Sortation apparatus for storage systems and associated methods

Abstract

A package sortation system includes a storage structure, an auto-packing machine configured to form packages, a robot including one or more bin retrieval devices, and a sortation device. The storage structure includes pillars defining vertical shafts, the pillars supporting a grid formed of a first set of parallel rails extending in a first direction and a second set of parallel rails extending in a second direction perpendicular to the first direction, the first and second set of parallel rails collectively defining a plurality of grid spaces. The bin retrieval includes a grapple extendable and retractable in a vertical direction, and the sortation device is arranged to be manipulated by grapple of the robot to sort packages from the auto-packing machine into a respective one of a plurality of end locations.

Description

[0001] Docket No. 127308-856276

[0002] SORTATION APPARATUS FOR STORAGE SYSTEMS AND ASSOCIATED METHODS

[0003] CROSS REFERENCE

[0004] The present disclosure relates to and claims priority to U.S. Provisional Application No. 63 / 685,063. filed on August 20, 2024, the entire contents of which is incorporated herein by reference.

[0005] TECHNICAL FIELD

[0006] The present disclosure relates to robotic systems for distribution fulfillment centers, and more particularly, to package sortation devices and associated methods for sorting packages on grid-based storage structures.

[0007] BACKGROUND

[0008] Distribution fulfillment centers, such as warehouses, require systems that enable the efficient storage and retrieval of a large number of diverse products. Traditionally, inventory items are stored in containers and arranged on rows of shelving on either side of an aisle. Each container, or bin, holds a plurality of items of one or more product types. The aisles provide access between the shelving for an operator or robot to traverse the aisles and retrieve the items. It is well understood that the aisles reduce the storage density of the system. In other words, the amount of space used for the storage of products (e.g., the shelving) is relatively small compared to the amount of space required for the storage system as a whole. As warehouse space is often scarce and expensive, alternative storage systems that maximize storage density are desired.

[0009] In one alternative approach, which offers a significant improvement in storage density, containers are stacked on top of one another and arranged in adjacent rows. That is, no aisle is provided between the adjacent rows of stacked containers. Thus, more containers, and in turn more inventory, can be stored in a given space.

[0010] Various methods for retrieving inventory' from the stacked containers have been contemplated. For example, U.S. Pat. Pub. No. 2021 / 0032034, discloses a system in which containers are stacked and arranged in a plurality of rows underneath a grid, and the containers are retrieved by robots operating on the grid, which subsequently pick and pack inventory' into order bins. Furthermore, WO 2024 / 049831, which is incorporated by reference herein in its entirety, discloses an auto-packing machine (e.g., an auto-bagger, and auto-boxer, and the like) provided on or adjacent to a grid-based storage structure,

[0011] 1

[0012] 105497822 1 Docket No. 127308-856276 thereby allowing the robots operating on the grid to pick and pack inventory into a packaging that is shipped to an end consumer. While the systems disclosed in WO 2024 / 049831 automate picking and packaging tasks, additional systems that automate sortation tasks and that improve sortation efficiency remain desired

[0013] BRIEF SUMMARY

[0014] The sortation systems and sortation devices disclosed herein, allow a robot positioned on the grid to sort packages into a plurality of different sorting locations, such as Gaylords, for outbound shipment. Among its advantages, the sortation device can be used by a robot positioned on the grid, and as a result, the warehouse need not include a separate sortation area containing dedicated sortation equipment that would otherwise diminish the storage density7of the warehouse and add additional complexity7, cost and failure modes. Furthermore, the sortation device can be utilized by any robot performing fulfillment tasks on the grid. That is. the storage structure itself, and the warehouse in general, need not include expensive conveyors or other fixed sortation systems that render scalability difficult as it would require modifying the fixed infrastructure. Finally, in some implementations, the robot performing a picking task, may simultaneously perform a sortation task, without traversing about the grid, thereby increasing the order fulfilment throughput while also reducing the number of robots required to fulfill and sort a given number of orders or perform a given number of fulfillment tasks.

[0015] In one aspect of the present disclosure, a package sortation system, includes: a storage structure including pillars defining vertical shafts, the pillars supporting a grid formed of a first set of parallel rails extending in a first direction and a second set of parallel rails extending in a second direction perpendicular to the first direction, the first and second set of parallel rails collectively defining a plurality of grid spaces; an autopacking machine configured to form packages; a robot including one or more bin retrieval devices, the bin retrieval device including a grapple extendable and retractable in a vertical direction; and a sortation device manipulatable by the grapple of the robot and configured to sort the packages formed by the auto-packing machine into a respective one of a plurality of sorting locations.

[0016] The auto-packing machine may be disposed on the grid, or disposed adjacent the grid and at a height that is substantially equal to a height of the grid. The plurality of sorting locations may be a plurality of end-sorting locations. The package sortation system may further include a plurality7of chutes arranged to transfer the packages into the plurality7

[0017] 2

[0018] 105497822 1 Docket No. 127308-856276 of sorting locations. Each of the plurality of chutes may include a receiving portion, and at least some of the receiving portions may be arranged above one another. The autopacking machine may be an auto-bagger or an auto-boxer.

[0019] The sortation device may include a main frame secured to a platform at a fulcrum; a first handling portion connected to the platform and configured to be manipulated by the grapple of the robot; and a second handling portion connected to the platform and configured to be manipulated by another grapple of the robot, such that movement of the first handling portion relative to the second handling portion pivots the platform about the fulcrum.

[0020] The main frame may be arranged to engage at least one of the pillars defining a vertical shaft to guide movement of the sortation device as the sortation device is moved in a vertical direction. The first and second handling portions may include a sidewall emulating certain engagement features of a storage bin that is securable by the grapple. In another embodiment of the present disclosure, a sortation device is provided, and the sortation device includes: a main frame secured to a platform at a fulcrum; a first handling portion connected to the platform and configured to be manipulated by a robot; and a second handling portion connected to the platform and configured to be manipulated by the robot.

[0021] The main frame may be arranged to engage at least one pillar of a grid-based storage structure to inhibit horizontal movement of the sortation device and guide vertical movement of the sortation device. The first and second handling portions may include a sidewall emulating engagement features of a storage bin that is securable by first and second grapples of the robot.

[0022] In yet another embodiment of the present disclosure, a method of sorting packages, incudes: picking an inventory item, using a robot, disposed on a grid of a storage structure; placing the picked inventory item into an auto-packing machine to a form a package; receiving the package by a sortation device; and moving the sortation device, using the robot, to direct the package into one of a plurality of sorting locations located below the grid.

[0023] The body of the robot may remain stationary relative to the grid during and between the picking step and the moving step. The method may further include picking another inventory' item using the robot, and wherein the picking another inventory' item may be simultaneously performed with the moving step. The moving step may include lifting or lowering at least one grapple of the robot in a vertical direction. The moving step may

[0024] 3

[0025] 105497822 1 Docket No. 127308-856276 include lifting or lowering a first grapple of the robot in a vertical direction relative to a second grapple of the robot to pivot a platform of the sortation device about a fulcrum. The moving step may include angling the platform to direct the package onto a desired one of a plurality of chutes. The plurality of locations may be a plurality of Gaylords, and the method may further include sliding the package down the desired one of the plurality of chutes and into a respective Gaylord.

[0026] BRIEF DESCRIPTION OF THE DRAWINGS

[0027] FIG. 1 is a schematic illustration of a grid-based storage structure for housing a plurality of stacked bins according to an embodiment of the present disclosure.

[0028] FIG. 2 is a plan view of a portion of the storage structure of FIG. 1.

[0029] FIG. 3 is a perspective view of a robot provided with two bin retrieval devices designed to operate on the grid-based storage structure of FIG. 1.

[0030] FIG. 4 is a perspective view of support arms of the bin retrieval device of the robot of FIG. 3.

[0031] FIG. 5 A is a plan view of a grapple of the bin retrieval device of the robot of FIG. 3.

[0032] FIG. 5B is a perspective view' of a portion of the grapple of FIG. 5A.

[0033] FIGS. 6A - 6G illustrate a sortation system, from various orientations, in accordance with an embodiment of the present disclosure.

[0034] FIG. 6H is a perspective view of a grid-based storages structure having a plurality of sortation systems shown in FIGS. 6A-6G.

[0035] FIG. 7 is a perspective view illustrating a plurality of chutes of the sortation system of FIGS. 6A - 6E.

[0036] FIGS. 8A and 8B are a perspective view and a front elevation view7, respectively, of a sortation device of the sortation system of FIGS. 6A - 6G.

[0037] FIG. 9 is a perspective view of a sortation device according to another embodiment of the present disclosure.

[0038] FIGS. 10A and 10B are front elevation views of a sortation device according to yet another embodiment of the present disclosure.

[0039] FIGS. 11A and 11B are perspective views illustrating a robot operating the sortation device of FIGS. 8A and 8B to sort packages.

[0040] DETAILED DESCRIPTION

[0041] The technology disclosed herein relates to a sortation system including a sortation device for sorting packages within a grid-based storage structure. The sortation device is

[0042] 4

[0043] 105497822 1 Docket No. 127308-856276 designed to direct packages into a respective one of a plurality of chutes extending to sorting locations, such as Gaylords, and may be operated by a robot disposed on the grid, for example, the robot picking and packing an order into a packaging that will be delivered to an end consumer. In this regard, the order may be picked, packed, labeled, and sorted for outbound shipment, using a single type of robot, and often using a single robot, without requiring separate packing and / or sortation equipment that would otherwise reduce the storage density of the warehouse and add undesired cost, complexity and challenges to maintaining or scaling the storage structure.

[0044] As used herein, the terms “automated” or “autonomous” refers to a device or a system capable of operating autonomously at least some of the time. Put differently, the terms “automated” or “autonomous” include devices and systems that are operated with the assistance of a human at certain times so long as they can be operated autonomously at least some of the time. Is it also noted that the terms “storage bin,” “order bin,” and “package” refer to any vessel capable of housing one or more items. This nomenclature is used merely for readability as inventory is transferred between different vessels at various order fulfilment stages. For the avoidance of doubt, unless explicitly stated otherwise, the terms “storage bin,” “order bin,” and “package” encompasses any vessel including, containers, bins, totes, cartons, boxes, bags, or any other structure capable of storing inventory' items or parcels. Also as used herein, the terms “substantially,” “generally.” “about” and the like are intended to mean that slight deviations from absolute are included within the scope of the term so modified.

[0045] FIG. 1 is a highly schematic illustration of a storage structure 1 configured to efficiently store a plurality of storage bins 10 according to an embodiment of the present disclosure. Storage bins 10 temporarily store product items (not shown) and may have a bottom edge configured to nest within a rim of another storage bin such that the storage bins can be stacked on top of one another to form stacks 12. Each of the stacks 12 may be housed w ithin a framew ork 14 of storage structure 1.

[0046] Framework 14 includes a plurality of pillars 16 and a grid 20 formed of a series of rails 22. With additional reference to FIG. 2, pillars 16 may be secured within a respective stabilizing / leveling foot 18 to form vertically extending shafts within which stacks 12 are housed. Pillars 16 support grid 20 at a top level of storage structure 1. More specifically, grid 20 is formed from a first set of parallel rails 22a designed to guide movement of robots 100 in a first direction (e.g., the x-direction) and a second set of parallel rails 22b, arranged perpendicular to the first set of parallel rails, designed to guide

[0047] 5

[0048] 105497822 1 Docket No. 127308-856276 movement of the robots in a second direction (e.g., the y-direction). A plurality of robots 100 (shown in FIG. 3) may be installed on grid 20 and tasked with performing various fulfilment tasks, for example, storage bin retrieval tasks, picking and packing tasks, and sorting tasks. In this manner, rails 22 allow robots 100 to move laterally in two directions (e.g., the x-direction and in the y-direction) across the top of storage structure 1 such that the robots can be moved into position above any one of the stacks 12. The combination of the first set of parallel rails 22a and the second set of parallel rails 22b form grid 20 defining a plurality of grid spaces.

[0049] FIG. 2 is a plan view of a single grid space. As shown in FIG. 2, the cross-sectional area of each shaft may be slightly larger than the perimeter of the storage bin 10. Thus, when a lowermost storage bin is secured within stabilizing / leveling feet 18, and additional storage bins are stacked thereon, a small gap 24 (e.g., space) exists between an outer surface of each of the storage bins 10 within a respective stack 12 and at least one pillar 16 (if not all the pillars) that define the vertical shaft in which the stack of storage bins 10 is housed.

[0050] Robot 100, as shown in FIG. 3, includes a communication interface to send and receive data between the robot and a remote processor, such as a Warehouse Management System (WMS), enabling the remote processor to control movement and operation of each of the robots about grid 20. Robot 100 may also include a body 102, a wheel assembly 104 arranged to move the body along rails 22a. 22b, one or more bin retrieval devices 106, and a picking arm 108. In one embodiment, wheel assembly 104 may include a plurality of wheels, a motor, and one or more transmissions (belts or linkages) operably coupling each one of the wheels to the motor. The orientation of the wheels may be controlled by the motor and the one or more transmissions. More specifically, the motor is coupled to each one of the wheels, via the one or more transmissions, such that rotation of the motor simultaneously pivots the orientation of each one of the wheels. As a result, the wheels may be simultaneously pivoted between a first orientation in which each of the wheels is aligned with the first set of rails 22a and a second orientation in which each of the wheels is aligned with the second set of rails 22b (e.g., 90 degrees). A drive mechanism may be associated with wheel assembly 104 to rotate the wheels and move body 102 along the rails in which the wheels are positioned.

[0051] In an alternative embodiment, the wheel assembly 104 of robot 100 may be constructed with first and second sets of non-pivotable wheels, one or more displacement mechanisms for lifting and lowering the first and second sets of wheels, and one or more

[0052] 6

[0053] 105497822 1 Docket No. 127308-856276 drive mechanisms. Specifically, wheel assembly 104 may include a first set of non- pivotable wheels consisting of a pair of wheels on the front of the robot and a pair of wheels on the back of the robot, and a second set of non-pivotable wheels consisting of a pair of a wheels on each lateral side of the robot. The wheel assembly may also include or more displacement mechanisms for lifting the first set of wheels away from the first set of rails 22a and lowering the first set of wheels into engagement with the first set of rails, and lifting the second set of wheels away from the second set of rails 22b and lowering the second set of wheels into engagement with the second set of parallel rails. The one or more drive mechanisms of the wheel assembly may be used to rotate the first and second set of non-pivotable wheels along the rail to which the wheels are engaged.

[0054] As shown in FIG. 3, robot 100 may include two bin retrieval devices 106: a first bin retrieval device extending from a front of body 102 and a second bin retrieval device extending from a back of the body. However, it is contemplated that robot 100 may include zero, one, two, three or four bin retrieval devices 106 and that the bin retrieval devices may extend from any side of body 102 in any arrangement.

[0055] With additional reference to FIGS. 4. 5A and 5B. each bin retrieval device 106 includes a pair of support arms 110 and a grapple 112 designed to grasp and extract storage bins 10 from framework 14. Grapple 112 may be suspended from support arms 110 by cables 114 which are connected to a winding mechanism 116 such as a spool, hoist, or winch. The cables can thus be wound and unwound to adjust the height of grapple 112 with respect to the support arms in the z-direction.

[0056] Grapple 112 includes a bin securement feature such as a pivotable or extendable flap 120. Grapple 112 may be two-sided or three-sided to define one or more “open side(s)” or may be four-sided to define an enclosed perimeter having an open interior. As illustrated in FIGS. 5A and 5B, grapple 112 is three-sided and is formed by opposing grapple arms 122 and a connector 124. Grapple arms 122 and connector 124 collectively define an open side and an open interior. Each flap 120 may be pivotable relative to a respective grapple arm 122 between a deployed condition, in which the flap pivots or otherwise moves away from the grapple arm from it is connected into the open interior, and an undeployed condition in which the flap lies substantially flush against the grapple arm or is otherwise disposed within the footprint of the grapple arm. Movement of flaps 120 between the undeployed and deployed condition may be controlled by an actuator disposed within grapple 112 that is configured to convert an electrical signal carried through the cables to motion of the flaps. When flaps 120 are in the undeployed condition,

[0057] 7

[0058] 105497822 1 Docket No. 127308-856276 the open interior is larger than storage bin 10, allowing grapple 112 to be lowered into gap 24, and around a stack 12 of storage bins 10, before the flaps are deployed and brought into contact with an engagement feature such as a rib (not shown) on a side of the storage bin. In this manner, bin retrieval device 106 is arranged to extract one or more storage bins 10 in a single lift (e.g., the storage bin grasped by grapple 112 and any storage bins stacked thereon).

[0059] Picking arm 108 may be movable in at least three dimensions to allow end effector 126 to pick inventory' items from a storage bin 10 and to transfer the picked inventory. End effector 126 may be a pneumatically actuated end effector such as a suction cup.

[0060] FIGS. 6A - 6G illustrate a package sortation system for autonomously sorting packages containing inventory retrieved from grid-based storage structures such as storage structure 1. The package sortation system may include storage structure 1, robot 100, an auto-packing machine 200 such as an auto-bagger or auto-boxer, a sortation device 300 manipulatable by the robot, and a plurality7of chutes 400, each of which extend to a respective sorting location, which may be an end-sorting location, such as a Gaylord 500. As shown in FIG. 6H, storage structure 1 may include a plurality of package sortation systems.

[0061] Although auto-packing machine 200 is primarily described herein as an autobagger, it will be appreciated that the auto-packing machine 200 may also be an auto-boxer (e.g., a carton-wrap machine or carton-erector machine), or any other machine capable of autonomously forming a packaging for shipment to an end-consumer. Auto-packing machine 200 may be disposed on grid 20 or on a platform, or other structure, at a height that is substantially equal to a height of the grid. As used herein, this means auto-packing machine 200 is disposed at a height that permits robot 100, operating on grid 20, to transfer inventory items to the auto-packing machine via its picking arm 108.

[0062] The auto-bagger may' include a transfer mechanism 202, a bagging and sealing component 204, and a labeling device 206. Transfer mechanism 202 may be configured as a conveyer, an infeed such as a chute, a guiding element, or a staging surface, arranged to receive one or more items from robot 100 and to transfer those item(s) towards the bagging and sealing component 204. In some embodiments, a raised and angled platform or chute may be used to re-orient inventory items as they are transferred toward transfer mechanism 202. For example, if a tall and thin item, such as a cereal box, is placed on the angled platform, it will tip onto its long flat surface and slide down the angled platform

[0063] 8

[0064] 105497822 1 Docket No. 127308-856276 towards transfer mechanism 202, thereby properly orienting the item prior to reaching bagging and sealing component 204.

[0065] Bagging and sealing component 204 may be designed to open a bag, for example, a bag formed of Polyethylene (a polybag), and to the seal the bag after the one or more items pertaining to an order have been placed within the bag to form a sealed package. Alternatively, bagging and sealing component 204 may be configured to wrap a material such as polyethylene around one or more inventory items to form a bag. Labeling device 206 is configured to print a shipping label on the package for outbound shipment.

[0066] Auto-packing machine may also include an insert or wrapping component configured to at least partially surround or wrap the inventory items in additional protective or packaging materials such as bubble wrap, void fill dunnage, crinkle paper, foam, corrugate, cardboard, paper, tissue paper, gift paper, air pillows, trays, pack slips or invoice paper sheets, marketing inserts, etc., prior to being sealed by bagging and sealing component 204. In other embodiments, the one more inventory7items may be wrapped in the additional packaging material by a wrapping device that is separate from, or prior to the infeed of auto-packing machine 200, such as a StraPack. with or without assistance from robot 100. For example, robot 100 may retrieve and place wrapping materials on the transfer mechanism 202, then place inventory items on top of the wrapping materials, before a separate wrapping device secures the wrapping materials around, or partially around, one or more of the inventory items with a strap such as a rubber band. tape, clip, etc. While robot 100 may assist in transferring the inventory items and / or the wrapping materials, in other embodiments, the wrapping materials may be automatically disposed and automatically wrapped around inventory7items by one or more other devices without assistance from robot 100.

[0067] A sorting transfer mechanism 208 such as a chute, conveyer, push-tray, cross-belt and the like, may' transfer packages from auto-packing machine 200 to sortation device 300. In this regard, sorting transfer mechanism 208 is designed to transport the labeled package to sortation device 300 without requiring assistance from robot 100. In some embodiments, the auto-bagger may include a scale, for example, within transfer mechanism 202 or sorting transfer mechanism 208, to weigh the inventory items and / or the package prior to or after the packaging has been sealed.

[0068] In other embodiments, the picking arm 108 or other mechanism of robot 100 may be used to grab and transfer the package from auto-packing machine 200 directly to transfer mechanism 208, directly to sortation device 300, or directly to a chute 400.

[0069] 9

[0070] 105497822 1 Docket No. 127308-856276

[0071] Consequently, it will be appreciated that the package sortation system need not include sorting transfer mechanism 208.

[0072] The plurality of chutes 400, as shown in FIG. 7, is designed to receive the package from the sortation device 300 and to deposit the package into a desired sorting location, which in some instances may be an end-sorting location such as Gaylord 500 to stage the packages for pickup. Example sorting locations include a bin, basket truck, cart, shelf, chute, cubby, pallet, Gaylord 500 or similar. In conventional warehouses, packages are sorted and deposited into Gaylord 500 for pickup by a particular transportation carrier, or for pre-sortation performed on behalf of the carrier by region, city, zip code, address, delivery route, etc. That is, packages for Carrier A are deposited into one or more Gaylords pertaining to Carrier A, packages for Carrier B are deposited into one or more Gaylords pertaining to Carrier B, packages for Carrier C deposited into one or more Gaylords pertaining to Carrier C. When the truck for a respective carrier arrives at the warehouse, the Gaylords pertaining to that carrier are then loaded onto the truck for outbound shipment. While FIGS. 6A-6F illustrate the sorting location as Gaylords 500, it will be appreciated that alternative sorting locations may be utilized. For example, if the sorting location is a pallet, one or more manipulator devices may be provided at the end of each chute 400 to neatly stack or palletize the packages on the pallet.

[0073] As shown in FIG. 7, each chute 400 may include a receiving portion 402 and a transportation portion 404 extending away from the receiving portion and toward a Gaylord 500. Receiving portion 402 may be declined, include a curved or angled outer wall 406, and be positioned within a vertical shaft located adjacent to the vertical shaft in which sortation device 300 is disposed. In this regard, the receiving portion is configured to receive a package from sortation device 300 coming from a first lateral direction and to convey that package to transportation portion 404. The transportation portion 404 in turn then conveys the package in a second lateral direction perpendicular to the first lateral direction and into a respective sorting location such as Gaylord 500 within a staging area.

[0074] While FIG. 7 illustrates sixteen total chutes, arranged in two-sets, it will be appreciated that the sortation system may include any number of chutes, and intermediary chutes, in any arrangement. For example, in some embodiments, two or more chutes 400 of the same or different sortation systems may extend or otherwise route packages into the same sorting location. Nevertheless, it will also be appreciated that overlapping at least some of receiving portions 402 in a vertical direction will increase the sorting density.

[0075] 10

[0076] 105497822 1 Docket No. 127308-856276

[0077] FIGS. 8A and 8B illustrate a sortation device 300 for sorting packages, or inventory items not enclosed in packaging, to a desired sorting location according to an embodiment of the present disclosure. Sortation device 300 may be designed generally to operate like a seesaw and include a main frame 302 secured to a platform 304 that is pivotable about a fulcrum 306, a first handling portion 308 including a sub-frame 310 attached to the platform at a first side of the fulcrum, and a second handling portion 312 including a subframe 314 attached to the platform at a second side of the fulcrum.

[0078] The main frame 302 of sortation device 300 may be attached to a center of platform 304 at fulcrum 306 as will be explained in further detail hereinafter. As shown in FIGS. 6A - 6E, main frame 302 may be designed to sit within a vertical shaft defined by pillars 16, while first handling portion 308 and second handling portion 312 may be designed to sit within opposite vertical shafts located adjacent to the vertical shaft in which the main frame is disposed. In one embodiment, main frame 302 is advantageously designed to be constrained by one or more of the pillars 16 defining that vertical shaft in which the main frame sits. For example, main frame 302 may have a rectangular crosssection that is sized to match the geometry of pillars 16, and may define edges 316 that are adapted to engage the pillars to prevent the main frame from swaying in a horizontal direction as the sortation device is extended and retracted in the vertical direction. One or more of the edges 316 may include rollers, bearings, or the like to assist main frame 302 in sliding along pillars 16 as sortation device 300 travels in a vertical direction within the shaft.

[0079] First handling portion 308 may include a sub-frame attached to platform 304 at a first side of fulcrum 306. Similarly, second handling portion 312 may include a subframe 314 attached to platform 304 at a second side of fulcrum 306 opposite to first handling portion 308. First handling portion 308 and second handling portion 312 may be shaped and sized to emulate at least a portion of a storage bin 10, or to emulate a similar interface to that of the storage bin such that it may be grasped and handled by the grapple 112 of robot 100. That is, first handling portion 308 and second handling portion 312 may include a sidewall having an engagement feature, such as a rib, configured to be grasped by grapple 112 of robot 100. In this regard, robot 100 may lift and lower sortation device 300 in a vertical direction by simultaneously lifting and / or lowering its grapples 112, and tilt the sortation device in either direction, about fulcrum 306, by lifting or lowering one of the grapples relative to the other one of its grapples. When platform 304 is tilted, gravity will cause the package to slide along the

[0080] 11

[0081] 105497822 1 Docket No. 127308-856276 platform and into a desired chute. As shown in FIGS. 11A and 11B, platform 304 may include side walls to prevent the packages from falling off platform 304.

[0082] Returning now to FIG. 6A, the storage structure 1 may include one or more shelves 26 located adjacent to auto-packing machine 200. Shelf 26 may be attached to one of the rails 22 and sit within a respective grid space. More specifically, the shelf may be similarly sized to a storage bin 10 such that a gap G exists between two or more sides of the shelf and rails 22. In this regard, shelf 26 is configured to hold an order bin, filled with ordered items, near the top of grid 20 where it can be accessible by the picking arm 108 of robot 100. The configuration of shelf 26 also allows the grapple 112 of robot 100 to pass around the shelf and to grasp or otherwise handle the first handling portion 308 and the second handling portion 312 of sortation device 300 located beneath grid 20. As shown in FIG. 6A, in some embodiments, the sortation system may include a covering placed over certain grid-spaces around auto-packing machine 200. The coverings create a safe walking path for a person to access auto-packing machine 200 when a service, material replenishment, or maintenance is required.

[0083] While sortation device 300 is primarily described herein as a fully passive device that sorts packages into a desired sorting locations based on the relative height of one or more of the grapples 112 of robot 100, in other embodiments, sortation device 300 may be provided with autonomously actuatable components controllable by robot 100 or a remote processor such as the WMS. For example, sortation device 300 may include conveyors, push-trays, or other actuatable components for dispensing the packages from the sortation device such that the grapple 112 of robot 100 is only partially responsible for depositing the package into a desired chute. That is, the grapple of robot 100 may be responsible for adjusting the height of sortation device 300, and the actuator may be responsible for dispensing the package from the sortation device to the desired chute 400. Still yet, in other examples, the sortation system need not include any of the sortation devices described herein. Instead, the packages produced from auto-packing machine 200 may be transferred to a Bombay, or Bombay-like bin, or another vessel such as a storage bin 10, an order bin, etc. Robot 100 may then, if necessary, transport vessel and the packages contained therein, to a location located adjacent chutes 400 before the transferring the packages on a desired chute 400. The packages may be transferred directly from the Bombay, or Bombay-like bin, onto chutes 400 or using the picking arm 108 of robot 100.

[0084] An example process, or method, of sorting packages into individual sorting locations using the disclosed sortation system is now described below. First, as orders are

[0085] 12

[0086] 105497822 1 Docket No. 127308-856276 received by the warehouse, the WMS will direct robot 100 to pick inventory items from storage bins 10 and place inventory items into an order bin. In some embodiments, the order bin may be structurally similar to storage bin 10. In other embodiments, the order bin may be of a different construction so long as it is capable of being directly or indirectly carried by robot 100 about the grid.

[0087] After receiving pick and pack instructions from the WMS, robot 100 may secure an order bin, for example, to grapple 112 and use wheel assembly 104 to drive about grid 20 to a desired location. By way of example, if the desired SKU is housed in a storage bin 10 located at the top of a stack 12, wheel assembly 104 may drive along rails 22 to position the grapple 112 securing the order bin above a grid space located adjacent to the grid space within which the item is located. Once in position, end effector 126 (e g., suction cup) may be positioned within storage bin 10 to grasp the item. After the item has been grasped, picking arm 108 may be moved toward the order bin to place the item within the order bin.

[0088] On the other hand, if the desired item is housed within a storage bin 10 upon which other storage bins are stacked, the storage bin housing the desired item (e.g., the "target bin”) must first be extracted. To extract the target bin, robot 100 moves along rails 22 to position storage bin retrieval device 106 over the stack 12 housing the target bin. Grapple 112 may then be lowered into gap 24 and around stack 12 until the grapple is positioned around the storage bin stacked directly on top of the target bin. With grapple 112 in position, flaps 120 may be deployed and brought into engagement with a rib, or another engagement feature, on a side of the storage bin to secure the storage bin to the grapple. With storage bin 10 secured to grapple 112, the winding mechanism 116 may be wound to retract the grapple and to lift the storage bin and any storage bins located on top of that storage bin.

[0089] The body 102 of robot 100 may then be moved to another location and each of the storage bins secured by grapple 112 may be placed on top of another stack 12. In some instances, each of the previously extracted storage bins 10 may be located entirely below the surface of grid 20. In other instances, at least some of the previously extracted storage bins 10 that were placed on top of another stack 12 may be located above the surface of grid 20. In such instances, the “open side” of the grapple 112 allows robot 100 to return to the stack 12 containing the target the container, and to extract the target bin. With the extracted target bin secured to grapple 112. the picking arm 108 may pick the item from the target bin and pack the picked item into the order bin. The target bin and the storage

[0090] 13

[0091] 105497822 1 Docket No. 127308-856276 bins that were temporarily displaced may then be returned to stack 12, for example, in their original order.

[0092] It will be appreciated that other robots 100 operating on grid 20 may assist in extracting the “non-target bins” (e.g., the bins stacked on top of the “target bin”), the “target bin,” or picking and packing the inventory' item. Put differently, a single robot 100 need not perform each task necessary to pick and pack an item. That is. robots 100 operating on grid 20 may be assigned tasks from the WMS and work in conjunction with one another to fulfill one or more orders and increase overall fulfilment efficiency. This process may be repeated until robot 100 has picked and placed all the items pertaining to a particular order into the order bin.

[0093] When an order bin contains one or more complete orders, robot 100 may traverse grid 20 to a sorting location as shown in FIGS. 6A - 6E. Robot 100 may then lower its grapples 112 in a vertical direction causing the order bins to be retained on shelves 26. The grapples 112 may continue to be lowered through gap G and respectively about first handling portion 308 and second handling portion 312 of sortation device 300. In this position, flaps 120 may be deployed and brought into contact with an engagement feature, such as a rib, provided on first handling portion 308 and second handling portion 312. The grapples 112 of robot 100 may then be retracted to lift sortation device 300 to a receiving location located adjacent to sorting transfer mechanism 208 as shown in FIG. 6A.

[0094] Next, or in parallel to the previous step, the picking arm 108 of robot 100 may be utilized to pick one or more items from the order container and to place the one or more items onto transfer mechanism 202 of auto-packing machine 200. In some embodiments, a scale disposed within auto-packing machine may weigh the items to confirm that the item(s) is the correct item(s) and to properly label the package for outbound shipment. Bagging and sealing component 204 may hold a polybag in an open position, as the one or more items are transported along the conveyer and dispensed into the open polybag before the bagging and sealing component seals the polybag. One or more shipping labels may be applied to the outside of the package for outbound shipment. In some examples, auto-packing machine 200 may optionally print and / or apply branded tape, stickers or custom graphics onto the outside of the package. Again, although auto-packing machine 200 is described above as an auto-bagger, it will be appreciated that auto-packing machine may alternatively be an auto-boxer designed to package an order into a box or corrugate material in a similar manner.

[0095] 14

[0096] 105497822 1 Docket No. 127308-856276

[0097] The sealed package may then be dispensed from auto-packing machine 200 and received by sorting transfer mechanism 208. Once the package is received by sorting transfer mechanism 208, the package will slide onto the sortation device 300. A remote processor, such as the WMS, may then send signals to robot 100 which will be used to adjust grapples 112 to the correct relative height and to dispense the package onto a specific chute 400 for delivery to a particular sorting location such as Gaylord 500. For example, if the package is to be deposited into the Gaylord 500 labeled “xx” in FIG. 6A, the WMS will instruct robot 100 to deposit the package onto the chute 400 labeled “yy” in FIG. 6B.

[0098] To accomplish this task, robot 100 will unwind cables 114 to lower both grapples 112 of bin retrieval devices 106 while the platform 304 of sortation device 300 remains substantially horizontal so as to prevent the package from sliding while lowering the sortation device 300 as shown in FIG. 11 A. As sortation device 300 is lowered in a vertical direction, the edges 316 of main frame 302 may slide or roll along, or otherwise occasionally contact, pillars 16 to prevent the sortation device from swaying as the sortation device is lowered in the vertical direction. After sortation device 300 has reached an appropriate depth, robot 100 may lift first handling portion 308, while retaining or lowering second handling portion 312 to alocation located adjacent the chute labeled “yy” which will pivot platform 304 about fulcrum 306 as shown in FIG. 11B. As a result, the package will slide along platform 304 and into the receiving portion 402 of the chute 400 labeled “yy.”

[0099] The package, once received within the receiving portion 402 of chute 400, will be guided by outer wall 406 and into transportation portion 404, which will then transport the package into the Gaylord 500 labeled “xx.” As a result, the package is automatically sorted into a sorting location, which may in some instances be an end-sorting location, where it may await pickup from its desired carrier. It will be appreciated, that robot 100 may continue picking items and placing or packing the picked item onto the transfer mechanism 202 of auto-packing machine while the same robot sorts packages into chutes 400 that transfer packages to the targeted Gaylords. In this manner, a single robot can simultaneously pack items into packaging via auto-packing machine 200 and sort the formed packages into sorting location, while the body 102 of robot 100 remains stationary. Thus, the sortation devices disclosed herein significantly improve order fulfillment throughput and reduce the number of robots needed for a given number of tasks or orders. Nevertheless, in other examples, a plurality of robots 100 may operate in parallel to

[0100] 15

[0101] 105497822 1 Docket No. 127308-856276 perform the picking and sorting tasks, for example, one robot may be tasked with picking items and transferring the picked items to auto-packing machine while one or more other robots is tasked with operating the sortation device.

[0102] Gaylords 500 may remain underneath chutes 400 or be moved to a separate staging area when full until the respective carrier trucks arrive. Various known robotic devices, such as robotic pallet handlers, forklifts, autonomous mobile robots (AMRs), automated guided vehicles (AGVs), etc., may be utilized to move Gaylords 500 about the warehouse, to place Gaylords 500 on pallets, and / or to load the Gaylords 500 onto the tuck for outbound shipping.

[0103] Although sortation device 300 is described above as a pivotable seesaw-like device, it will be appreciated that the sortation device may be constructed differently. For example, as shown in FIG. 9, sortation device 300' may be a diverting mechanism that is manipulatable by a single grapple 112 to divert packages into a plurality of sorting locations. For example, sortation device 300' may include a single handling portion 308' configured similarly to first handling portion 308 and / or second handling portion 312, and a series of platforms 304' stacked on top of one another and oriented at angles facing in different directions. The grapple 112 of robot 100 may raise and lower the single handling portion 308' to a desired level so that the package is received by a select one of the platforms 304' designed to divert to the package into a desired chute 400 extending to a sorting location such as Gaylord 500.

[0104] In yet another example, as shown in FIGS. 10A and 10B, sortation device 300" may include a plurality of platforms 318a-318d (collectively “318”) that are fixed to storage structure 1 at a declined angle to divert a package into an adjacent shaft and a plurality of tiltable platforms 320a-320e (collectively “320”) disposed within an adjacent shaft. Each tiltable platform 320a-320e may be transitionable between a natural (e.g., default) declined position and a tilted inclined position to divert the package into a desired chute. The plurality7of tiltable platforms 320 may be include a handling portion that is configured similarly to first handling portion 308 and / or second handling portion 312 such that the grapple 112 of robot 100 is capable of tilting a desired platform to divert the package into a desired chute 400, for example, by grasping the desired platform with its grapple and lifting or lowering the grapple. When the grapple 112 of robot 100 releases tiltable platform 320, gravity or a spring-like mechanism may transition the tiltable platform back to its default or declined position.

[0105] 16

[0106] 105497822 1 Docket No. 127308-856276

[0107] In use, with reference to FIG. 10B, a package produced from auto-packing machine 200 may be deposited into the shaft containing fixed platform 318. The package may slide from the uppermost fixed platform 318a to an uppermost tillable platform 320a, back to a second fixed platform 320b, and then to tiltable platform 320b, which has been tilted by the grapple 112 of robot 100 to divert the package into the chute labeled “zz”. In this regard, it will be appreciated that robot 100 may utilize grapple 112 to manipulate any one of the tillable platforms 320a-e to divert the package into any one of the plurality of chutes 400.

[0108] The sortation systems described herein allow a single robot positioned on the grid to efficiently sort packages into a plurality of different gaylords for outbound shipment while simultaneously packing other orders. As a result, the warehouse need not include a separate sortation area, dedicated sortation equipment or dedicated robotic sorters that would otherwise diminish the storage density of the warehouse, or add cost, complexity or present other challenges in maintaining or scaling the storage structure. Furthermore, neither the storage structure itself, nor the warehouse in general, need to include expensive conveyors, large-fixed sortation equipment, or other systems designed to transport and sort packages.

[0109] Although the invention herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present invention. It is therefore to be understood that numerous modifications may be made to the illustrative embodiments and that other arrangements may be devised without departing from the spirit and scope of the present invention as defined by the appended claims.

[0110] 17

[0111] 105497822 1

Claims

Docket No. 127308-856276CLAIMSWhat is claimed is:

1. A package sortation system, comprising: a storage structure including pillars defining vertical shafts, the pillars supporting a grid formed of a first set of parallel rails extending in a first direction and a second set of parallel rails extending in a second direction perpendicular to the first direction, the first and second set of parallel rails collectively defining a plurality of grid spaces; an auto-packing machine configured to form packages; a robot including a bin retrieval device, the bin retrieval device including a grapple extendable and retractable in a vertical direction; and a sortation device manipulatable by the grapple of the robot and configured to sort the packages formed by the auto-packing machine into a respective one of a plurality of sorting locations.

2. The package sortation system of claim 1 , wherein the auto-packing machine is disposed on the grid.

3. The package sortation system of claim 1 , wherein the auto-packing machine is disposed adjacent the grid and at a height that is substantially equal to a height of the grid.

4. The package sortation system of claim 1, wherein the plurality of sorting locations is a plurality of end-sorting locations.

5. The package sortation system of claim 1, further comprising a plurality of chutes arranged to transfer the packages into the plurality of sorting locations.

6. The package sortation system of claim 5, wherein each of the plurality' of chutes includes a receiving portion, and wherein at least some of the receiving portions are arranged above one another.18105497822 1Docket No. 127308-8562767. The package sortation system of claim 1, wherein the auto-packing machine is an auto-bagger or an auto-boxer.

8. The package sortation system of claim 1, wherein the sortation device, comprises: a main frame secured to a platform at a fulcrum; a first handling portion connected to the platform and configured to be manipulated by the grapple of the robot; and a second handling portion connected to the platform and configured to be manipulated by another grapple of the robot, wherein relative movement of the first handling portion relative to the second handling portion pivots the platform about the fulcrum.

9. The package sortation system of claim 8. wherein the main frame is arranged to engage at least one of the pillars defining a vertical shaft to guide movement of the sortation device as the sortation device is moved in a vertical direction.

10. The package sortation system of claim 8, wherein the first and second handling portions include a sidewall emulating engagement features of a storage bin that are configured to be grasped by the grapple.

11. A sortation device, comprises: a platform; and a first handling portion connected to the platform and configured to be manipulated by a first grapple of a robot, wherein movement of the first handling portion tilts the platform.

12. The sortation device of claim 11. further comprising: a main frame arranged to engage at least one pillar of a grid-based storage structure to guide vertical movement of the sortation device within a vertical shaft; and a second handling portion connected to the platform and configured to be manipulated by a second grapple of a robot.19105497822 1Docket No. 127308-85627613. The sortation device of claim 12, wherein the first and second handling portions include a sidewall emulating engagement features of a storage bin that are configured to be grasped by the first and second grapples of the robot.

14. A method of sorting packages, comprising: picking an inventory item, using a robot, disposed on a grid of a storage structure; placing the picked inventory item into an auto-packing machine to a form a package; receiving the package by a sortation device; and moving the sortation device, using the robot, to direct the package into one of a plurality of locations located beneath the grid.

15. The method of claim 14, wherein a body of the robot remains stationary relative to the grid during the picking step and the moving step.

16. The method of claim 14, further comprising picking another inventory item, using the robot, and wherein the picking another inventory item is simultaneously performed with the moving step.

17. The method of claim 14, wherein the moving step comprises lifting or lowering at least one grapple of the robot in a vertical direction.

18. The method of claim 14, wherein the moving step comprises lifting or lowering a first grapple of the robot in a vertical direction relative to a second grapple of the robot to pivot a platform of the sortation device about a fulcrum.

19. The method of claim 18, wherein the moving step comprises angling the platform to direct the package onto a desired one of a plurality of chutes.20105497822 1Docket No. 127308-85627620. The method of claim 19, wherein the plurality of locations is a plurality of Gaylords, and the method further comprises sliding the package down the desired one of the plurality of chutes and into a respective Gaylord.21105497822 1

Images