In-rack transit plane automatic storage and retrieval systems and methods

Abstract

Some embodiments provide automated order fulfilment systems, comprising: a storage structure comprising: levels; storage level changing structures establishing vertical pathways; a plurality of aisles comprising tracks configured to be utilized by mobile robots to move along the aisle; storage locations configured to each store one of multiple containers; and multiple sets of in-rack transit planes (IRTP) interspersed within the storage structure and spaced from each other along a first dimension of the storage structure, wherein each of the multiple sets of IRTPs comprises two or more IRTPs vertically spaced with each IRTP positioned in one of the levels; and workstations each configured to accept and dispense the multiple containers, wherein the workstations are distributed along the storage structure, and wherein at least one IRTP of each set of IRTPs of the multiple sets of IRTPs is proximate one or more of the workstations.

Description

IN-RACK TRANSIT PLANE AUTOMATIC STORAGE AND RETRIEVALSYSTEMS AND METHODSCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application No. 63 / 627,520 filed January 31, 2024, which is incorporated herein by reference in its entirety.TECHN ICAL FI ELD

[0002] This invention relates generally to automated inventory control, storage and retrieval.BACKGROU N D

[0003] The management of inventory can be critical to the operation of many industries. Some industries use systems to move inventory. There is a need to improve the control and distribution of inventory.BRI EF DESCRI PTION OF DRAWI NGS

[0004] Disclosed herein are embodiments of systems, apparatuses and methods pertaining automated inventory control, storage and retrieval. This description includes drawings, wherein:

[0005] FIG. 1 illustrates a simplified block diagram, perspective view of at least a portion of an exemplary automated order fulfilment system, in accordance with some embodiments.

[0006] FIG. 2 illustrates a simplified block diagram, overhead view of a portion of an exemplary automated order fulfillment system, in accordance with some embodiments.

[0007] FIG. 3 illustrates a simplified block diagram, side view of a portion of an exemplary automated order fulfillment system, in accordance with some embodiments.

[0008] FIG. 4 illustrates a simplified block diagram, cross-sectional view of a portion of an exemplary automated order fulfillment system, in accordance with some embodiments.

[0009] FIG. 5, illustrates a simplified block diagram, overhead cross-sectional view of a portion of an exemplary storage structure, in accordance with some embodiments.

[0010] FIG. 6 illustrates a simplified block diagram, side view of a portion of an exemplary storage structure, in accordance with some embodiments.

[0011] FIG. 7 illustrates a simplified block diagram, overhead cross-sectional view of a portion of an exemplary storage structure, in accordance with some embodiments.

[0012] FIG. 8 illustrates a simplified block diagram, cross-sectional view of a portion of an exemplary automated order fulfillment system, in accordance with some embodiments.

[0013] FIG. 9 illustrates a simplified block diagram, cross-sectional view of a portion of an exemplary automated order fulfillment system, in accordance with some embodiments.

[0014] FIG. 10 illustrates a simplified perspective view of a portion of a storage structure of an order fulfillment system with a workstation coupled with and / or incorporated within the storage structure, in accordance with some embodiments.

[0015] FIG. 11 illustrates a simplified cross-sectional, overhead view of a portion of an exemplary storage structure, in accordance with some embodiments.

[0016] FIG. 12 illustrates a simplified block diagram, cross-sectional view of a portion of an exemplary automated order fulfillment system, in accordance with some embodiments.

[0017] FIG. 13 illustrates a simplified block diagram, overhead cross-sectional view of an exemplary order fulfillment system, in accordance with some embodiments.

[0018] FIG. 14 illustrates a simplified block diagram, cross-sectional view of a portion of an exemplary automated order fulfillment system, in accordance with some embodiments.

[0019] FIG. 15 illustrates an overhead, cross-sectional view of an exemplary storage structure, in accordance with some embodiments.

[0020] FIG. 16 illustrates a simplified flow diagram of an exemplary process of automated order fulfilment, in accordance with some embodiments.

[0021] FIG. 17 illustrates a simplified flow diagram of an exemplary process of fulfilling orders through an order fulfillment system, in accordance with some embodiments.

[0022] FIG. 18 illustrates a simplified flow diagram of an exemplary process of fulfilling orders through an order fulfillment system, in accordance with some embodiments.

[0023] FIG. 19 illustrates an exemplary system for use in implementing methods, techniques, devices, apparatuses, systems, servers, sources and providing product order fulfillment, decanting, consolidation and inventory management, in accordance with some embodiments.

[0024] 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. 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. Certain actions and / or steps maybe 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.DETAI LED DESCRIPTION

[0025] 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.

[0026] 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. In one non-limiting embodiment, the acceptable manufacturing tolerance is ± .25%. For purposes of this disclosure, a connection may be a direct connection or an indirect connection (e.g., via one or more other parts). In some cases, when a first element is referred to as being connected, affixed or coupled to a second element, the first and second elements may be directly connected, affixed or coupled to each other or indirectly connected, affixed or coupled to each other. When a first element is referred to as being directly connected, affixed or coupled to a second element, then there are no intervening elements between the first and second elements (other than possibly an adhesive or weld used to connect, affix or couple the first and second elements).

[0027] Automated order fulfillment systems have limited capacity based on numerous factors.Some of those factors include resources, time to complete tasks, congestion and other such factors. Many of these factors are improved through embodiments of the present automatedorder fulfillment systems and methods. In part, some embodiments provide automated order fulfillment systems that drastically reduce travel time of mobile robots operating to retrieve and transport items between storage and workstations where items can be retrieved and complied in fulfilling respective orders. Further, some embodiments improve efficiency in part by providing the buffering, staging and sequencing of items supplied to workstations. Still further, some embodiments provide greater item storage within the same area footprint as previous systems in by incorporating buffering and sequencing within a storage structure rather than external to a storage structure.

[0028] FIG. 1 illustrates a simplified block diagram, perspective view of at least a portion of an exemplary automated order fulfilment system 100, in accordance with some embodiments. FIG. 2 illustrates a simplified block diagram, overhead view of a portion of an exemplary automated order fulfillment system 100, in accordance with some embodiments. FIG. 3 illustrates a simplified block diagram, side view of a portion of an exemplary automated order fulfillment system 100, in accordance with some embodiments. FIG. 4 illustrates a simplified block diagram, cross-sectional view (along a Y-axis and perpendicular to an X-axis) of a portion of an exemplary automated order fulfillment system 100, in accordance with some embodiments. Referring to FIGS. 1-4, the order fulfillment system 100 includes a storage structure 102 having a horizontal first dimension DI (illustrated as being along an X-axis) and sometimes referred to as a length, a horizontal second dimension D2 (illustrated along a Y-axis) and sometimes referred to as a width, and a third dimension D3 (illustrated along a Z-axis) and sometimes referred to as a height. The storage structure is further assembled to include multiple levels 104 that are vertically spaced (e.g., along the Z-axis as illustrated in FIG. 1) and separated by respective vertical distances, and multiple storage level changing structures 106 spaced along the first dimension of the storage structure 102 and establishing vertical pathways between the levels 104. The storage level changing structures 106 can be configured to be utilized by mobile robots 110 to vertically move between the levels. The automated order fulfillment system 100 can further include one or more control circuits 101 and / or robot routing control circuits that are in wireless communication via one or more wireless and / or wired distributed communication networks 103 (e.g., wireless local area network (LAN), wired LAN, wide area network (WAN), cellular network, Wi-Fi, Bluetooth, Ethernet, other such communication network, or a combination of two or more of such networks). In some embodiments, the control circuit 101 is in communication with the workstations 126, sensors, databases (e.g., inventory databases, customer databases, history databases, etc.),inventory management system, order receiving systems, other systems of the order fulfillment system 100, or a combination of two or more of such system.

[0029] The storage structure 102 further includes a plurality of aisles 112 each extending through at least a respective portion of the storage structure and along at least a portion of the first dimension DI of the storage structure. In some embodiments, at least some and typically each aisle 112 of the plurality of aisles comprises tracks, rails, and / or other such structures configured to be utilized and / or engaged by the mobile robots 110 to horizontally move along the aisle. At least some of the aisles include storage locations 114 positioned on the levels 104, and spanning at least one side and typically both sides of each aisle 112. The storage locations 114 can be configured to each store at least one of multiple containers that store one or more items to be retrieved in satisfying fulfillment orders that are to be fulfilled through the fulfillment system 100 and / or facility.

[0030] In some embodiments, one or more sets 120 of in-rack transit planes 122 (IRTP) can be interspersed within the storage structure 102 and horizontally spaced from each other along the first dimension DI of the storage structure. Each of the multiple sets 120 of IRTPs comprises one or more IRTPs 122. When a set 120 includes two or more IRTPs 122, those two or more IRTPs can be vertically spaced from each other, with each IRTP 122 positioned in one of the levels 104. The IRTPs, in some embodiments, are horizontal planar structures each comprising a horizonal planar surface extending over an area and configured to enable the mobile robots 110 to travel on the IRTPs in any horizontal direction (e.g., across a plane along the X-axis and Y-axis, as illustrated in FIG. 1). One or more of the IRTPs 122 can each cooperate with one or more aisles 112, one or more level changing structures 106, and / or one or more workstations 126 to enable mobile robots 110 to traverse through the order fulfillment system 100 between storage locations 106 and workstations 126 while a flow of the mobile robots are controlled to improve throughput, reduce congestion, reduce mobile robot demand, and other such benefits. The mobile robots 110 can maneuver across the X-Y plane of each IRTP 122 allowing transition between different aisles 112, different workstations 126 and / or other portions of the storage structure. Some embodiments may further include one or more transit planes at one or more ends and / or portions of one of the ends of the storage structure 102.

[0031] In some embodiments, the storage structure 102 includes and / or cooperates with at least one and typically multiple workstations 126. The workstations 126 can be configured to accept and dispense multiple containers 302 (e.g., totes, boxes, bags, subtotes, bins, etc.) transported bythe mobile robots 110. In some implementations, mobile robots 110 enter the workstations 126 while transporting at least one container 302 and maintain the container on the mobile robot as the mobile robot moves the container into, through and out of the workstation 126 without releasing the container 302. The workstations 126 can be distributed along the storage structure 102. In some embodiments, workstations 126 are distributed along one or more sides of the storage structure (e.g., distributed at least on both sides extending in the first dimension DI). One or more other workstations may be positioned at one or more ends of the storage structure and / or separated from the storage structure.

[0032] In some embodiments, some or all of the workstations 126 can be positioned proximate one of the sets 120 of the IRTPs 122. In some implementations, at least one IRTP of sets 120 of IRTPs 122, of the multiple sets of IRTPs, is proximate one or more of the workstations, and in some embodiments aligns with and cooperates with one or more of the workstations 126.

[0033] Further details of the workstations 126, storage structure 102, mobile robots 110, planar structure which may be utilized with at least some embodiments are described for example in the following U.S. patents and patent applications: U.S. Patent No. 9,139,363, entitled "Automated System For Transporting Payloads," issued September 22, 2015; U.S. Patent No. 10,435,241, entitled "Storage and Retrieval System," issued October 8, 2019; U.S. Patent No. 11,142,398, entitled "Order Fulfillment System," issued October 12, 2021; U.S. application publication No. 2023 / 0095494, entitled "Automatic Storage and Retrieval System having Staging and Sequencing Buffer Locations and Segregated Storage", published March 30, 2023 (Attorney Docket No. 8842- 157747-US_8182US03), U.S. application publication No. 2022 / 0063910, entitled Order Fulfillment System, published March 3, 2022, and U.S. Application Serial No. 18 / 268,204, entitled "Methods and Apparatus for Facilitating Transport of Items Between a Store and a Customer via a Customer Access Portal" (Attorney Docket No. 8842-156750-US_8154US01); where each of these patents and applications are incorporated herein by reference in their entirety.

[0034] Still referring to FIGS. 1-4, in some embodiments, each set 120 of IRTPs 122 of the multiple sets of IRTPs comprises at least a first IRTP positioned at a first level 104 and physically couples with at least a respective one of the workstations 126 establishing a path to or from the respective one of the workstations. For example, in some embodiments, an IRTP 122 can be positioned to physically couple with at least one workstation via a set of tracks, rails or the like extending from the IRTP directly to the workstation 126. One or more of the workstations 126, in some embodiments, can be a multi-level workstation. For example, a first workstation level may be afeed or inbound workstation level used by mobile robots 110 to enter the workstation, and a second workstation level, vertically separated from the first workstation level, may be used as an outbound or exit workstation level used by the mobile robots to exit the workstation. One or more workstation level changing structures can be incorporated within the workstation and configured to be engaged by and used by the mobile robots 110 to self-propel between at least the first workstation level and the second workstation level. With multilevel workstations, the sets 120 of IRTPs 122 may comprise at least two IRTPs positioned proximate at least one of the workstations, and in some embodiments each aligns with and cooperates with a respective one of the multiple workstation levels. For example, a lower of the two IRTPs 122 may be designated as an inbound IRTP and may be cooperated with a lower workstation level 304 providing a feed or inbound path from the lower IRTP to the respective the workstation, and an upper of the two IRTPs 122 may be designated as an outbound IRTP and may be cooperated with a second or upper workstation level 305 providing an exit or outbound path from the respective the workstation and onto the upper IRTP. Additionally or alternatively, one or more workstations may be single level workstations. A single IRTP may cooperate with the single workstation level providing a pathway for the mobile robots to access the workstation. For example, one or more workstations may be a flowthrough workstation where a mobile robot enters on one side of the flowthrough workstation at the single workstation level, travels across a width of the workstation at the single workstation level and exits the workstation from the single workstation level. One or more workstations may include and / or other workstations may also be used that comprise one or more functionality such as but not limited to: enabling one or more mobile robots pulls in and wait while a workstation task is performed and then backs out, enabling one or more mobile robots to additionally or alternatively release a container at the workstation and then the same or a different mobile robot may later retrieve the dropped off container, one or more workstations may additionally be cooperated with one or more conveyor systems enabling containers to additionally or alternatively be transported to and from the workstation, and / or other workstation functionalities and / or workstations can be utilized (e.g., one or more workstations described in the above and below mentions patents and patent applications).

[0035] As introduced above, the set 120 of IRTPs can each include one or more IRTPs 122, and typically include multiple IRTPs 122 vertically spaced. One or more or all of the IRTPs can be aligned with different levels 104 of the storage structure 102. In some embodiments, one or more or each set 120 of IRTPs comprises at least three IRTPs 122 that are each vertically aligned (e.g.,along the Z-axis) with each other and each of the at least three IRTPs are positioned at a different one of the levels 104 of the storage structure 102. Again, in some embodiments, one or more of the sets 120 of IRTPs each cooperate with one or more workstations 126. For example, one or more of the sets 120 of IRTPs can comprise a first IRTP and a second IRTP, of the at least three IRTPs. The first and second IRTPs can each be aligned at a different respective level with and coupled with one or more workstations 126. FIG. 3, for example, illustrates exemplary sets 120 of multiple IRTPs that each comprise four IRTPs 122a-122d. Each set 120 of four IRTPs 122a-122d include one or more IRTPs that align with at least one workstation 126. For example, as illustrated in FIG. 3, the sets 120 of IRTPs include a first IRTP 122a that couples and / or aligns with first workstation levels 304 (e.g., horizontally aligns along a level 1O4_L1), and a second IRTP 122b that couples and / or aligns with a second workstation levels 305 (e.g., horizontally aligns along a level 104_L2). One or more IRTPs may not align with a workstation.

[0036] In some embodiments, one or more of the IRTPs are configured to extend along the second dimension D2, and in some instances at least substantially across the second dimension D2 of a portion of the storage structure 102 in which it is positioned (e.g., the storage structure may have multiple different sections or portions with different second dimensions, and respective IRTPs positioned within those respective sections may have different dimensions to correspond with the respective second dimension of the portion of the storage structure within which it is positioned). In some embodiments, two or more IRTPs 122 of one or more sets 120 of IRTPs can extend along the respective second dimension D2 across the storage structure 102 intersecting multiple aisles 112 at the respective level 104 with which the respective IRTP is positioned establishing cross-aisle movement paths. Further, one or more of the IRTPs 122 can extend along the second dimension to cooperate at each of opposite ends with different workstations 126. FIG. 4, for example, shows an exemplary embodiment comprising a first IRTP 122a, of a set of IRTPs, couple with two workstations 126a, 126b with each of the two workstations 126a-126b being positioned at opposite ends 402a, 402b, respectively, of the first IRTP 122a. As described above, in some embodiments, two or more IRTPs may align and / or cooperate with a workstation. Again, FIG. 4 shows the exemplary embodiment further comprising a second IRTP 122b, of the set of IRTPs, couple with the two workstations 126a, 126b with each of the two workstations 126a-126b being positioned at opposite ends 402a, 402b, respectively, of the second IRTP 122b.

[0037] FIG. 5, illustrates a simplified block diagram, overhead cross-sectional view of a portion of an exemplary storage structure 102, in accordance with some embodiments. The levels 104containing at least one of the IRTPs 122 comprises and / or provides a two-dimensional (2D) grid of mobile robot travel paths across the respective level. The 2D mobile robot travel paths can comprise multiple first dimension travel paths 504 along the plurality of aisles 112 that each intersect with at least one and typically multiple second dimension travel paths 506 across the plurality of IRTPs 122 positioned spaced and separated along the first dimension DI of the storage structure 102 at the respective levels. For example, a first mobile robot 110a may route from a first storage location 114a along a first dimension travel path 504a_l to intersect a second dimension travel path 506a to intersect another first dimension travel path 504a_2. Similarly, a second mobile robot 110b may route from a second storage location 114b along a first dimension travel path 504b_l to intersect a second dimension travel path 506b to intersect another first dimension travel path 504b_2. Accordingly, the two or more or each of the IRTP 122 of each of the multiple sets 120 of IRTPs extend in the second dimension D2 intersecting with a respective subset of aisles 112, of the plurality of aisles, along a respective one of the levels establishing multiple transit paths within the storage structure to and from the respective subset of aisles of the storage structure. Further, the storage level changing structures 106, which are typically spaced at different locations along the first dimension DI of the storage structure 102, can couple the 2D grids of mobile robot travel paths and the levels to establish a three-dimensional (3D) grid of mobile robot travel paths throughout the storage structure. Substantially any relevant number of 2D grids of mobile robot travel paths, having the same or varying dimensions, can be stacked to achieve a desired storage location capacity. The interconnection of the 2D grids via the storage level changing structures 106 enables vertical movement (e.g., Z-axis direction) between the 2D grids (e.g., X-Y axes). The 2D grid and 3D grid or array of mobile robot travel paths provides for much shorter travel distances, reduced travel times, increased efficiency, and other such benefits. Some embodiments can further increase efficiencies while utilizing fewer mobile robots 110.

[0038] Referring to at least FIG. 3, in some embodiments, at least a subset of one or more storage level changing structures 106 are positioned proximate each workstation 126. These storage level changing structures 106 proximate the workstations can provide inbound and / or outbound routes from other levels to the levels of the IRTPs at the levels that cooperate with the respective workstations 126. In some embodiments, for each of the workstations 126, at least one inbound storage level changing structure 106a is positioned on a first side 310 of a respective workstation 126 and / or a first side of a respective set 120 of IRTPs aligned with the respective workstation, and an outbound storage level changing structure 106b positioned on a second side 311 of therespective workstation and / or a second side of the respective set 120 of IRTPs aligned with the respective workstation. The inbound storage level changing structure 106a can, in some embodiments, be unidirectional and restricted to mobile robots 110 in route to the respective workstation. For example, inbound storage level changing structure 106a may be restricted to movement of mobile robots moving down in the storage structure. The outbound storage level changing structure 106b can, in some embodiments, be unidirectional and restricted to mobile robots 110 in route to the respective workstation. For example, inbound storage level changing structure 106a may be restricted to a unidirectional up movement of the mobile robots leaving the workstation. For example, a first set of two or more storage level changing structure 106 may be positioned on a first side of a set 120 of IRTPs 122, and each of the two or more storage level changing structure 106 of the first set may be dedicated to a unidirectional movement (e.g., a down movement). Similarly, a second set of two or more storage level changing structure 106 may be positioned on a second side of the set 120 of IRTPs 122, and each of the two or more storage level changing structure 106 of the second set may be dedicated to an opposite unidirectional movement than the first set (i.e., an up movement). Other storage level changing structure 106 of the fulfillment system may similarly be restricted to one of an up or a down directional movement of the mobile robots 110. In some embodiments, one or more of the storage level changing structure may provide bidirectional movement.

[0039] The flow of mobile robots 110 can be improved and / or congestion be reduced in some embodiments by utilizing different levels of IRTPs as inputs and exits from the respective workstations. In some embodiments, a first IRTP 122a can horizontally extend along a first level 104 and is aligned with a workstation exit level 305 of at least one and often two workstation 126 such that at least a subset of the mobile robots exiting the one or two workstations onto the first IRTP 122a travel along at least a portion of the first IRTP toward a respective outbound storage level changing structure 106b proximate the respective one or two workstations. Similarly, a second IRTP 122b, of a set of two or more IRTPs, can horizontally extends along a second level 304 vertically spaced from the first IRTP 122a and is aligned with at least a workstation inbound level 304 of at least one and often two first workstations. At least a subset of the mobile robots can vertically access the second IRTP from a respective inbound storage level changing structure 106a proximate the respective one or two workstations and horizontally enter, for example, the first workstation from the second IRTP 122b.

[0040] Referring to FIGS. 1-4, in some embodiments the control circuit 101 configured to wirelessly communicate instructions to the mobile robots 110 in routing mobile robots between the storage locations 106 and the workstations 126. In some embodiments, the control circuit 101 is further configured to define buffering of two or more of the mobile robots 110 within the storage structure 102 and proximate an assigned one of the workstations 126. For example, FIG. 3 illustrates sets 320a, 320b of one or more mobile robots buffered in one or more aisles 112 proximate respective workstations 126, in according to some embodiments. When an order for which one or more mobile robots are buffered is ready to be fulfilled, reaches a threshold position within an order fulfillment queue and / or is within a predicted timing of fulfilling the order, the buffered mobile robots associated with that order can be directed to move from the buffered aisle directly onto an inbound IRTP and / or engage a storage level changing structures 106 and move itself vertically to the inbound IRTP in preparation with propelling itself into the workstation 126 consistent with an order fulfillment queue. The buffering of mobile robots 110 can be used to enhance routing of mobile robots in staging and sequencing of containers transported by the mobile robots to facilitate management of congestion, improve speed of product transport, improve speed of order fulfillment, reduce numbers of mobile robots, enhance workstation utilization, reduce delays, increase utilization of the storage structure, improves efficiency, may remove wait constraints of fulfilling overlapping orders and dwell times between orders, enables leapfrogging and / or reprioritizing of task assignments when there is threshold productivity gain and / or simplification, improves fulfillment system equipment productivity, reduces costs, improves capacity, and other such benefits. Cooperating the workstations along the storage structure and with the IRTPs enables mobile robots to temporarily be buffered directly within the storage structure 102 in preparation for fulfillment of respective fulfillment orders in accordance with order fulfillment queues. In some embodiments, separate order fulfillment queues can be maintained for each workstation 126.

[0041] In some embodiments, the control circuit 101 in defining buffering of mobile robots 110 can be configured to identify that one or more mobile robots are associated with a first fulfillment order and are buffered and temporarily stopped, while retaining a respective container 302, on a first aisle 112 of the storage structure 102 and proximate a first workstation 126 that is assigned to fulfill at least a portion of the first fulfillment order. In some instances, the control circuit can further identify that a second mobile robot 110 is also associated with the first fulfillment order, and based on that association with the first fulfillment order and the first mobile robot beingbuffered, can communicate a buffer instruction to the second mobile robot directing the second mobile robot to the first aisle adjacent to the first mobile robot, to stop and wait in the first aisle while retaining a respective container 302 in buffering the second mobile robot. This buffering of the second robot with the buffered first mobile robot enables the containers corresponding to the first fulfillment order to be compiled prior to routing the containers to the workstation so that the mobile robots associated with the first fulfillment order can be cooperatively routed to the workstation in attempts to streamline the retrieval of items in fulfilling the first fulfillment order.

[0042] FIG. 6 illustrates a simplified block diagram, side view of a portion of an exemplary storage structure 102, in accordance with some embodiments. FIG. 7 illustrates a simplified block diagram, overhead cross-sectional view of a portion of an exemplary storage structure 102, in accordance with some embodiments. Referring to FIGS. 6-7, in buffering mobile robots 110, the control circuit 101 in some embodiments can direct mobile robots to one or more aisles 112 of one or more neighboring storage structure sections 602b of the storage structure 102 adjacent the inbound storage level changing structure 106a and / or a workstation section 602a of the storage structure with which the assigned workstation 126 is positioned and / or aligned. For example, the control circuit may identify that a first mobile robot 110a arrives prior to the respective fulfillment order is to be fulfilled, and can direct the first mobile robot 110a to stop as the mobile robot descends the inbound storage level changing structure 106a at a level consistent with the aisle 112a into which the first mobile robot 110. The control circuit may, in some embodiments, instruct the first mobile robot to buffer in an aisle aligned with the inbound storage level changing structure 106a used by the first mobile robot and / or an aisle with which the mobile robot arrived. For example, referring to FIG. 7, in some embodiments, a mobile robot descending a first inbound storage level changing structure 106a can be directed to a corresponding first aisle 112a, a mobile robot descending a second inbound storage level changing structure 106a_2 can be directed to a corresponding second aisle 112, a mobile robot descending a third inbound storage level changing structure 106a_3 can be directed to a corresponding third aisle 112c, and so forth. In other instances, the control circuit may direct the first mobile robot to move onto an IRTP 122 and move laterally to an assigned aisle. As introduced above, in some embodiments, the control circuit may organize mobile robots being queued to line up with other mobile robots already buffered for the same fulfillment order (e.g., using one of the IRTP 122 to move across to an appropriate aisle before or after descending a storage level changing structure. In some embodiments, the control circuit 101 may further instruct one or more other mobile robots (e.g.,110b, 110c) to move to make room for the first mobile robot 110a on the intended aisle 112a. It is noted, that in some embodiments, a first dimension 702 (e.g., along the X-axis) of one or more of the IRTPs 122 may be less than a similar dimension 704 of the workstation section 602a within which the IRTP is positioned. This difference in dimension can provide a gap between the storage level changing structures 106 and the IRTPs to allow the mobile robots 110 to move vertically up and down without interference from the IRTPs. In other embodiments, one or more of the IRTPs may have openings through which the mobile robots can pass when moving vertically. Further, tracks, rails and / or other such structures can extend across the gaps between the storage level changing structures 106 and the IRTPs to enable the mobile robots to move back and forth between the storage level changing structures 106 and the IRTPs 122.

[0043] Directing a mobile robot to be buffered can be dependent, in some embodiments, upon a confirmation that the fulfillment order is not being processed by the assigned workstation at the time the mobile robot is moving toward the assigned workstation, the fulfillment order is later than a threshold position within the order fulfillment queue corresponding to the assigned workstation, other such factors, or a combination of such factors. The threshold position within the order fulfillment queue can be dependent on an expected time it will take the mobile robots associated with an order to reach the assigned workstation, a predicted time to fulfill the fulfillment order at the workstation, and / or other such factors.

[0044] The one or more mobile robots buffered for an order and / or arriving at a time to route to the workstation can be directed to advance to the inbound IRTP 122a without buffering when the fulfillment order is to be fulfilled and / or fulfilled within a threshold time. In some embodiments, an order fulfillment queue corresponding to the workstation can be evaluated by the control circuit. This queue evaluation can include, for example, a determination of an expected timing of fulfillment of the fulfillment order, a comparison of expected timing of fulfillment relative to one or more timing thresholds (e.g., buffer wait threshold, order fulfillment duration threshold, etc.), number of orders in the order fulfillment queue, expected and / or estimated duration to fulfill the one or more orders of the order fulfillment queue, congestion, mobile robot buffer positions within storage structure 102, number of open buffer aisles and / or buffer areas of one or more IRTPs, other such factors or a combination of two or more of such factors.

[0045] Some embodiments additionally or alternatively utilize one or more aisles 104 a workstation section 602a and positioned vertically above the one or more IRTPs 122a, 122b that are aligned with the first workstation. FIG. 8 illustrates a simplified block diagram, cross-sectionalview of a portion of an exemplary automated order fulfillment system 100, in accordance with some embodiments, with a first workstation 126a positioned aligned with and / or incorporated with a workstation section 602a of the storage structure 102. FIG. 9 illustrates a simplified block diagram, cross-sectional view (along a Y-axis and perpendicular to an X-axis) of a portion of an exemplary automated order fulfillment system 100, in accordance with some embodiments. Referring to at least FIGS. 8-9, in some embodiments, one or more aisles 112a, 112b, 112c at multiple levels (e.g., levels 1O4_L1 - 104_L18) within a workstation section 602a, aligned with and / or in which a first workstation 126a is positioned, can additionally or alternatively be utilized in buffering and / or sequencing one or more mobile robots 110. For example, a set 802 of levels (e.g., four levels 104_L3 - 104_L6) along a first aisle 112a can be utilized in buffering and / or sequencing one or more mobile robots 110 intended to be routed to the first workstation 126a in fulfilling one or more fulfillment orders. Lower levels (e.g., levels 1O4_L1 and 104_L2) may correspond to an inbound IRTP 122a and an outbound IRTP 122b. As described above, some embodiments may additionally utilize the inbound IRTP in buffering and / or sequencing one or more mobile robots. One or more levels 104 of one or more neighboring sections 602b may additionally or alternatively be used in buffering and / or sequencing containers 302. In some implementations, a neighboring section 602b, adjacent to a workstation section 602a, may not include IRTPs at the lower levels (e.g., the bottom two lower levels 1O4_L1 and 104_L2). As such, these lower levels may be used as part of the buffering and / or sequencing. In some embodiments the lowest level 1O4_L1 is aligned with the input to the workstation 126a, and as such mobile robots 110 buffered and / or sequenced in aisles at the lowest level 1O4_L1 can merely move from the aisle at the lowest level 1O4_L1 directly onto the lowest level IRTP 122a without having to engage a storage level changing structure 106. Accordingly, the control circuit 101 in routing mobile robots may prioritize the lowest level 1O4_L1 aisles 112 of the neighboring section 106b over other levels.

[0046] FIG. 10 illustrates a simplified perspective view of a portion of a storage structure 102 of an order fulfillment system 100 with a workstation 126 coupled with and / or incorporated within the storage structure 102, in accordance with some embodiments. Referring to at least FIGS. 1 and 7-10, mobile robots 110 can be buffered at one or more locations as described above and further below. For example, FIG. 10 illustrates buffer locations "B" within one or more aisles proximate the workstation 126. As described above, in some embodiments, workstation 126 can be multi-level workstations (e.g., two workstation levels 304, 305, three workstation levels, fourworkstation levels or other relevant numbers of workstation levels). Mobile robots 110 can be routed from the buffer locations B (e.g., in one or more aisles in a workstation section 602a and / or one or more aisles in a neighboring section 602b). The mobile robots when at a level above the inbound IRTP 122a can move from the respective aisle and engage an inbound storage level changing structure 106a coupled with the respective aisle, and self-propel to move down the inbound storage level changing structure 106a to the level at which the inbound IRTP 122a is positioned (e.g., in many embodiments, the inbound IRTP 122a is the lowest level (1O4_L1) or a set of lower most levels, such as when the workstation includes multiple inbound workstation levels).

[0047] The mobile robot can move out SI from the inbound storage level changing structure 106a and onto the inbound IRTP 122a. In some embodiments, the workstation may have one or multiple access bays 1002a, 1002b and similarly include one or multiple entries across the inbound IRTP 122a. As such, the mobile robot can be routed to travers the inbound IRTP 122a to align with an assigned robot entry of the multiple robot entries of the workstation 126a. The robot can then rotate to align with the orientation of the respective access bay of the workstations. In accordance with the sequencing, the mobile robot can advance S2 along the inbound IRTP 122a to move through the respective workstation entry and into an entry level 304 of the workstation (e.g., a lowest workstation level) and cooperate S3 with one or more workstation level changing structures 1004 within the workstation. When the access bay is clear (e.g., a previous mobile robot moves out from alignment with the access bay and the workstation), the mobile robot can selfpropel vertically along the workstation level changing structures 1004 within the workstation to position itself in alignment with the access bay of the workstation S4 to enable an assigned workstation task to be performed relative to the positioned mobile robot. The workstation task can include picking one or more items from a product container 302p being transported by the mobile robot, inserting one or more items into a container (e.g., when the container is an order container, a consolidation task is being performed, a decanting task is being performed, etc.), one or more items of an order can be removed in an order dispensing task, one or more containers are inserted and cooperated with the mobile robot in a container induction task in inducting one or more containers into the storage structure 102, the mobile robot may be removed from the workstation, and / or other such tasks. Accordingly, in some embodiments two or more of the workstations 126 can be configured to function as multi-function workstations enabling the performance of multiple different tasks, including for example, decanting cases, collections orother such plurality of items into one or more of the multiple containers, inducting at least a subset of the multiple containers into the storage structure, picking eaches from the multiple product containers, placing items into order containers, consolidating items from several containers into fewer containers, dispensing fulfilled orders, other such tasks or a combination of two or more of such tasks. In some embodiments, the workstations and IRTPs are sized to readily cooperate with the sections 602. In some embodiments, for example, the sections are modular enabling easy assembly to fit within substantially any relevant area. The sections 602, for example, can have a width that is substantially equal to a fixed number of storage locations, such as 7 storage locations wide, 8 storage locations wide, 10 storage locations wide, 6 storage locations wide or substantially any other relevant sizing.

[0048] Once the workstation task has been completed, the mobile robot can be directed S5 to exit the workstation through an exit of the workstation to move out El and onto the outbound IRTP 122b. Once on the outbound IRTP 122b, the mobile robot can follow an exit path to move away from the workstation. In some embodiments, for example, each mobile robot exiting the workstation may move along the outbound IRTP 122b away from the workstation to align with a predefined outbound storage level changing structure 106b, rotate E2 to align with an orientation to engage the outbound storage level changing structure 106b, advance off of the outbound IRTP 122b and engage E3 the outbound storage level changing structure 106b. Once engaged, the mobile robot can self-propel vertically to a designated level 104 to initiate a subsequently assigned task (e.g., returning the container being transported to one of the storage locations, which may be proximate a subsequent container to be retrieved by the mobile robot, transport the container directly to a different workstation (which may include buffering proximate the different workstation), transport the container to loop back toward the same workstation and buffer relative to the same workstation in preparation for fulfilling a subsequent order at the same workstation, and / or other such subsequent tasks. The workstations provide access to the interior of the containers 302. In some embodiments, a worker and / or one or more automated picking systems (e.g., articulated arm or other such systems) can retrieve one or more items from a container positioned within an access bay or opening of the workstation. In some embodiments, one or more of the workstations comprise multiple access bays. Workstations and multi-access bay workstations can be implemented similar to those described in U.S. Patent Nos. 9,139,363; 10,435,241; 11,142,398; U.S. application publication No. 2023 / 0095494; and U.S. Provisional Application Serial No. 63 / 626,967, (Attorney Docket No. 8842-157459-USPR_8291US01) andentitled "Retail Fulfillment Dispense And Decant Systems And Methods", each of which is incorporated herein by reference in its entirety.

[0049] Still further, in some embodiments, the control circuit 101 can direct other mobile robots, such as mobile robots transporting empty order containers 302x to utilize the inbound IRTP 122a in routing the empty order containers to the workstation in cooperation with other product containers 302p transported by the one or more mobile robots buffered and / or bypassing the buffer. The product containers 302p carry one or more items used to fulfill one or more fulfillment orders, while one or more order containers 302x can receive and consolidate one or more items picked at the workstation from the product containers 302p and inserted into the respective order containers.

[0050] FIG. 11 illustrates a simplified cross-sectional, overhead view of a portion of an exemplary storage structure 102, in accordance with some embodiments. FIG. 12 illustrates a simplified block diagram, cross-sectional view (along a Y-axis and perpendicular to an X-axis) of a portion of an exemplary automated order fulfillment system 100, in accordance with some embodiments. Referring to at least FIGS. 11-12, in some embodiments empty order containers 302x can be moved to a workstation 126 based on a predefined order container movement pattern. Again, in some embodiments, workstations may have multiple access bays 1002a, 1002b, and one of those access bays may be designated to receive the order containers, while the other one or more access bays 1002b can be designated to receive product containers 302p. The configuration enable picking of items from product containers and moving them to the order container in compiling items of a fulfillment order. Mobile robots transporting order containers can be staged in one or more aisles (e.g., 112x and 112y). These staging aisles may be different than aisles used to buffer product containers. This can enable ready flow of empty order containers without interfering with buffering. In other instances, the mobile robots transporting the order containers can be interspersed within the buffer aisles with mobile robots transporting product contains. The mobile robots transporting the order containers can be routed to move from the staging aisles and onto the inbound IRTP 122a in to line up with one or more other mobile robots transporting order containers. Typically, the mobile robots queue in alignment with the assigned access bay (e.g., access bay 1002a). However, one or more mobile robots may make one or more turns on the inbound IRTP 122a consistent with the queue. It is noted that mobile robots transporting order containers may further be staged or buffered in aisles at different levels 104 than the inbound IRTP 122a and engage a respective inbound storage level changing structure 106a tovertically move itself to the appropriate level of the inbound IRTP 122a. Similarly to the process described with regard to FIG. 10, the mobile robots transporting order totes can move into an entry of the workstation, engage a workstation level changing structure to propel itself vertically to an appropriate workstation access level and to position the order container in alignment with the respective access bay 1002a.

[0051] In some embodiments, other aisles and / or one or more IRTPs can additionally or alternatively be used to buffer mobile robots and / or be used in sequencing mobile robots to achieve an intended order of mobile robots sequentially moving into the respective workstation 126. For example, the control circuit 101 in defining the buffering, can be configured in some embodiments to communicate an instruction to a third mobile robot and separate instruction to a fourth mobile robot, which are each associated with a second fulfillment order assigned to be fulfilled at a first workstation, to travel through the storage structure 102 (e.g., along one or more aisles, one or more IRTPs and / or one or more storage level changing structures) to an IRTP 122 aligned with and coupled with the first workstation 126 and to stop and wait, without releasing respective containers 302 being transported by the third mobile robot and the fourth mobile robot, before proceeding to the first workstation following at least the third mobile robot waiting a respective buffer period of time. In some embodiments, one or more of the IRTPs 122 can be sized to enable multiple mobile robots 110 to simultaneously be positioned on and / or traveling across the same IRTP. For example, a first IRTP 122 can be sized to enable two or more mobile robots (e.g., the third and fourth mobile robots) to be buffered on the first IRTP while allowing at least one additional mobile robot (e.g., a fifth mobile robot) to enter and travel on the first IRTP to approach and enter the first workstation while the third mobile robot and the fourth mobile robot wait on the first IRTP and without being blocked from the first workstation by the third mobile robot and the fourth mobile robot. The buffer period of time can be dependent on one or more factors, such as but not limited to a position of a corresponding order within an order fulfillment queue, expected average duration to complete an order, number of containers to be routed to an assigned workstation in fulfilling an assigned portion or all of an order assigned to the workstation, distance of travel of containers of an order to reach an assigned workstation, the order fulfillment queue of one or more other fulfillment orders to be processed at the assigned workstation prior to the fulfillment order of interest, the number of containers and mobile robots associated with the fulfillment order earlier in the order fulfillment queue, expected rate ofprocessing each of the containers at the assigned workstation 126, other such factors, or a combination of two or more of such factors.

[0052] The control circuit 101, in some embodiments, further routes one or more mobile robots to sequence and / or organize mobile robots that are to approach and enter a particular workstation 126. The sequencing can provide an ordered sequence of mobile robots. This can, for example, enable mobile robots of a single fulfillment order to be arranged sequentially one after the other to sequentially enter the same workstation assigned to fulfill at least the relevant portion of a single fulfillment order. For example, in some embodiments, the control circuit 101 can be configured to communicate instructions to a first mobile, which is transporting a container with an item intended to be used in fulfilling a first fulfillment order, to move onto a first IRTP 122 of a first set 120 of IRTPs and position itself between a second mobile robot and a third mobile robot already on the first IRTP in approaching a first workstation 126 coupled with the first IRTP in accordance with an order fulfillment sequence corresponding to the first fulfillment order and one or more other fulfillment orders assigned to be fulfilled through the first workstation. The sequencing can additionally or alternatively be managed by releasing buffered mobile robots from the aisles associated with an inbound IRTP and / or directly feeding one or more mobile robots without buffer. In some embodiments, sequencing is performed within storage aisles on multiple levels (e.g., first level 1O4_L1, and second level_L2) adjacent to an IRTP 122 feeding a workstation.

[0053] In some embodiments, the order fulfillment system 100 can include multiple different zones or regions. For example, in some embodiments, the order fulfillment system 100 can include multiple different temperature zones within which different items can be temporarily stored that are to be maintained at different temperatures while waiting to be retrieved to fulfill different fulfillment orders.

[0054] FIG. 13 illustrates a simplified block diagram, overhead cross-sectional view of an exemplary order fulfillment system 100, in accordance with some embodiments. The order fulfillment system can include multiple different zones 1302-1304. For example, the zones can comprise a first temperature zone 1302 that is maintained at a first temperature and / or within a first temperature range (e.g., ambient temperature range, such as between +80°F to +43°F), a second temperature zone 1303 that can be maintained at a second temperature and / or within a second temperature range that is lower in temperature than the first temperature range (e.g., chilled temperature, such as between +41°F to +35°F), and a third temperature zone 1304 that can be maintained at a third temperature and / or within a third temperature range that is lowerin temperature than the second temperature range (e.g., frozen temperature, such as between 34° to -10°F). Interior walls 1308, curtains, doors, and / or other structures can be included to separate the zones and aid in maintaining the intended temperatures within the respective zones 1302-1304. As one non-limiting example, an order fulfillment system 100 can include an ambient temperature zone, a chill temperature zone, and a frozen temperature zone. One or more temperature systems can be cooperated with one or more of the zones to manage the temperature (e.g., based on sensor feedback from within one or more locations within the respective zones).

[0055] The order fulfillment system 100 includes one or more storage structures 102 within each zone and / or extending between two or more zones, and configured to enable mobile robots 110 to move through the storage structure, at least within a respective one of the different zones, and in some embodiments may move between different zones. One or more workstations 126 may be included in and / or cooperated with one or more or all of the different zones 1302-1304. For example, one or more workstations 126 can be distributed along the first zone 1302 (e.g., extending alone the first dimension DI), and one or more workstations 126 can be distributed along the second zone 1303 (e.g., extending alone the first dimension DI). In some embodiments, one or more of the zones may not include a workstation (e.g., a frozen zone may not include a workstation to avoid having a picker or picker system operating in the third temperature range). Mobile robots 110 can be routed to retrieve one or more third temperature zone containers 302 and transport the third temperature zone containers to a workstation in the first zone 1302 and / or a workstation in the second zone 1303.

[0056] Further, one or more of the different zones 1302-1304 can include one or more sets 120 of one or more IRTPs 122. In some embodiments, one or more IRTPs may horizontally extend between two or more of the different zones. For example, one or more IRTPs 122 of one or more sets 120 of IRTPs can extend along the second dimension D2 between the first zone 1302 and the second zone 1303 establishing one or more horizontal transition paths for the mobile robots 110 between the first zone 1302 and the second zone 1303. Some embodiments include one or more passages 1310, doors, curtains, openings, and / or other such structures within the walls 1308 that can enable the mobile robots 110 to pass along a respective one of the IRTPs 122 between two different zones. Further, the passages 1310 may be configured to reduce temperature changes, such as include a door that can be opened when one or more mobile robots pass, a curtain that reduces and / or limits airflow between zones, other such structures, or a combination of two ormore of such structures. The one or more transition paths between the different zones can be configured to be utilized by the mobile robots 110 in transporting at least a subset of the multiple containers 302 between zones (e.g., between a first temperature zone 1302 and a second temperature zone 1303).

[0057] In some embodiments, one or more IRTPs 122x of one or more sets 120x of IRTPs may be limited to a single zone. For example, an IRTP 122x may not extend between a first zone 1302 (e.g., ambient temperature zone) and a third zone 1304 (e.g., a frozen temperature zone). As described above, one or more and typically all of the IRTPs 122 intersect multiple different aisles 112 at the respective level 104 with which the respective IRTP is positioned establishing 2D crossaisle mobile robot travel or movement paths. The storage structure 102 in some embodiments further includes multiple storage level changing structures 106 in each of the zones 1302-1304 providing paths between the multiple levels 104 within each zone and establishing one or more three-dimensional (3D) grids of mobile robot travel paths throughout the different zones 1302- 1304 of the storage structure 102.

[0058] The fulfillment system 100 further includes one or more workstations 126. One or more of the IRTPs 122, 122x can be positioned to align with and cooperate with at least one workstation 126. In some embodiments, one or more of the IRTPs 122 of one or more sets 120 of IRTPs couple with two workstations 126 positioned at opposite ends of the respective IRTP, for example opposite ends separated along the second dimension D2 (e.g., Y-axis).

[0059] While FIG. 13 illustrates the different zones 1302-1304 being horizontally adjacent, in some embodiments, one or more portions of a zone or an entire zone may be vertically separated from one or more other zones or one or more portions of another zone. For example, at least a first portion of a first temperature zone can be vertically separated from at least a first portion of the second temperature zone. Further, vertically separated zones can in some embodiments also include two or more levels. In some embodiments, a first portion of a first zone can comprise a first subset of levels of the levels 104, and a second portion of a second zone positioned below the first portion of the first zone can comprise a second subset of levels different than the first subset of levels. One or more IRTPs may be included in one or more of the separate zones, and in some embodiments, one or more IRTPs may extend between two or more of the separate zones. As one non-limiting example, a first IRTP 122 of a first set of IRTPs can be vertically aligned with and vertically separated from a second IRTP and the second IRTP can horizontally extend betweena first temperature zone and a second temperature zone establishing a horizontal temperature transition path between first temperature zone and the second temperature zone.

[0060] FIG. 14 illustrates a simplified block diagram, cross-sectional view (along a Y-axis and perpendicular to an X-axis) of a portion of an exemplary automated order fulfillment system 100, in accordance with some embodiments. The fulfillment system comprises a storage structure 102 with multiple container storage locations 114 distributed along aisles 112. In some embodiments, the storage structure 102 can comprises multiple different zones 1402-1403. For example, the storage structure may include a first temperature zone 1402 and a second temperature zone 1403 maintained at a different temperature than the first temperature zone. One or more sets 120 of one or more IRTPs 122 can be included with one or more and typically all of the IRTPs 122 intersecting multiple different aisles 112 at the respective level 104 with which the respective IRTP is positioned establishing horizontal transition paths between aisles and / or storage level changing structures 106.

[0061] In some embodiments, at least a first portion or all of the second temperature zone 1403 is vertically separated from at least a portion or all of the first temperature zone 1402. The second zone or portion of the second temperature zone 1402 can comprise a first subset of levels (e.g., 104 L13 through 104 L18) of the levels, and the portion of the first temperature zone 1402 comprises a second subset of levels (e.g., 1O4_L1 through 104_L12) different than the first subset of levels. Further, in some implementations, one or more of the IRTPs of a set of IRTPs may be separated between the different zones. For example, one or more IRTPs (e.g., IRTPs 122a - 122b) of a set of IRTPs can be vertically aligned with and vertically separated from the one or more additional IRTPs (e.g., IRTP 122c-122d) of the set of IRTPs first IRTP. The storage structure 102 may include additional separate zones that may be vertically and / or horizontally separated (e.g., similar to that illustrated in FIG. 13). For example, a third zone may be adjacent at least the first zone. Further, when horizontally adjacent, in some embodiments one or more of the IRTPs may extend between the two horizontally adjacent zones. For example, an IRTP may horizontally extends between the first temperature zone and a third temperature zone establishing a horizontal temperature transition path between first temperature zone and the third temperature zone.

[0062] As described above and further below, the interspersing of the IRTPs 122 and the distribution of the workstations alone the first dimension greatly improves the efficiency of the operation of the fulfillment system 100. Some of the improvements is achieved through reducedtravel distances and / or time between storage locations 114 and an assigned workstation 126. In many previous fulfillment systems employing mobile robots, the mobile robots typically had to travel along aisles to an end of the storage structure before being able to move laterally and then travel along other aisles significant distances along a length of the storage structure before reaching an assigned workstation. As such, mobile robots typically overlapped movement in one direction to the end of the storage structure with movement in the opposite direction to reach a workstation.

[0063] The interspersing of IRTPs 122 and / or sets 120 of IRTPs within the storage structure along the first dimension DI of the storage structure provides, in part, the grid of travel paths enabling much more direct routing between storage locations 114 the assigned workstations. FIG. 15 illustrates an overhead, cross-sectional view of an exemplary storage structure 102, in accordance with some embodiments. The storage structure includes multiple sets 120 of IRTPs 122 interspersed within the storage structure and horizontally spaced from each other along the first dimension DI of the storage structure. Also illustrated are exemplary more direct mobile robot travel paths 1502-1508, without having to go to ends of the storage structure, without having to double-back, and other route optimization that greatly improves the efficiency, reduced fulfillment time, reduces traffic, decreases cycle time, enables an increase in the number of mobile robots that can be used and / or increase performance with few mobile robots, and other such benefits. Further, the IRTPs provide for a greater alternative routes between storage locations and workstations, which can reduce congestion, avoid congestion, limit delays and other benefits.

[0064] FIG. 16 illustrates a simplified flow diagram of an exemplary process 1600 of automated order fulfilment, in accordance with some embodiments. In step 1602, a first fulfilment order is identified that is to be fulfilled at a first workstation 126 of multiple workstations. In step 1604, a set of storage locations 114, of multiple storage locations within a storage structure 102 holding respective containers 302 each storing one or more items to satisfy the first fulfillment order, are identified. In step 1606, a control circuit wirelessly communications instructions to one or more mobile robots in routing the mobile robots between the storage locations and the workstations. In step 1608, one or more mobile robots 110 are routed to travel longitudinally along the aisles 112, vertically via storage level changing structures 106, and laterally via the multiple sets 120 of IRTPs 122 within the storage structure 102 to move the containers between the identified storage locations and the first workstation. In some embodiments, the routing can include for examplerouting a first mobile robot transporting a first container to move across a first IRTP 122 of a first set of IRTPs, of the multiple sets of IRTPs, that is positioned at a first level and that physically couples with at least the first workstation along an established path via the first IRTP to or from the first workstation. Some embodiments, in routing mobile robots, may route the first mobile robot to traverse laterally across a third IRTP, of the first set of IRTPs comprising at least three IRTPs each vertically aligned at a different one of the levels 104 of the storage structure 102, between a first aisle at a second level and a second aisle at the second level. In some embodiments, the first IRTP and a second IRTP, of the at least three IRTPs of the first set of IRTPs, can align with and coupled with the first workstation. In step 1610, instructions are communicated to cause buffering of two or more of the mobile robots within the storage structure and proximate an assigned one of the workstations.

[0065] FIG. 17 illustrates a simplified flow diagram of an exemplary process 1700 of fulfilling orders through an order fulfillment system, in accordance with some embodiments. In step 1602, cross-aisle movement paths are established via two or more IRTPs 122 of each set 120 of IRTPs of multiple different sets of IRTPs that extend along a second dimension D2 across a storage structure 102 intersecting multiple aisles 112 of the aisles at the respective level 104 with which the respective IRTP 122 is positioned. In step 1704, at least a first IRTP 122, of the two or more IRTPs, is coupled with two workstations 126 of multiple workstations. In some embodiments, each of the two workstations are positioned at opposite ends of the first IRTP. In step 1706 a two- dimensional (2D) grid of mobile robot travel paths are established at each of the levels containing at least one IRTPs 122. The two-dimensional grid of mobile robot travel paths can comprise multiple first dimension travel paths along the plurality of aisles 112 each intersecting with multiple second dimension travel paths across one or more of the IRTPs 122, of different ones of the multiple sets of IRTPs, positioned spaced along the first dimension of the storage structure at the respective levels. In step 1708, a three-dimensional (3D) grid is established of mobile robot travel paths throughout the storage structure 102 comprising the storage level changing structures 106 spaced at different locations along the first dimension DI of the storage structure coupling the 2D grids of mobile robot travel paths and the levels. In step 1710, for each of the workstation, at least an inbound storage level changing structure, of the storage level changing structures, is cooperated and positioned on a first side of a respective workstation, and an outbound storage level changing structure, of the storage level changing structures, is cooperated and positioned on second side of the respective workstation. Some embodiments stack as manyx-y grids as desired with robots that can move in between the x-y grids. This results in much faster moves and fewer robots as the 3D moves and / or robot travel routes are much shorter.

[0066] FIG. 18 illustrates a simplified flow diagram of an exemplary process 1800 of fulfilling orders through an order fulfillment system, in accordance with some embodiments. In step 1802, it is identified that a first mobile robot is associated with a first fulfillment order, and the first mobile robot is buffered and temporarily stopped, while retaining a first container, on a first aisle 112 of the storage structure 102 and proximate a first workstation 126 that is assigned to fulfill at least a portion of the first fulfillment order. In step 1804, it is identified that a second mobile robot is associated with the first fulfillment order. In step 1806, a first instruction is communicated, for example from the control circuit 101, to the second mobile robot directing the second mobile robot to the first aisle adjacent to the first mobile robot in buffering the second mobile robot. In optional step 1808, a second instruction is communicated to a third mobile robot associated with a second fulfillment order assigned to be fulfilled at the first workstation directing the third mobile robot to travel through the storage structure to a first IRTP aligned with and coupled with the first workstation and to stop and wait, while on the first IRTP and without releasing a container being transported by the third mobile robot, before proceeding to the first workstation following the third mobile robot waiting a respective buffer period of time.

[0067] In optional step 1810, a third instruction is communicated to a fourth mobile robot that is also associated with the second fulfillment order assigned to be fulfilled at the first workstation, to travel through the storage structure to the first IRTP and to stop and wait on the first IRTP, without releasing a respective container being transported by the fourth mobile robot, before proceeding to the first workstation following the third mobile robot waiting the respective buffer period of time. In step 1812, a fourth instruction is communicated to a fifth mobile directing the fifth mobile robot to move onto the first IRTP of a first set of IRTPs and position itself between two mobile robots already on the first IRTP in approaching the first workstation in accordance with an order fulfillment sequence.

[0068] In accordance with an example embodiment a non-transitory program storage device readable by a machine may be provided, such as memory, for example, tangibly embodying a program of instructions executable by the machine for performing operations, the operations. Any combination of one or more computer readable medium(s) may be utilized as the memory. The computer readable medium may be a computer readable signal medium or a non-transitory computer readable storage medium. A non-transitory computer readable storage medium doesnot include propagating signals and may be, for example, but not limited to, an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, or device, or any suitable combination of the foregoing. More specific examples (a non-exhaustive list) of the computer readable storage medium would include the following: an electrical connection having one or more wires, a portable computer diskette, a hard disk, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or Flash memory), an optical fiber, a portable compact disc read-only memory (CD-ROM), an optical storage device, a magnetic storage device, or any suitable combination of the foregoing.

[0069] 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. 19 illustrates an exemplary system 1900 that may be used for implementing any of the components, circuits, circuitry, systems, functionality, apparatuses, processes, or devices of the fulfillment system 100, and / or other above or below mentioned systems or devices, or parts of such circuits, circuitry, functionality, systems, apparatuses, processes, or devices. For example, the system 1900 may be used to implement some or all of the fulfillment system 100, the control circuit 101, the mobile robots 110, mobile robot control circuits, the workstations 126, inventory systems, point of sale systems, and / or other such components, circuitry, functionality and / or devices. However, the use of the system 1900 or any portion thereof is certainly not required.

[0070] By way of example, the system 1900 may comprise one or more control circuits or processor modules 1912, one or more memory 1914, and one or more communication links, paths, buses or the like 1918. Some embodiments may include one or more user interfaces 1916, and / or one or more internal and / or external power sources or supplies 1940. The control circuit 1912 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 1912 can be part of control circuitry and / or a control system 1910, which may be implemented through one or more processors with access to one or more memory 1914 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 controlcircuit 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 1900 may be used to implement one or more of the above or below, or parts of, components, circuits, systems, processes and the like.

[0071] The user interface 1916 can allow a user to interact with the system 1900 and receive information through the system. In some instances, the user interface 1916 includes a display 1922 and / or one or more user inputs 1924, such as buttons, touch screen, track ball, keyboard, mouse, etc., which can be part of or wired or wirelessly coupled with the system 1900. Typically, the system 1900 further includes one or more communication interfaces, ports, transceivers 1920 and the like allowing the system 1900 to communicate over a communication bus, a distributed computer and / or communication network 103 (e.g., a local area network (LAN), the Internet, wide area network (WAN), etc.), communication link 1918, 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 1920 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 1934 that allow one or more devices to couple with the system 1900. 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 1934 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.

[0072] In some embodiments, the system may include one or more sensors 1926 to provide information to the system and / or sensor information that is communicated to another component, such as the control circuits 101, the mobile robots 110, the workstations 126, other such systems or a combination of two or more of such systems. The sensors can include substantially any relevant sensor, such as movement sensors, 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, accelerometers, gyroscopes, and other 1such 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.

[0073] The system 1900 comprises an example of a control and / or processor-based system with the control circuit 1912. Again, the control circuit 1912 can be implemented through one or more processors, controllers, central processing units, logic, software and the like. Further, in some implementations the control circuit 1912 may provide multiprocessor functionality.

[0074] The memory 1914, which can be accessed by the control circuit 1912, typically includes one or more processor-readable and / or computer-readable media accessed by at least the control circuit 1912, and can include volatile and / or nonvolatile media, such as RAM, ROM, EEPROM, flash memory and / or other memory technology. Further, the memory 1914 is shown as internal to the control system 1910; however, the memory 1914 can be internal, external or a combination of internal and external memory. Similarly, some or all of the memory 1914 can be internal, external or a combination of internal and external memory of the control circuit 1912. 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 103. The memory 1914 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. 19 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.

[0075] Some embodiments provide automated order fulfilment systems, comprising: a storage structure having a horizontal first dimension and a horizontal second dimension, wherein the storage structure is configured to enable mobile robots to travel through the storage structure, and wherein the storage structure comprises: levels that are vertically spaced; storage level changing structures spaced along the first dimension of the storage structure and establishing vertical pathways between the levels, wherein the storage level changing structures are configured to be utilized by the mobile robots to vertically move between the levels; a plurality ofaisles each extending through at least a respective portion of the storage structure and along at least a portion of the first dimension of the storage structure, wherein each aisle of the plurality of aisles comprises tracks configured to be utilized by the mobile robots to horizontally move along the aisle; storage locations positioned on the levels, and spanning at least one side of each aisle of the plurality of aisles, wherein the storage locations are configured to each store one of the multiple containers; and multiple sets of in-rack transit planes (I RTP), wherein the multiple sets of IRTPs are interspersed within the storage structure and horizontally spaced from each other along the first dimension of the storage structure, wherein each of the multiple sets of IRTPs comprises two or more IRTPs vertically spaced with each IRTP positioned in one of the levels; and workstations each configured to accept and dispense multiple containers, wherein the workstations are distributed along the storage structure, and wherein at least one IRTP of each set of IRTPs of the multiple sets of IRTPs is proximate one or more of the workstations.

[0076] Some embodiments provide methods of automated order fulfilment, comprising: identifying a first fulfilment order to be fulfilled at a first workstation of multiple workstations; identifying a set of storage locations of multiple storage locations within a storage structure holding respective containers storing items to satisfy the first fulfillment order, the storage structure comprising a horizontal first dimension and a horizontal second dimension, levels that are vertically spaced, storage level changing structures that are spaced along the first dimension of the storage structure establishing vertical pathways between the levels, a plurality of aisles each extending along at least a portion of the first dimension of the storage structure with the multiple storage locations positioned on the levels spanning at least one side of each aisle of the plurality of aisles, and multiple sets of in-rack transit planes (IRTP) interspersed within the storage structure, horizontally spaced from each other along the first dimension of the storage structure and with each IRTP positioned in one of the levels wherein each set of IRTPs comprise two or more IRTPs vertically spaced, and wherein the multiple workstations are distributed along the storage structure, and wherein at least one IRTP of each set of IRTPs of the multiple sets of IRTPs is proximate one or more of the multiple workstations; and routing mobile robots to travel longitudinally along the aisles, vertically via the storage level changing structures and laterally via the multiple sets of IRTPs within the storage structure to move the containers between the identified storage locations and the first workstation, wherein the workstations are each configured to accept and dispense the containers in fulfilling fulfillment orders.

[0077] In some embodiments, buffering of containers 302 being transported by mobile robots 110 can be integrated within the storage structure 102 and / or the IRTPs 122. The integration of the IRTPs in part provides for more alternative flow pathways for the mobile robots traveling to and from the workstations 126, which increases system performance. Some embodiments decrease in overall footprint, while potentially increasing storage density and simplifying supply chain and installation. The IRTPs provide more direct paths between workstations and storage locations providing faster routing and / or delivery time, more degrees of freedom for mobile robot movement, increase in throughput capacity, provides easier to manage sequencing with less disparity of time for mobile robots arriving at workstation and other benefits.

[0078] Some embodiments can keep the containers 302 captive within the storage structure and can avoid moving containers into or out of the system. The IRTPs can cooperate with universal workstations 126 capable of performing multiple different system activities or tasks (e.g., pick, dispense, offline induction of inventory to containers, decant, consolidation, etc.). Further, in some embodiments, one or more of the workstations 126 can enable containers to be moved out while another container is moved in. For example, some workstations provide a multi-level station that moves containers into the workstation at one level and exit the workstation at a different level. Additionally, one or more of the workstations 126 can be a multi-access bay workstation with two or more access bays. The multi-function workstations can provide the ability to interleave picking and dispense tasks, order by order, so operators can stay productive without having to be reassigned to different workstations with every surge.

[0079] This application incorporates by reference the entirety of each of the following U.S. patent publications: U.S. Publication No. 2014 / 0288696 published September 25, 2014, having U.S. Application Serial No. 14 / 213,187, filed on March 14, 2014, and entitled "Automated system for transporting payloads" (Applicant Ref. No. ALRT-001-101); U.S. Patent Publication No. 2017 / 0313514 published November 2, 2017, having U.S. Application Serial No. 15 / 591,956, filed on May 10, 2017, and entitled "Order fulfillment system" (Applicant Ref. No. ALRT-003-101); U.S. Patent Publication No. 2019 / 0270591 published September s, 2019, having U.S. Application Serial No. 16 / 419,910, filed on May 22, 2019, and entitled "Order fulfillment system" (Applicant Ref. No. ALRT-003-2); U.S. Patent Publication No. 2018 / 0134492 published May 17, 2018, having U.S. Application Serial No. 15 / 816,832, filed on November 17, 2017, and entitled "Automated-service retail system and method" (Applicant Ref. No. ALRT-004-101); U.S. Patent Publication No. 2018 / 0194556 published July 12, 2018, having U.S. Application Serial No. 15 / 867,373, filed onJanuary 10, 2018, and entitled "Interchangeable automated mobile robots with a plurality of operating modes configuring a plurality of different robot task capabilities" (Applicant Ref. No. ALRT-007-101); U.S. Patent Publication No. 2018 / 0150793 published May 31, 2018, having U.S. Application Serial No. 15 / 826,045, filed on November 29, 2017, and entitled "Automated retail supply chain and inventory management system" (Applicant Ref. No. ALRT- 008-101); U.S. Patent Publication No. 2018 / 0305123 published October 25, 2018, having U.S. Application Serial No. 15 / 956,346, filed on April 18, 2018, and entitled "Picking workstation with mobile robots & machine vision verification of each transfers performed by human operators" (Applicant Ref. No. ALRT-009-102); U.S. Patent Publication No. 2018 / 0247257 published August 30, 2018, having U.S. Application Serial No. 15 / 903,993, filed on February 23, 2018, and entitled "Inventory management system and method" (Applicant Ref. No. ALRT-018-101); U.S. Patent Publication No. 2018 / 0341908 published November 29, 2018, having U.S. Application Serial No. 15 / 987,736, filed on May 23, 2018, and entitled "Fully automated self-service store" (Applicant Ref. No. ALRT-022- 101); U.S. Patent Publication No. 2019 / 0047787 published February 14, 2019, having U.S. Application Serial No. 16 / 058,065, filed on August 8, 2018, and entitled "Universal gripper for tote and sub-tote transport" (Applicant Ref. No. ALRT-023-001); U.S. Patent Publication No. 2020 / 071076 published March 5, 2020, having U.S. Application Serial No. 16 / 554,512, filed on August 28, 2019, and entitled "Tote handling for chilled or frozen goods" (Applicant Ref. No. ALRT- 032-101); U.S. Patent Publication No. 2020 / 0156871 published May 21, 2020, having U.S. Application Serial No. 16 / 676,732, filed on November 7, 2019, and entitled "System having robotic workstation" (Applicant Ref. No. ALRT-034-101); U.S. Patent Publication No. 2020 / 0223630 published July 16, 2020, having U.S. Application Serial No. 16 / 742,119, filed on January 14, 2020, and entitled "System having workstation with tote retention and release mechanism" (Applicant Ref. No. ALRT-039-101); U.S. Patent Publication No. 2021 / 0300664 published September 30, 2021, having U.S. Application Serial No. 16 / 831,468, filed on March 26, 2020, and entitled "Tote handling for chilled or frozen goods" (Applicant Ref. No. ALRT-041-001); U.S. Provisional Application Serial No. 63 / 013,504, filed on April 21, 2020, and entitled "Transport Rack Cartridge" (Applicant Ref. No. ALRT-042-001); and U.S. Provisional Application Serial No. 63 / 067,759, filed on August 19, 202, and entitled "High Density Micro Fulfillment Center "HD-MFC" with Nightly G2P Storage Batch Pick Replenishment from Store Floor and Method of Operating Same" (Applicant Ref. No. ALRT-046- 001).

[0080] 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.

Claims

Claims1. An automated order fulfilment system, comprising: a storage structure having a horizontal first dimension and a horizontal second dimension, wherein the storage structure is configured to enable mobile robots to travel through the storage structure, and wherein the storage structure comprises: levels that are vertically spaced; storage level changing structures spaced along the first dimension of the storage structure and establishing vertical pathways between the levels, wherein the storage level changing structures are configured to be utilized by the mobile robots to vertically move between the levels; a plurality of aisles each extending through at least a respective portion of the storage structure and along at least a portion of the first dimension of the storage structure, wherein each aisle of the plurality of aisles comprises tracks configured to be utilized by the mobile robots to horizontally move along the aisle; storage locations positioned on the levels, and spanning at least one side of each aisle of the plurality of aisles, wherein the storage locations are configured to each store one of multiple containers; and multiple sets of in-rack transit planes (IRTP), wherein the multiple sets of IRTPs are interspersed within the storage structure and horizontally spaced from each other along the first dimension of the storage structure, wherein each of the multiple sets of IRTPs comprises two or more IRTPs vertically spaced with each IRTP positioned in one of the levels; and workstations each configured to accept and dispense the multiple containers, wherein the workstations are distributed along the storage structure, and wherein at least one IRTP of each set of IRTPs of the multiple sets of IRTPs is proximate one or more of the workstations.

2. The order fulfilment system of claim 1, wherein each set of IRTPs of the multiple sets of IRTPs comprises a first IRTP positioned at a first level that physically couples with at least a respective one of the workstations establishing a path to or from the respective one of the workstations.

3. The order fulfillment system of claim 2, wherein each set of IRTPs comprises at least three IRTPs each vertically aligned at a different one of the levels of the storage structure, wherein the first IRTP and a second IRTP, of the at least three IRTPs of each of the multiple sets of IRTPs, are aligned at a level with and coupled with the respective workstation.

4. The order fulfillment system of claim 1, wherein two or more IRTPs of each set of IRTPs of the multiple sets of IRTPs extend along the second dimension across the storage structure intersecting multiple aisles of the plurality of aisles at the respective level with which the respective IRTP is positioned establishing cross-aisle movement paths, and at least a first IRTP of the two or more IRTPs couples with two workstations of the workstations, wherein each of the two workstations are positioned at opposite ends of the first IRTP.

5. The order fulfillment system of claim 4, further comprising: wherein each of the levels containing at least one of the IRTPs comprises a two-dimensional (2D) grid of mobile robot travel paths comprising multiple first dimension travel paths along the plurality of aisles each intersecting with multiple second dimension travel paths across one or more of the IRTPs, of different ones of the multiple sets of IRTPs, positioned spaced along the first dimension of the storage structure at the respective levels, and the storage level changing structures spaced at different locations along the first dimension of the storage structure coupling the 2D grids of mobile robot travel paths and the levels and establishes a three-dimensional (3D) grid of mobile robot travel paths throughout the storage structure.

6. The order fulfillment system of claim 4, wherein the storage level changing structures comprise, for each of the workstations, at least an inbound storage level changing structure positioned on a first side of a respective workstation and an outbound storage level changing structure positioned on second side of the respective workstation.

7. The order fulfillment system of claim 6, wherein: the first IRTP horizontally extends along a first level, of the levels, and is aligned at a level with at least an exit level of a first workstation, of the two workstations, such that at least a subset of the mobile robots exiting the first workstation onto the first IRTP travel along at least a portion of the first IRTP toward a respective outbound storage level changing structure proximate the first workstation; and a second IRTP, of the two or more IRTPs, horizontally extends along a second level, of the levels, vertically spaced from the first IRTP and is aligned with at least an inbound level of the first workstation, such that at least the subset of the mobile robots vertically access the second IRTP from a respectiveinbound storage level changing structure proximate the first workstation and horizontally enter the first workstation from the second IRTP.

8. The order fulfillment system of claim 1, further comprising: a control circuit configured to wirelessly communicate instructions to the mobile robots in routing mobile robots between the storage locations and the workstations, and defining buffering of two or more of the mobile robots within the storage structure and proximate an assigned one of the workstations.

9. The order fulfillment system of claim 8, wherein the control circuit in defining the buffering, is configured to: identify that a first mobile robot is associated with a first fulfillment order and is buffered and temporarily stopped, while retaining a first container, on a first aisle of the storage structure and proximate a first workstation, of the workstations, that is assigned to fulfill at least a portion of the first fulfillment order; identify that a second mobile robot is associated with the first fulfillment order; and communicate a first instruction to the second mobile robot directing the second mobile robot to the first aisle adjacent to the first mobile robot in buffering the second mobile robot.

10. The order fulfillment system of claim 9, wherein the control circuit in defining the buffering, is configured to: communicate a second instruction to a third mobile robot and third instruction to a fourth mobile robot, each associated with a second fulfillment order assigned to be fulfilled at the first workstation, to travel through the storage structure to a first IRTP aligned with and coupled with the first workstation and to stop and wait, without releasing respective containers being transported by the third mobile robot and the fourth mobile robot, before proceeding to the first workstation following the third mobile robot waiting a respective buffer period of time.

11. The order fulfillment system of claim 10, wherein the first IRTP is sized enabling at least a fifth mobile robot to enter and travel on the first IRTP to approach and enter the first workstation while the third mobile robot and the fourth mobile robot wait on the first IRTP and without being blocked from the first workstation by the third mobile robot and the fourth mobile robot.

12. The order fulfillment system of claim 9, wherein the control circuit is further configured to communicate a second instruction to a third mobile, of the mobile robots, to move onto a first IRTP of a first set of IRTPs and position itself between a fourth mobile robot and a fifth mobile robot already on the first IRTP in approaching the first workstation coupled with the first IRTP in accordance with an order fulfillment sequence.

13. The order fulfillment system of claim 1, wherein the storage structure comprises a first temperature zone and a second temperature zone maintained within a second temperature range that is lower than a first temperature within the first temperature zone, and a third temperature zone maintained within a third temperature range lower than the second temperature range; wherein at least a first IRTP of a first set of IRTPs, of the multiple sets of IRTPs, horizontally extends between the first temperature zone and the second temperature zone establishing a horizontal first temperature transition path between the first temperature zone and the second temperature zone and configured to be utilized by the mobile robots in transporting at least a subset of the multiple containers between the first temperature zone and the second temperature zone.

14. The order fulfillment system of claim 13, wherein at least a first portion of the second temperature zone is vertically separated from at least a second portion of the third temperature zone, and wherein the first portion of the second temperature zone comprises a first subset of levels of the levels, and the second portion of the third temperature zone comprises a second subset of levels different than the first subset of levels; and wherein at least a second IRTP of the first set of IRTPs is vertically aligned with and vertically separated from the first IRTP, and the second IRTP horizontally extends between the first temperature zone and the third temperature zone establishing a horizontal second temperature transition path between the first temperature zone and the third temperature zone.

15. The order fulfillment system of claim 1, wherein two or more workstations, of the workstations, are configured to function as multi-function workstations performing at least decanting cases of items into one or more of the multiple containers, inducting at least a subset of the multiple containers into the storage structure, picking eaches from the multiple containers, and dispensing fulfilled orders.

16. The order fulfillment system of claim 1, wherein each IRTP of each of the multiple sets of IRTPs extends in the second dimension intersecting with a respective subset of aisles, of the plurality of aisles, along a respective one of the levels establishing multiple transit paths within the storage structure to and from the respective subset of aisles of the storage structure.

17. A method of automated order fulfilment, comprising: identifying a first fulfillment order to be fulfilled at a first workstation of multiple workstations; identifying a set of storage locations of multiple storage locations within a storage structure holding respective containers storing items to satisfy the first fulfillment order, the storage structure comprising a horizontal first dimension and a horizontal second dimension, levels that are vertically spaced, storage level changing structures that are spaced along the first dimension of the storage structure establishing vertical pathways between the levels, a plurality of aisles each extending along at least a portion of the first dimension of the storage structure with the multiple storage locations positioned on the levels spanning at least one side of each aisle of the plurality of aisles, and multiple sets of in-rack transit planes (IRTP) interspersed within the storage structure, horizontally spaced from each other along the first dimension of the storage structure and with each IRTP positioned in one of the levels wherein each set of IRTPs comprise two or more IRTPs vertically spaced, and wherein the multiple workstations are distributed along the storage structure, and wherein at least one IRTP of each set of IRTPs of the multiple sets of IRTPs is proximate one or more of the multiple workstations; and routing mobile robots to travel longitudinally along the plurality of aisles, vertically via the storage level changing structures and laterally via the multiple sets of IRTPs within the storage structure to move the containers between the identified storage locations and the first workstation, wherein the multiple workstations are each configured to accept and dispense the containers in fulfilling fulfillment orders.

18. The method of claim 17, wherein the routing the mobile robots comprises routing a first mobile robot transporting a first container to move across a first IRTP of a first set of IRTPs, of the multiple sets of IRTPs, positioned at a first level that physically couples with at least the first workstation along an established path via the first IRTP to or from the first workstation.

19. The method of claim 18, wherein the routing the first mobile robot comprises routing the first mobile robot to traverse laterally across a third IRTP, of the first set of IRTPs comprising at least three IRTPs each vertically aligned at a different one of the levels of the storage structure, between a first aisleat a second level and a second aisle at the second level, wherein the first IRTP and a second IRTP, of the at least three IRTPs of the first set of IRTPs, are aligned with and coupled with the respective workstation.

20. The method of claim 17, further comprising: establishing cross-aisle movement paths via two or more IRTPs of each set of IRTPs of the multiple sets of IRTPs extend along the second dimension across the storage structure intersecting multiple aisles of the plurality of aisles at the respective level with which the respective IRTP is positioned, and coupling at least a first IRTP of the two or more IRTPs with two workstations of the multiple workstations, wherein each of the two workstations are positioned at opposite ends of the first IRTP.

21. The method of claim 20, further comprising: establishing, at each of the levels containing at least one of the IRTPs, a two-dimensional (2D) grid of mobile robot travel paths comprising multiple first dimension travel paths along the plurality of aisles each intersecting with multiple second dimension travel paths across one or more of the IRTPs, of different ones of the multiple sets of IRTPs, positioned spaced along the first dimension of the storage structure at the respective levels; and establishing a three-dimensional (3D) grid of mobile robot travel paths throughout the storage structure comprising the storage level changing structures spaced at different locations along the first dimension of the storage structure coupling the 2D grids of mobile robot travel paths and the levels.

22. The method of claim 20, further comprising: cooperating, for each of the multiple workstations, at least an inbound storage level changing structure, of the storage level changing structures, positioned on a first side of a respective workstation and an outbound storage level changing structure, of the storage level changing structures, positioned on second side of the respective workstation.

23. The method of claim 17, further comprising: wirelessing communicating, from a control circuit, instructions to the mobile robots in routing the mobile robots between the storage locations and the multiple workstations; and defining buffering of two or more of the mobile robots within the storage structure and proximate an assigned one of the multiple workstations.

24. The method of claim 17, wherein the defining the buffering comprises: identifying that a first mobile robot is associated with a first fulfillment order and is buffered and temporarily stopped, while retaining a first container, on a first aisle of the storage structure and proximate a first workstation, of the multiple workstations, that is assigned to fulfill at least a portion of the first fulfillment order; identifying that a second mobile robot is associated with the first fulfillment order; and communicating a first instruction to the second mobile robot directing the second mobile robot to the first aisle adjacent to the first mobile robot in buffering the second mobile robot.

25. The method of claim 24, wherein the defining the buffering comprises: communicating a second instruction to a third mobile robot and a third instruction to a fourth mobile robot, each associated with a second fulfillment order assigned to be fulfilled at the first workstation, to travel through the storage structure to a first IRTP aligned with and coupled with the first workstation and to stop and wait, without releasing respective containers being transported by the third mobile robot and the fourth mobile robot, before proceeding to the first workstation following the third mobile robot waiting a respective buffer period of time.

26. The method of claim 24, further comprising: communicating a second instruction to a third mobile, of the mobile robots, to move onto a first IRTP of a first set of IRTPs and position itself between a fourth mobile robot and a fifth mobile robot already on the first IRTP in approaching the first workstation coupled with the first IRTP in accordance with an order fulfillment sequence.

Images