form, the system may include: an order fulfillment facility pathways; mobile robots moving along pathways; a first picking workstation at which items are transferred; a second picking workstation at which items are transferred; a dedicated product pathway for items being transferred to one of the workstations; a dedicated order pathway for items being transferred from one of the workstations; and one of the dedicated pathways may be a shared pathway for transferring items to or from both workstations.

Description

AUTOMATED STORAGE AND RETRIEVAL SYSTEMWITH SHARED PATHWAYS FOR MOBILE ROBOTS AND METHODCross-Reference to Related Application(sl

[0001] This application claims the benefit of and priority to U.S. Application 63 / 610,124, filed December 14, 2023, which is incorporated by reference in its entirety.Technical Field

[0002] This invention relates generally to an automated storage and retrieval system, and more particularly, to an automated storage and retrieval system with shared pathways to picking workstations.Background

[0003] Automated storage and retrieval systems (ASRS) are being used increasingly in the context of fulfilling merchandise orders. In some forms, these systems may include mobile robots that move about a storage structure at an order fulfillment facility to pick and transfer containers and items. There may be locations in the facility that are high traffic areas, such as at pathways to workstations where items for orders are transferred. In one aspect, it would be desirable to improve the traffic flow at and around workstations to increase the efficiency and speed of fulfilling orders.Brief Description of the Drawings

[0004] Disclosed herein are embodiments of systems, apparatuses and methods involving pathways at order fulfillment facilities, such as may be used in automated storage and retrieval systems. This description includes drawings, wherein:

[0005] FIG. 1 A is a perspective view of a picking workstation in accordance with some embodiments;

[0006] FIG. IB is a side view of the picking workstation of FIG. 1A in accordance with some embodiments;

[0007] FIG. 1 C is a top view of the picking workstation of FIG. 1 A in accordance with some embodiments;

[0008] FIG. ID is a front view of the picking workstation of FIG. 1A in accordance with some embodiments;

[0009] FIG. 2A is a perspective view of an order fulfillment facility in accordance with some embodiments;

[0010] FIG. 2B is a partial schematic view of the order fulfillment facility of FIG. 2A in accordance with some embodiments;

[0011] FIG. 3 A is a perspective view of the order fulfillment facility of FIG. 2A in accordance with some embodiments;

[0012] FIG. 3B is a perspective view of the order fulfillment facility of FIG. 2A in accordance with some embodiments;

[0013] FIG. 3C is a perspective view of the order fulfillment facility of FIG. 2A in accordance with some embodiments;

[0014] FIG. 3D is a schematic view of a portion of the order fulfillment facility of FIG. 2A in accordance with some embodiments;

[0015] FIG. 4 is a top view of a portion of an order fulfillment facility in accordance with some embodiments;

[0016] FIG. 5 is a top view of a portion of an order fulfillment facility in accordance with some embodiments;

[0017] FIG. 6 is a partial schematic view of the portion of the order fulfillment facility of FIG. 5 in accordance with some embodiments;

[0018] FIG. 7 is a partial schematic view of the portion of the order fulfillment facility of FIG. 5 in accordance with some embodiments;

[0019] FIG. 8 is a partial schematic view of the portion of the order fulfillment facility of FIG. 5 in accordance with some embodiments; and

[0020] FIG. 9 is a flow diagram in accordance with some embodiments.

[0021] 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 toimprove 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

[0022] 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 form,” “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 disclosure. Thus, appearances of the phrases “in one embodiment,” “in an embodiment,” “in some embodiments”, “in some implementations”, and similar language throughout this specification do not all refer to the same embodiment.

[0023] The terms “top” and “bottom,” “upper” and “lower” and “vertical” and “horizontal as may be used herein are by way of example and illustrative purposes only and are not meant to limit the description of the embodiments inasmuch as the referenced item can be exchanged in position and orientation. Also, as used herein, the terms "substantially" and / or "about" mean that the specified dimension or parameter may be varied within an acceptable manufacturing tolerance for a given application.

[0024] Generally speaking, pursuant to various embodiments, systems, apparatuses and methods are provided herein for an automated order fulfillment system. In one form, the system includes: an order fulfillment facility with a plurality of pathways; a plurality of mobile robots configured to move along the plurality of pathways at the order fulfillment facility; a first pickingworkstation at which items are configured to be transferred from product containers to order containers; a second picking workstation at which items are configured to be transferred from product containers to order containers; a dedicated product pathway along which a first set of mobile robots carrying product containers move to transport items in the product containers to one of the first picking workstation and second picking workstation; and a dedicated order pathway along which a second set of mobile robots carrying order containers move to transport items in the order containers from one of the first picking workstation and the second picking workstation, the items having been transferred to the order containers from product containers. Further, in the system, one of the dedicated product pathway and the dedicated order pathway is a shared pathway along which one or more mobile robots either: transport one or more items in a first product container to the first picking workstation and one or more items in a second product container to the second picking workstation; or transport one or more items in a first order container from the first picking workstation and one or more items in a second order container from the second picking workstation.

[0025] In some implementations, in the system, the order fulfillment facility includes a storage structure including a plurality of storage locations configured to store containers containing items, each storage location being accessible by a pathway; and the plurality of mobile robots are configured to access the plurality of storage locations to retrieve containers at the plurality of storage locations and transport them to at least one of the first picking workstation and the second picking workstation. In some implementations, the system further includes a buffer sequence structure, the buffer sequence structure comprising staging locations for containers being processed at the first picking workstation and the second picking workstation, the buffer sequence structure defining buffer lanes along the dedicated product pathway and the dedicated order pathway. In some implementations, the buffer sequence structure includes at least two levels of buffer lanes, mobile robots traveling in a first direction toward the first and second picking workstations on a first level and mobile robots traveling in a second, opposite direction away from the first and second picking workstations on a second level. In some implementations, each of the at least two levels includes a first end near the first or second picking workstations and a second end at a transit plane, the transit plane enabling travel of mobile robots between the storage structure and the buffer sequence structure. In some implementations, the shared pathway is ashared order pathway along which the one or more mobile robots move to transport the one or more items in the first order container from the first picking workstation and the one or more items in the second order container from the second picking workstation. In some implementations, a first dedicated product pathway is located to a first side of the shared order pathway, the first dedicated product pathway configured for movement of mobile robots transporting items to the first picking workstation. In some implementations, a second dedicated product pathway is located to a second side of the shared order pathway opposite the first side, the second dedicated product pathway configured for movement of mobile robots transporting items to the second picking workstation. In some implementations, a first dedicated order pathway is located adjacent the first dedicated product pathway, the first dedicated order pathway being located on a side of the first dedicated product pathway opposite the shared order pathway. In some implementations, a second dedicated order pathway is located adjacent the second dedicated product pathway, the second dedicated order pathway being located on a side of the second dedicated product pathway opposite the shared order pathway. In some implementations, positions of the first picking workstation and the second picking workstation are staggered relative to the shared pathway, the first picking workstation being disposed, at least in part, in front of the second picking workstation along the shared pathway. In some implementations, positions of the first picking workstation and the second picking workstation are staggered in elevation relative to one another, the first picking workstation being disposed, at least in part, at a higher elevation than the second picking workstation. In some implementations, a picker at one or both of the first and second picking workstations comprises a human operator or a robotic operator.

[0026] In another form, there is provided a method of fulfilling orders for items in an automated order fulfillment system. The method includes: by a first set of mobile robots, moving along a dedicated product pathway at an order fulfillment facility where the first set of mobile robots carry product containers to transport items in the product containers to one of a first picking workstation, at which items are configured to be transferred from product containers to order containers, and a second picking workstation, at which items are configured to be transferred from product containers to order containers; and by a second set of mobile robots, moving along a dedicated order pathway at the order fulfillment facility where the second set of mobile robots carry order containers to transport items in the order containers from one of the first pickingworkstation and the second picking workstation, the items having been transferred to the order containers from product containers. Further, in the method, one of the dedicated product pathway and the dedicated order pathway is a shared pathway along which one or more mobile robots either: transport one or more items in a first product container to the first picking workstation and one or more items in a second product container to the second picking workstation; or transport one or more items in a first order container from the first picking workstation and one or more items in a second order container from the second picking workstation.

[0027] In some implementations, with respect to the method, the order fulfillment facility includes a storage structure including a plurality of storage locations configured to store containers containing items, each storage location being accessible by a pathway; and a plurality of mobile robots are configured to access the plurality of storage locations to retrieve containers at the plurality of storage locations and transport them to at least one of the first picking workstation and the second picking workstation. In some implementations, the shared pathway is a shared order pathway along which the one or more mobile robots move to transport the one or more items in a first order container from the first picking workstation and the one or more items from the second order container from the second picking workstation. In some implementations, a first dedicated product pathway is located to a first side of the shared order pathway, the first dedicated product pathway configured for movement of mobile robots transporting items to the first picking workstation; and a second dedicated product pathway is located to a second side of the shared order pathway opposite the first side, the second dedicated product pathway configured for movement of mobile robots transporting items to the second picking workstation. In some implementations, a first dedicated order pathway is located adjacent the first dedicated product pathway, the first dedicated order pathway being located on a side of the first dedicated product pathway opposite the shared order pathway; and a second dedicated order pathway is located adjacent the second dedicated product pathway, the second dedicated order pathway being located on a side of the second dedicated product pathway opposite the shared order pathway. In some implementations, positions of the first picking workstation and the second picking workstation are staggered relative to the shared pathway, the first picking workstation being disposed, at least in part, in front of the second picking workstation along the shared pathway. In some implementations, positions of the first picking workstation and the second picking workstation arestaggered in elevation relative to one another, the first picking workstation being disposed, at least in part, at a higher elevation than the second picking workstation.

[0028] In one aspect, and without limitation, this disclosure is directed generally to a facility, such as an order fulfillment facility, that includes multiple mobile robots that operate to pick and transfer containers in the context of an automated storage and retrieval system. In one form, mobile robots move about the facility and retrieve containers (for example, totes) of items (such as retail goods) that are stored in specific storage locations in the facility, as part of the automated storage and retrieval system. It has been found that there are locations in the facility that are high traffic areas, such as at pathways (for example, aisles) to picking workstations where pickers (human or robotic operators) transfer items for orders. In one aspect, this disclosure seeks to improve the traffic flow at and around the picking workstations to increase the efficiency and speed of fulfilling orders.

[0029] In one aspect, and without limitation, this disclosure relates to the flow of order containers (sometimes referred to as order totes or O-totes) and purchase containers (sometimes referred to as purchase totes, product totes, product containers, or P-totes) to picking workstations. At the workstations, a picker will preferably transfer one or more items from a purchase container to an order container. There may be a dedicated pathway for movement of mobile robots with purchase containers and a separate dedicated pathway for movement of mobile robots with order containers. In one aspect, this disclosure provides an architecture with a common purchase container aisle or a common order container aisle for adjacent picking workstations. In some forms, it has been found that multiple product containers are required for a single order container such that the order container traffic may be much less than the product container traffic. In this instance, it may be desirable to use shared order container pathways that service adjacent picking workstations. This architecture may result in a reduced footprint of the structure and may improve efficiency in the flow of mobile robots to and from the picking workstations.

[0030] Referring now to FIG. 1A, there is shown a perspective view of one example of a picking workstation 10. Referring to FIG. IB, there is shown a side view of the picking workstation 10. Referring also to FIG. 1C, there is shown a top view of the picking workstation 10. Referring next to FIG. ID, there is shown a front view of the picking workstation 10. In this form, picking workstation 10 has ramps that support mobile robots 12, 14 where mobile robots 12, 14 themselvesclimb through the workstation, and where the only moving parts may be the mobile robots 12, 14 and the pickers 16 hands 18. Here, product and order containers 20, 22 are provided where the operator 16 is directed by a light directed pick and put system 24 and where the light directed pick and put system highlights products to be moved from product containers to order containers and where a GUI 26 may further be provided. In the disclosed embodiment, mobile robots containing product and order containers are circulated through the workstation from one level to another where the operator fulfills orders of combinations of eaches in order containers by drawing from one or more of the product containers as directed by the light directed pick / put system. This picking workstation 10 is just one example of a workstation that may be used herein. Examples of workstations and methods are disclosed in U.S. Patent Application Publication No. 2021 / 0241217, which is incorporated herein by reference in its entirety.

[0031] FIG. 2A shows a perspective view of one example of an order fulfillment facility 100 showing a storage structure 102 including a number of bays 104 of storage locations 106. The bays 104 each include a y-z array of storage locations 106 in horizontal rows and level changing towers along the rows which in embodiments may be vertical towers. Mobile robots 130 may travel between storage levels in the z-direction within the level changing towers. The pairs of bays 104 that are arranged to face each other, separated by aisles 108. An aisle 108 may have a width such that a mobile robot 130 traveling within an aisle 108 may transfer containers to the bays 104 on either side of the aisle 108.

[0032] The order fulfdlment facility 100 includes decks 112 spaced apart at different vertical levels of the storage structure 102. The decks 112 may be arranged in pairs and extend between the aisles so that robots 130 can maneuver in the x-y plane of each deck to travel between different aisles. The order fulfillment facility 100 also includes an express deck 116 arranged to extend between the aisles so that robots 130 can maneuver in the x-y plane to travel between different aisles. Decks 112 may be provided for transit of mobile robots 130 between aisles or for transit of mobile robotsl30 between aisles and workstations (such as workstations 115). Here, express deck(s) 116 may be provided for x-direction movement, transit deck(s) 112 may be provided for workstation return and transit deck(s) 112 may be provided for staging and sequencing locations (buffer locations) feeding workstations.

[0033] FIG. 2A also shows examples of workstations 115. Each workstation is equipped to receive pairs of mobile robots. A first mobile robot at a station carries a product container, in combination with successive mobile robots with items for fulfilling product requests to make up an order. A second mobile robot at the station carries an order container, in combination with successive mobile robots as required, within which items from the product containers are placed to fulfill product requests to make up an order having one or more order containers. Workers at a workstation manually transfer items from a product container to an order container under guidance of an inventory control system at the workstation.

[0034] As noted above, the order fulfillment facility 100 may further include a number of mobile robots 130 for transferring containers or other product or order containers to and from workstations 115 and storage locations 106 in the bays 104. The mobile robots 130 may be self- guided and / or rail-guided so as to move horizontally and vertically within aisles 108 to transfer containers or other product containers between the mobile robots 130 and storage locations 106. For example, a track system including horizontal rails may be affixed to the bays 104 at different vertical levels. The horizontal rails provide access to storage shelves on either side of an aisle 108 in the x-direction on a given level. The bays 104 include vertical level changing towers 122 within which the mobile robots may travel vertically in the z-direction between levels of storage locations 106.

[0035] FIG. 2B shows a partial view of the order fulfillment facility 100 that includes a storage structure 102 and workstations 115. The mobile robots 130 (not shown) attempt to traverse at a steady flow between any storage location within the storage structure 102 and any workstation 115. The mobile robots 130 can maneuver in the x-y plane of each deck 112 resulting in congestion 121 of the mobile robots at the workstations 115. The congestion 121, if not managed, may reduce the overall efficiency of the order fulfillment facility 100. A challenge in a discrete pick design is the sequenced, steady flow of product from any location in the storage block 102 to any workstation 151 where the flow of product must be efficiently sequenced with steady flow to and from any location in the facility 100.

[0036] Further details of the workstations, storage structure and mobile robot which may be used are described for example in the following U.S. patents and patent application publications: U.S. Patent No. 9,139,363; U.S. PatentNo. 10,435,241; U.S. PatentNo. 11,142,398;and U.S. Patent Application Publication No. 2023 / 0095494. Each of these patents and published applications are incorporated by reference herein in their entirety.

[0037] FIGS. 3A-3D are schematic illustrations and perspective views of the order fulfillment facility 100 in one form. Although the aspects of this form will be described with reference to the drawings, it should be understood that these aspects can be embodied in many forms. In addition, any suitable size, shape or type of elements or materials could be used. It is also noted that while X, Y and Z axis are referred to, reference of these axes may have any suitable directional identifiers. Referring to FIGS. 3A-3D, the order fulfillment facility 100 may include a storage structure 102, transit deck pairs 117, staging and sequencing towers 120 and workstations 115. The storage structure 102 may include a number of bays 104 of storage locations 106. The bays 104 each may include an y-z array of storage locations 106 and horizontal rows and level changing towers 122 along the rows which in embodiments may be vertical towers. The transit deck pairs 117 may extend between the aisles 108 so that the mobile robots 130 (not shown) can maneuver in the x-y plane providing one way transit of the mobile robots 130 between the storage structure 102 and the staging and sequencing towers 120. Here, decks 117 may be narrow, oneway transit decks to segment z-axis and x-axis throughput volumes yielding a compact design with maintenance access from a platform. The staging and sequencing towers 120 may have staging or storage shelves 124 similar to those storage locations 106 and vertical level changing towers 125. In one aspect, staging or storage locations 124 may be located on both sides of the vertical level changing towers 125 and in alternative embodiments the staging locations 124 may be located on either side of the vertical level changing towers 125. The workstations 115 may be located at the ground level of the staging sequencing towers 120 and may be configured to receive the mobile robots 130 from the staging and sequencing towers 120. In alternative embodiments, the workstations 115 may be interfaced with the staging and sequencing towers 120 at any level. The workstations 115 may be configured to receive the mobile robots 130 from the staging and sequencing towers 120 and return the mobile robots 130 to the storage structure 102 via secondary vertical level changing towers 128 and the transit deck pairs 117. Here, the staging and sequencing towers 120 are coupled to respective workstations 115 to remove sequencing constraints from the storage structure 102. In the embodiment shown, multiple transit planes 117 are provided to spread throughput over multiple levels. Further, the buffer / sequencer 120 may connect workstations 115to the transit planes 117 and allows the subsystems to work substantially independent of one another as will be described in greater detail.

[0038] Referring now to FIG. 3B, the storage structure 102 of the order fulfillment facility 100 may be divided into multiple zones 119. Dividing throughput across multiple zones removes 1 / 0 constraints from the storage system and increases throughput capacity. Each zone 119 may be a three-dimensional array of storage locations 106. In one aspect, the zone 119 may be a 13x6x16 array and in alternative embodiments the zone 119 may be of any suitable size. Each zone 119 may have one set of transit deck pairs 117 and in alternative embodiments each zone 119 may have any suitable number of transit deck pairs 117. Here, 2 X axis planes are shown provided within a tier group of 6 levels. Further, within the same cluster (8 aisles with 6 levels), the decks provide redundancy as needed to go between clusters. As the direction of opposing x flows is dedicated by deck pair 117 as shown, there are no sequence restrictions or timing constraints within this subsystem providing a significant division of throughput resulting in single, bi-directional vertical towers.

[0039] Referring now to FIG. 3C, a path Pl or P2 may be established for a mobile robot 130 (not shown) that flows from any location 106 in the storage structure 102 to any workstation 115 or from any workstation 115 to any location 106 in the storage structure 102. For example, path Pl begins at a location 106 within zone 119a, aisle 2, and then progresses to vertical level changing tower 122, then to the lower transit deck 117 of zone 119a, then to vertical level changing tower 125 and ending at the workstation 115. Path P2 begins at workstation 115, and then progresses to vertical level changing tower 125, then to lower transit deck 117 of zone 119b, then to vertical level changing tower 122 and ending at a location 106 within zone 119b, aisle 7. The paths Pl and P2 may be followed by a mobile robot 130 where the mobile robot 130 may be carrying a product container or an order container. As discussed above and shown by paths Pl and P2, the mobile robot 130 may only traverse in one direction while on the transit deck 117. The same paths Pl and P2 may be traversed by a single mobile robot at different times, or the paths Pl and P2 may be followed by two different mobile robots at the same time.

[0040] Referring now to FIG. 3D, in one aspect, the mobile robot 130 may transition from the staging and sequencing towers 120 over a transit deck 117 and onto the vertical level changing tower 122 at any desired aisle 108 within the storage structure 102. The vertical level changingtower 122 may position the mobile robot 130 in the Z direction at any desired level and the mobile robot 130 may transition down the aisle 108 to any desired location 106 within the storage structure 102.

[0041] Accordingly, in some forms, there is disclosed an order fulfdlment facility 100 with pathways 108 through the facility 100, which may be in the form of aisles, and mobile robots 130 move along these pathways 108. The order fulfillment facility 100 preferably includes a storage structure 102 with storage locations 106 that store containers containing items, and each storage location 106 is accessible by a pathway 108. The mobile robots 130 are configured to access the storage locations 106 to retrieve containers at the storage locations 106 and to transport them to the workstations.

[0042] The order fulfilment facility 100 described above is one example of a facility 100 where mobile robots 130 move about the facility 100 engaged in certain tasks. A relatively large number of mobile robots 130 tend to approach the workstations, thereby creating a high traffic area. There are a limited number of pathways 108 that the mobile robots 130 can travel along to reach the workstations. In one aspect, approaches described in this disclosure involve creating an efficient use of the pathways 108 around the workstations so as to facilitate the work being performed by pickers at the workstations. The pickers generally transfer items from product containers to order containers and may be human or robotic operators.

[0043] FIG. 4 shows an example of an automated order fulfillment system 200 that includes pathways 202 approaching picking workstations 204. In this example, mobile robots 206 with containers may travel from a storage structure to a transit plane / deck 208 after having retrieved items in the containers at the storage structure. The mobile robots 206 may travel from the transit plane 208 to a buffer sequence structure 210 (which may, for example and without limitation, be in the form of a tower structure). It is generally contemplated that the buffer sequence structure 210 may act as a staging area for mobile robots 206 moving to the picking workstations 204 in which certain mobile robots 206 may be prioritized in some manner. Mobile robots 206 may move vertically in level changing towers and may stop at certain positions while waiting for the next available tower or for a picking workstation. This buffer sequence structure 210 was described generally above, and various embodiments are also described in U.S. Patent Application Publication No. 2023 / 0095494, which was previously mentioned and which isincorporated by reference herein in its entirety. Tn this form, as can be seen from FIG. 4, there is one dedicated product pathway (or product container pathway) 202A and one dedicated order pathway (or order container pathway) 202B for each picking workstation 204.

[0044] FIGS. 5-8 shows another example of an automated order fulfillment system 300 that includes pathways 302 approaching picking workstations 304. In this form, as shown in FIG. 5, there is a first picking workstation 304A at which a first picker transfers items from product containers to order containers and a second picking workstation 304B at which a second picker transfers items from product containers to order containers. In addition, the system 300 includes a dedicated product pathway 302A along which a first set of mobile robots 306 carrying product containers move to transport items in the product containers to one of the first picking workstation 304A and second picking workstation 304B. Further, the system 300 includes a dedicated order pathway 302B along which a second set of mobile robots 306 carrying order containers move to transport items in the order containers from one of the first picking workstation 304A and the second picking workstation 304B, the items being transferred to the order containers from product containers. In some forms, product and order containers may move to and from the picking workstations along their respective pathways but with some or all of the to-and-from movement at different elevational levels.

[0045] In this example, however, it is contemplated that one of the pathways 302A, 302B will be shared by mobile robots 306 traveling to either the first picking workstation 304A or the second picking workstation 304B. In other words, one of the dedicated product pathway 302A and the dedicated order pathway 302B is a shared pathway along which one or more mobile robots 306 either: (1) transport one or more items in a first product container to the first picking workstation 304A and one or more items in a second product container to the second picking workstation 304B; or (2) transport one or more items in a first order container from the first picking workstation 304A and one or more items in a second order container from the second picking workstation 304B. In this example, the shared pathway is the order pathway 302B. It may have been determined, for instance, that fewer mobile robots 306 generally travel order pathways, so they can share a pathway 302B that services both the first and second picking workstations 304A, 304B. Although in this example the shared pathway is an order pathway, it is also contemplated that, in other circumstances, it may be desirable to make the shared pathway a product order pathway in whichmobile robots 306 carrying product containers use the same pathway to access first and second picking workstations 304A, 304B.

[0046] FIG. 5 shows a shared order pathway in a P-O-P configuration. In this form, the the shared pathway is a shared order pathway 302B along which mobile robots 306 move to transport item(s) in the first order container from the first picking workstation 304A and item(s) in the second order container from the second picking workstation 304B. In other words, the order pathway is shared by mobile robots 306 with order containers accessing both picking workstations. In the P-O-P configuration, a first dedicated product pathway 312 is located to a first side of the shared order pathway with the first dedicated product pathway 312 being configured for movement of mobile robots 306 transporting items to the first picking workstation 304A. Further, in this configuration, a second dedicated product pathway 314 is located to a second side of the shared order pathway 302B opposite the first side with the second dedicated product pathway 314 being configured for movement of mobile robots 306 transporting items to the second picking workstation 304B. This P-O-P configuration results in space savings in that three pathways can service two picking workstations, while under the P-O-P-O configuration of Figure 4, there would be four pathways servicing two picking workstations. In one form, this P-O-P configuration involving two workstations may be repeated (P-O-P-P-O-P . .. ) for additional pairs of workstations that may be in the same area.

[0047] Further, in one form, as can be seen in FIG. 5, the system 300 may include a buffer sequence structure 310 (as described above) having staging locations for containers being processed at the first picking workstation 304A and the second picking workstation 304B. The buffer sequence structure 310 may define buffer lanes 316 along the dedicated product pathway 302A and the dedicated order pathway 302B. In one form, as shown in FIG 8, the buffer sequence structure 310 may include at least two different levels (or elevations) of buffer lanes 316 with the mobile robots 306 traveling in a first direction toward either or both of the first and second picking workstations 304A, 304B on a first level 318 and the mobile robots 306 traveling in a second, opposite direction away from the first and second picking workstations 304A, 304B on a second level 320. In one form, these elevations may be at different heights for different workstations. These levels may include a first end near the first or second picking workstations 304A, 304B anda second end at a transit plane 308 with the transit plane 308 enabling travel of the mobile robots 306 between the storage structure 102 and the buffer sequence structure 310.

[0048] FIGS. 6 and 7 show a variation of the arrangement in FIG. 5. As stated above, the P-O-P configuration in FIG. 4 may be repeated for each pair of workstations. FIGS. 6 and 7, however, show an alternative O-P-O-P-O configuration in which the pathways on the outsides of the P-O-P configurations are order pathways. This O-P-O-P-O configuration may be desirable to provide more bagging and placement freedom for pickers at the picking workstations. Under this configuration, pickers will be able to transfer items from a purchaser container to one of two order containers. This choice may be desirable in certain circumstances.

[0049] As can be seen from FIGS. 6 and 7, the O-P-O-P-O configuration initially utilizes the P-O-P configuration described above. Then, a first dedicated order pathway 322 is located adjacent the first dedicated product pathway 312 with the first dedicated order pathway 322 being located on a side of the first dedicated product pathway 312 opposite the shared order pathway 302B. Similarly, a second dedicated order pathway 324 is located adjacent the second dedicated product pathway 314 with the second dedicated order pathway 324 being located on a side of the second dedicated product pathway 314 opposite the shared order pathway 302B. In one form, one or both of these first and second dedicated order pathways 322, 324 may also be shared order pathways, but that is not required. In one form, as described above, it is contemplated that a buffer sequence structure 310 may be used, and FIGS. 6 and 7 show an end of such a structure 310 (buffer sequence tower (BST) south most frame array).

[0050] In one form, as shown in FIGS. 6 and 7, it is contemplated that the picking workstations 304A, 304B are staggered in the down aisle direction. More specifically, the positions of the first picking workstation 304A and the second picking workstation 304B are staggered relative to the shared pathway 302B with the first picking workstation 304A being disposed, at least in part, in front of the second picking workstation 304B along the shared pathway 302B. This down aisle staggering may provide more spacing between adjacent pickers and workstations and / or may help limit the queuing of mobile robots 306 with containers.

[0051] In addition, it is also contemplated that the mobile robots 306 may include a tote transfer mechanism by which the mobile robots 306 may transfer the order containers (or totes) laterally to a designated transfer position closer to the picker, as can be seen in FIGS. 6 and 7. Thistransfer reduces the distance the picker has to reach to place an item in the order container. Further, it is contemplated that the mobile robot 306 may transfer the order container back to its original position on the mobile robot 306 after one or more items have been transferred to the order container by the picker. Alternatively, in another form, it is contemplated that the mobile robot 306 may leave the order container at the designated transfer position to be retrieved later by a different mobile robot 306. An example of a tote transfer mechanism that may be used herein is described in U.S. Published Patent Application No. 2017 / 0313514, which is incorporated by reference herein in its entirety.

[0052] Further, as shown in FIG. 8, the picking workstations 304 A, 304B may be staggered vertically. In other words, the first picking workstation 304A and the second picking workstation 304B may be staggered in elevation relative to one another with the first picking workstation being disposed 304A, at least in part, at a higher elevation than the second picking workstation 304B. This vertical staggering may be in addition to, or as an alternative to, the down aisle staggering described above. Again, this vertical staggering may provide more spacing between adjacent pickers and workstations and / or may help limit the queuing of mobile robots 306 with containers.

[0053] FIG. 9 shows a process 400 of fulfilling orders for items in an automated order fulfillment system. It is generally contemplated that the process 400 may involve some or all of the components of the facility 100 and may involve some or all of the features of the automated order fulfillment system 300. The above descriptions of the facility 100, automated order fulfillment system 300, and other features and components are generally incorporated herein.

[0054] At block 402, mobile robots are provided that move about a facility, such as an order fulfillment. The mobile robots move along pathways at the facility with a guide system for facilitating their movement along the pathways, such as aisles. It is generally contemplated that, in one aspect, the mobile robots are transporting containers of items, such as retail goods, for orders that are being fulfilled

[0055] At block 404, the mobile robots access storage locations at the facility and retrieve containers. In one form, it is contemplated that the order fulfillment facility may be a storage structure that includes storage locations configured to store containers that may each contain a particular type of time with each storage location being accessible by pathway(s). Further, the mobile robots may access the storage locations to retrieve containers (such as product containers)at the storage locations and transport them to the picking workstations. In one form, the mobile robots may travel from the storage structure to a transit plane (or deck) to a buffer sequence structure. The buffer sequence tower may act as a staging location for mobile robots with containers and may prioritize mobile robots arriving at the picking workstations.

[0056] At block 406, a first mobile robot may move along a first dedicated product pathway to a first picking workstation. In this form, this first mobile robot carries a first product container transporting items in the first product container to the first picking workstation. The first picking workstation is configured so that items from the first product container are transferred to a first order container.

[0057] At block 408, a second mobile robot may move along a second dedicated product pathway to a second picking workstation. In this form, the second mobile robot carries a second product container transporting items in the second product container to the second picking workstation. The second picking workstation is configured so that items from the second product container are transferred to a second order container. The first and second mobile robots may be part of a first set of mobile robots that deliver their product containers to either the first picking workstation or the second picking workstation via the first dedicated product pathway and the second product pathway, respectively.

[0058] At block 410, a third mobile robot may move along a dedicated and shared order pathway from the first picking workstation. In this form, the third mobile robot may carry a first order container from the first picking workstation. As stated, the first picking workstation is configured so that item(s) have been transferred to the first order container from product container(s), such as the first and second product containers.

[0059] At block 412, a fourth mobile robot may move along the dedicated and shared order pathway from the second picking workstation. In this form, the fourth mobile robot may carry a second order container from the second picking workstation. As stated, the second picking workstation is configured so that item(s) have been transferred to the second order container from product container(s), such as the first and second product containers. The third and fourth mobile robots may be part of a second set of mobile robots that retrieve their order containers from the first picking workstation and from the second picking workstation via the same, shared order pathway.

[0060] As described above, the two dedicated product pathways and the shared order pathway may be arranged according to a P-O-P configuration or architecture. This arrangement may be desirable, for example, where there are fewer order containers than purchase containers moving to and from the picking workstations. This P-O-P configuration may be repeated for additional picking workstations, i.e., more than two picking workstations. Although a shared order pathway has been described, it should be understood that a shared product pathway may be arranged instead. In other words, two dedicated order pathways and a dedicated and shared product pathway may be arranged according to an O-P-O configuration or architecture.

[0061] As shown at blocks 414 and 416, in one form, the pathway configuration may be arranged as an O-P-O-P-O architecture. This architecture may be accomplished by adding two additional order pathways to the ends of the P-O-P configuration. At block 414, a fifth mobile robot may move along a first dedicated order pathway adjacent to the first dedicated product pathway (and on an opposite side from the shared order pathway). It is generally contemplated that, in this form, the fifth mobile robot may carry another order container from the first picking workstation.

[0062] At block 416, a sixth mobile robot may move along a second dedicated order pathway adjacent to the second dedicated product pathway (and on an opposite side from the shared order pathway). It is generally contemplated that, in this form, the sixth mobile robot may carry another order container from the second picking workstation. One or both of the second and third order pathways may be shared order pathways, although that is not required. In addition, although an O-P-O-P-O configuration has been described, it should be understood that a corresponding P-O-P-O-P arrangement may be desirable in some circumstances.

[0063] At block 418, mobile robots may be transported to an order pickup area. It is generally contemplated that, once an order container contains a completed order, the order container may then be transported by the mobile robot to an order pickup area. It may then be further handled and processed at this location in the facility for ultimate transfer of the ordered items to a customer or other individual or entity placing the order.

[0064] 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 embodimentswithout 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.

Claims

CLAIMSWhat is claimed is:

1. An automated order fulfillment system comprising: an order fulfillment facility with a plurality of pathways; a plurality of mobile robots configured to move along the plurality of pathways at the order fulfillment facility; a first picking workstation at which items are configured to be transferred from product containers to order containers; a second picking workstation at which items are configured to be transferred from product containers to order containers; a dedicated product pathway along which a first set of mobile robots carrying product containers move to transport items in the product containers to one of the first picking workstation and second picking workstation; and a dedicated order pathway along which a second set of mobile robots carrying order containers move to transport items in the order containers from one of the first picking workstation and the second picking workstation, the items having been transferred to the order containers from product containers; wherein one of the dedicated product pathway and the dedicated order pathway is a shared pathway along which one or more mobile robots either: transport one or more items in a first product container to the first picking workstation and one or more items in a second product container to the second picking workstation; or transport one or more items in a first order container from the first picking workstation and one or more items in a second order container from the second picking workstation.

2. The system of claim 1 wherein:the order fulfillment facility comprises a storage structure including a plurality of storage locations configured to store containers containing items, each storage location being accessible by a pathway; and the plurality of mobile robots are configured to access the plurality of storage locations to retrieve containers at the plurality of storage locations and transport them to at least one of the first picking workstation and the second picking workstation.

3. The system of claim 2, further comprising a buffer sequence structure, the buffer sequence structure comprising staging locations for containers being processed at the first picking workstation and the second picking workstation, the buffer sequence structure defining buffer lanes along the dedicated product pathway and the dedicated order pathway.

4. The system of claim 3, wherein the buffer sequence structure comprises at least two levels of buffer lanes, mobile robots traveling in a first direction toward the first and second picking workstations on a first level and mobile robots traveling in a second, opposite direction away from the first and second picking workstations on a second level.

5. The system of claim 4, wherein each of the at least two levels comprises a first end near the first or second picking workstations and a second end at a transit plane, the transit plane enabling travel of mobile robots between the storage structure and the buffer sequence structure.

6. The system of claim 1, wherein the shared pathway is a shared order pathway along which the one or more mobile robots move to transport the one or more items in the first order container from the first picking workstation and the one or more items in the second order container from the second picking workstation.

7. The system of claim 6, wherein a first dedicated product pathway is located to a first side of the shared order pathway, the first dedicated product pathway configured for movement of mobile robots transporting items to the first picking workstation.

8. The system of claim 7, wherein a second dedicated product pathway is located to a second side of the shared order pathway opposite the first side, the second dedicated product pathway configured for movement of mobile robots transporting items to the second picking workstation.

9. The system of claim 8, wherein a first dedicated order pathway is located adjacent the first dedicated product pathway, the first dedicated order pathway being located on a side of the first dedicated product pathway opposite the shared order pathway.

10. The system of claim 9, wherein a second dedicated order pathway is located adjacent the second dedicated product pathway, the second dedicated order pathway being located on a side of the second dedicated product pathway opposite the shared order pathway.

11. The system of claim 1, wherein positions of the first picking workstation and the second picking workstation are staggered relative to the shared pathway, the first picking workstation being disposed, at least in part, in front of the second picking workstation along the shared pathway.

12. The system of claim 1, wherein positions of the first picking workstation and the second picking workstation are staggered in elevation relative to one another, the first picking workstation being disposed, at least in part, at a higher elevation than the second picking workstation.

13. The system of claim 1, wherein a picker at one or both of the first and second picking workstations comprises a human operator or a robotic operator.

14. A method of fulfilling orders for items in an automated order fulfillment system, the method comprising: by a first set of mobile robots, moving along a dedicated product pathway at an order fulfillment facility where the first set of mobile robots carry product containers to transport itemsin the product containers to one of a first picking workstation, at which items are configured to be transferred from product containers to order containers, and a second picking workstation, at which items are configured to be transferred from product containers to order containers; by a second set of mobile robots, moving along a dedicated order pathway at the order fulfillment facility where the second set of mobile robots carry order containers to transport items in the order containers from one of the first picking workstation and the second picking workstation, the items having been transferred to the order containers from product containers; wherein one of the dedicated product pathway and the dedicated order pathway is a shared pathway along which one or more mobile robots either: transport one or more items in a first product container to the first picking workstation and one or more items in a second product container to the second picking workstation; or transport one or more items in a first order container from the first picking workstation and one or more items in a second order container from the second picking workstation.

15. The method of claim 14 wherein: the order fulfillment facility comprises a storage structure including a plurality of storage locations configured to store containers containing items, each storage location being accessible by a pathway; and a plurality of mobile robots are configured to access the plurality of storage locations to retrieve containers at the plurality of storage locations and transport them to at least one of the first picking workstation and the second picking workstation.

16. The method of claim 14, wherein the shared pathway is a shared order pathway along which the one or more mobile robots move to transport the one or more items in a first order container from the first picking workstation and the one or more items from the second order container from the second picking workstation.

17. The method of claim 16, wherein:a first dedicated product pathway is located to a first side of the shared order pathway, the first dedicated product pathway configured for movement of mobile robots transporting items to the first picking workstation; and a second dedicated product pathway is located to a second side of the shared order pathway opposite the first side, the second dedicated product pathway configured for movement of mobile robots transporting items to the second picking workstation.

18. The method of claim 17, wherein: a first dedicated order pathway is located adjacent the first dedicated product pathway, the first dedicated order pathway being located on a side of the first dedicated product pathway opposite the shared order pathway; and a second dedicated order pathway is located adjacent the second dedicated product pathway, the second dedicated order pathway being located on a side of the second dedicated product pathway opposite the shared order pathway.

19. The method of claim 14, wherein positions of the first picking workstation and the second picking workstation are staggered relative to the shared pathway, the first picking workstation being disposed, at least in part, in front of the second picking workstation along the shared pathway.

20. The method of claim 14, wherein positions of the first picking workstation and the second picking workstation are staggered in elevation relative to one another, the first picking workstation being disposed, at least in part, at a higher elevation than the second picking workstation.

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