Systems and methods for the transfer of containers in automated storage and retrieval systems

Abstract

A system for transfer of containers includes a dispensing frame, a dispenser, and a container transfer mechanism. The dispensing frame holds a plurality of containers in a linear arrangement, the plurality of containers including an end container at one end of the linear arrangement. The dispenser is at the dispensing frame enabling release of the end container in a controlled manner from the one end of the linear arrangement, the dispenser enabling release of containers one at a time from the one end of the linear arrangement. The container transfer mechanism engages the end container following release of the end container from the dispenser. The container transfer mechanism engages and moves containers one at a time, following release from the one end of the linear arrangement, to mobile robots or to storage locations.

Description

[0001] Aty. Docket No. 1127P017372- WO (PCT)

[0002] SYSTEMS AND METHODS FOR THE TRANSFER OF CONTAINERS IN AUTOMATED STORAGE AND RETRIEVAL SYSTEMS

[0003] CROSS-REFERENCE TO RELATED APPLICATIONS

[0004]

[0001] This application is a non-provisional of and claims the benefit of United States provisional patent application number 63 / 702,510 filed on October 2, 2024, the disclosure of which is incorporated herein by reference in its entirety.

[0005] BACKGROUND

[0006] 1. Field

[0007]

[0002] This present disclosure generally relates to automated storage and retrieval systems, and more particularly, to the transfer of containers to and from storage locations and mobile robots in such systems.

[0008] 2. Brief Description of Related Developments

[0009]

[0003] Generally, in automated storage and retrieval systems, empty totes are inducted or removed into and from the automated storage and retrieval system in a very laborious manner. For example, tote induction and / or dispense workstations may be provided in the automated storage and retrieval system where operators manually position each tote at predetermined locations (e.g., aisles) of the workstation. The tote is manually positioned and pushed by the operator into the aisle for an automated robot to collect the tote from the workstation.

[0010]

[0004] Accordingly, the present disclosure addresses a number of those issues. Aty. Docket No. 1127P017372- WO (PCT)

[0011] BRIEF DESCRIPTION OF THE DRAWINGS

[0012]

[0005] The foregoing aspects and other features of the present disclosure are explained in the following description, taken in connection with the accompanying drawings, wherein:

[0013]

[0006] Figs. 1 and 2 are schematic perspective illustrations of a storage structure portion of an order fulfillment facility in accordance with the present disclosure;

[0014]

[0007] Figs. 3 and 4 are schematic perspective illustrations of container processing stations of the order fulfillment facility of Figs. 1 and 2 in accordance with the present disclosure;

[0015]

[0008] Figs. 5-7 are schematic illustrations of a system for transferring containers that may be employed within the order fulfilment facility of Figs. 1-4 in accordance with the present disclosure;

[0016]

[0009] Fig. 8 is a schematic illustration of a dispenser of the system for transferring containers illustrated in Figs. 5-7 and / or Figs. 14-21 in accordance with the present disclosure;

[0017]

[0010] Fig. 9 is a schematic illustration of a portion of the system for transferring containers illustrated in Figs. 5-7 and / or Figs. 14-21 in accordance with the present disclosure;

[0018]

[0011] Fig. 10 is a schematic illustration of a portion of the system for transferring containers illustrated in Figs. 5-7 and / or Figs. 14-21 in accordance with the present disclosure;

[0019]

[0012] Fig. 11 is a schematic illustration of a portion of the system for transferring containers illustrated in Figs. 5-7 and / or Figs. 14-21 and / or Figs. 14-21 in accordance with the present disclosure;

[0020]

[0013] Figs. 12 and 13 are schematic illustrations of the system for transferring containers of Figs. 5-7 in accordance with the present disclosure

[0021]

[0014] Figs. 14-21 are schematic illustrations of a system for transferring containers that may be employed within the order fulfilment facility of Figs. 1-4 in accordance with the present disclosure; Aty. Docket No. 1127P017372- WO (PCT)

[0022]

[0015] Figs. 22-28 are exemplary schematic perspective view illustrations of a portion of a lifting assembly of the system for transferring containers of Figs. 14-21 in accordance with the present disclosure;

[0023]

[0016] Fig. 29 is an exemplary flow diagram of a process in accordance with the present disclosure;

[0024]

[0017] Fig. 30 is an exemplary flow diagram of a process in accordance with the present disclosure;

[0025]

[0018] Fig. 31 is an exemplary flow diagram of a process in accordance with the present disclosure;

[0026]

[0019] Fig. 32 is an exemplary flow diagram of a process in accordance with the present disclosure; and

[0027]

[0020] Fig. 33 is an exemplary flow diagram of a process in accordance with the present disclosure.

[0028] DETAILED DESCRIPTION

[0029]

[0021] The following detailed description is meant to assist the understanding of one skilled in the art, and is not intended in any way to unduly limit claims connected or related to the present disclosure.

[0030]

[0022] The following detailed description references various figures, where like reference numbers refer to like components and features across various figures, whether specific figures are referenced, or not.

[0031]

[0023] Further, the following detailed description is not to be taken in a limiting sense, but is made merely for the purpose of describing the general principles thereof. Reference throughout this description, if any, to “one embodiment,” “an embodiment,” “some embodiments”, “an Aty. Docket No. 1127P017372- WO (PCT) 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 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.

[0032]

[0024] The word “each” as used herein refers to a single object (i.e., the object) in the case of a single object or each object in the case of multiple objects. The words “a,” “an,” and “the” as used herein are inclusive of “at least one” and “one or more” so as not to limit the object being referred to as being in its “singular” form.

[0033]

[0025] Spatial terms such as “left,” “right,” “top,” “bottom,” “upper,” “lower,” “front,” “back,” “vertical,” and “horizontal” as may be used herein are by way of example and illustration only are not meant to limit the description and may be exchanged in position and orientation.

[0034]

[0026] The terms “substantially” and “about” as may be used herein refer to a feature that may be varied within an acceptable manufacturing tolerance for a given application.

[0035]

[0027] Generally, the present disclosure provides systems, apparatuses and methods that may be useful to the bulk transfer of containers to / from storage locations and mobile robots.

[0036]

[0028] In accordance with the present disclosure, a system for transfer of containers includes a dispensing frame holding a plurality of containers in a linear arrangement, the plurality of containers including an end container at one end of the linear arrangement.

[0037]

[0029] A dispenser at the dispensing frame may enable the release of the end container in a controlled manner from the one end of the linear arrangement.

[0038]

[0030] The dispenser may enable release of containers one at a time from the one end of the linear arrangement. Aty. Docket No. 1127P017372- WO (PCT)

[0039]

[0031] A container transfer mechanism may engage the end container following release of the end container from the dispenser.

[0040]

[0032] The container transfer mechanism may engage and move containers one at a time, following release from the one end of the linear arrangement, to mobile robots or to storage locations.

[0041]

[0033] In accordance with the present disclosure, the system may include one or more of the following (each of the following being a non-essential and optional feature): the linear arrangement includes a stacked arrangement and the end container is a container at a top end or a bottom end of the stacked arrangement; the end container is at the bottom end of the stacked arrangement, the dispenser releases and drops the end container to a transfer position, and the container transfer mechanism pushes the end container from the transfer position; the dispenser includes a plurality of prongs to hold containers at the one end of the linear arrangement and to release one container at a time. In some implementations, the system includes a support surface for receiving the end container from the linear arrangement and for storing the end container until retrieved by a mobile robot, the support surface being disposed between the linear arrangement of containers and a mobile robot access area; one or more flipper arms to retain the end container on the support surface; an imaging device oriented to capture images at the one end of the linear arrangement to determine a condition of the end container; the end container is at the top end of the stacked arrangement, the dispenser includes a lifting assembly configured to lift the end container off the stacked arrangement, and the container transfer mechanism moves the end container to a mobile robot or to a storage location; the container transfer mechanism includes a support plate to move the end container to the mobile robot or to the storage location; the lifting assembly includes one or more grippers, the one or more grippers configured to engage the end container; the lifting assembly includes at least one rail configured to enable alignment of the one or more grippers relative to the end container; a first container includes at least one bale arm, the at least one bale arm movable from a first position to allow nesting of a second container in the first container and a second position to support the second container stacked on the first container to a second position, thereby enabling stacking of either empty containers or at least partially filled containers at the Aty. Docket No. 1127P017372- WO (PCT) dispensing frame; the lifting assembly includes adjustment members configured to move the at least one bale arm of the first container from the first position to the second position and / or from the second position to the first position; and / or the plurality of containers includes at least one empty container and / or at least one partially full container.

[0042]

[0034] In accordance with the present disclosure, there is provided a method for transfer of containers. The method including by a dispensing frame, holding a plurality of containers in a linear arrangement, the plurality of containers including an end container at one end of the linear arrangement.

[0043]

[0035] The method may include, by a dispenser at the dispensing frame, enabling release of the end container in a controlled manner.

[0044]

[0036] The dispenser may enable release of containers one at a time from the one end of the linear arrangement

[0045]

[0037] The method may include, by a container transfer mechanism, engaging the end container following release of the end container from the dispenser.

[0046]

[0038] The container transfer mechanism may engage and move containers one at a time, following release from the one end of the linear arrangement, to mobile robots or to storage locations.

[0047]

[0039] In accordance with the present disclosure, the method may include one or more of the following (each of the following being a non-essential and optional feature): the linear arrangement includes a stacked arrangement and wherein the end container is a container at a top end or a bottom end of the stacked arrangement; the end container is at the bottom end of the stacked arrangement, the method further including: by the dispenser, releasing and dropping the end container to a transfer position, and by the container transfer mechanism, pushing the end container from the transfer position; the end container is at the top end of the stacked arrangement, the method further including: by the dispenser, lifting the end container off the stacked arrangement, and by the container transfer mechanism, moving the end container to a mobile robot or to a storage Aty. Docket No. 1127P017372- WO (PCT) location; and / or the dispenser includes a lifting assembly and the container transfer mechanism comprises a support plate, the method further including: by the dispenser, lifting the end container from the top end of the stacked arrangement, and by the support plate, moving the end container to the mobile robot or to the storage location.

[0048]

[0040] In accordance with the present disclosure, a system for transfer of containers includes a dispensing frame holding a plurality of containers in a linear arrangement, the plurality of containers including an end container at one end of the linear arrangement.

[0049]

[0041] A container may be disposed adjacent the dispensing frame.

[0050]

[0042] A container transfer mechanism may engage the adjacent container and move the adjacent container into alignment with the dispensing frame.

[0051]

[0043] A stacker may receive the adjacent container at the one end of the dispensing frame and move the adjacent container into engagement with the end container.

[0052]

[0044] The present disclosure may involve generally a facility, such as an order fulfillment facility, that may include multiple mobile robots that operate to pick and transfer containers in the context of an automated storage and retrieval system.

[0053]

[0045] The mobile robots may move about a storage structure and retrieve containers of goods (which may also be referred to as totes) that are stored in specific storage locations in the facility, as part of the automated storage and retrieval system.

[0054]

[0046] The facility may include container processing stations, also referred to as tote processing stations or workstations, where containers, or totes, may be inducted into or dispensed from the automated storage and retrieval system. These containers may be transferred at the container processing stations to and from the mobile robots.

[0055]

[0047] The present disclosure may involve generally an order fulfillment facility and system that may involve the bulk transfer of containers to and from storage locations and mobile robots. Aty. Docket No. 1127P017372- WO (PCT)

[0056]

[0048] Certain operations may involve induction of containers into the automated storage and retrieval system at container processing stations and / or dispensing of containers from the automated storage and retrieval system at container processing stations. These operations may be labor intensive because they may require manual action and may not be highly automated. These operations may also lack efficiency as they may require the transfer of containers individually.

[0057]

[0049] The present disclosure relates to the partially or fully automated transfer of containers into and out of the automated storage and retrieval system.

[0058]

[0050] In some forms, this transfer of containers may have required an individual to manually position each container one-by-one at indicated lanes of a container processing station outside the system. The container once positioned may then be pushed by the individual into the lane for a respective mobile robot to collect on an opposite side of a container processing station and in the system. This process is labor intensive and lacks efficiency.

[0059]

[0051] Figs. 1-4 show parts of an order fulfillment facility 100 (or storage facility) that utilizes an automated storage and retrieval system (ASRS) in accordance with the present disclosure. More specifically, as part of the ASRS, Figs. 1 and 2 show a storage structure 102 that is generally intended to store various items at a number of storage locations 104.

[0060]

[0052] The storage structure 102 may include a y-z array of storage locations 104 in horizontal rows and climbing channels 105 (which also may be referred to as vertical towers or level changing towers) along the rows.

[0061]

[0053] Mobile robots may travel between storage levels in the z-direction within the climbing channels 105.

[0062]

[0054] Rows of storage locations 104 may be arranged to face each other, separated by horizontal pathways or aisles 106.

[0063]

[0055] The storage structure 102 may include decks 108 (which may also be referred to as transit planes or areas) spaced apart at different horizontal levels of the storage structure 102. Aty. Docket No. 1127P017372- WO (PCT)

[0064]

[0056] The decks 108 may extend between the aisles 106 so that mobile robots can maneuver in the x-y plane of each deck 108 to travel between different aisles 106.

[0065]

[0057] Further details relating to the general structure and operation of the storage structures and mobile robots, such as may be used in conjunction with this disclosure, are disclosed in U.S. Patent No. 9,139,363, issued September 22, 2015, entitled “Automated System for Transporting Payloads”; U.S. Patent No. 10,040,632, issued August 7, 2018, entitled” Automated System for Transporting Payloads”; U.S. Patent 10,435,241, issued October 8, 2019, entitled “Storage and Retrieval System”; U.S. Patent No. 10,952,533, issued March 23, 2021, entitled “Modular Structure for an Automated Storage and Retrieval System”; and U.S. Patent No. 11,142,398, issued October 12, 2021, entitled “Order Fulfdlment System”; which patents are all incorporated by reference herein in their entirety.

[0066]

[0058] Figs. 3 and 4 show container processing stations 110 at the order fulfillment facility 100 in accordance with the present disclosure.

[0067]

[0059] Operators (human individuals and / or robotic operators) may work at the container processing stations 110. Various operations may be performed at the container processing stations 110.

[0068]

[0060] Mobile robots may perform transport operations, including moving containers between storage locations 104 and the container processing stations 110 and including transporting order containers away from the container processing stations.

[0069]

[0061] Examples of container processing stations 110 and picking and transfer operations, such as may be used in conjunction with this disclosure, are disclosed, for example, in U.S. Patent No. 11,845,610, issued December 19, 2023, entitled “Automated Decant System”; U.S. Patent Publication No. 2021 / 0380343, published December 9, 2021, entitled “Robotic Each Picking in a Micro-Fulfillment Center”; and U.S. Patent No. 10,984,375, issued April 20, 2021, entitled “Picking Workstation with Mobile robots and Machine Vision Verification of Each Transfers Performed by Human Operators,” all of which are incorporated by reference herein in their entirety. Aty. Docket No. 1127P017372- WO (PCT)

[0070]

[0062] Figs. 5-7 illustrate a system 112 for the transfer of containers 116 that may be used at the order fulfillment facility 100 and as a part of an overall ASRS in accordance with the present disclosure.

[0071]

[0063] The system 112 may facilitate the induction and / or dispensing process of containers at the order fulfillment facility 100.

[0072]

[0064] The system 112 may facilitate the inducting of containers in bulk at locations within the order fulfillment facility 100.

[0073]

[0065] The system 112 may include a dispensing frame 114.

[0074]

[0066] The dispensing frame 114 may be in the form of an enclosure, such as a cage or cabinet, and may include mesh, walls, doors, etc.

[0075]

[0067] The dispensing frame 114 may be separate from the ASRS and / or integrated into the ASRS.

[0076]

[0068] The dispensing frame 114 may hold a plurality of containers 116 in a linear arrangement 118. The plurality of containers 116 includes an end container 120 at one end of the linear arrangement 118.

[0077]

[0069] The linear arrangement 118 may be a vertical or stacked arrangement such that the end container 120 will be at the top or the bottom of the linear arrangement 118.

[0078]

[0070] As illustrated in Figs. 5-7 for exemplary purposes only, the linear arrangement 118 is a stacked arrangement with the end container 120 at the bottom of the linear arrangement 118.

[0079]

[0071] The system 112 may include a dispenser 122, an example of which is shown in Fig. 8.

[0080]

[0072] The dispenser 122 may be disposed on the dispensing frame 114 and maintain the end container 120 at the one end of the linear arrangement 118 in the dispensing frame 114.

[0081]

[0073] The dispenser 122 may enable the release of the end container 120 in a controlled manner, for example, the dispenser 122 may enable the release of containers 116 one at a time from the one Aty. Docket No. 1127P017372- WO (PCT) end of the linear arrangement 118 or the dispenser 122 may enable the release of more than one container 166 at a time.

[0082]

[0074] The dispenser 122 may be, or otherwise include, a plurality of prongs 123 to hold the containers 116 at one end of the linear arrangement 118 and release the containers 116 one at a time. It should be understood that the dispenser 122 may include, as alternative options for the plurality of prongs 123, other mechanisms suitable for retaining and dispensing the containers 116 held in the dispensing frame 114, such as including stationary and / or movable platforms, movable sidewalls, robotic arms, vertical tracks or guides, etc.

[0083]

[0075] The system 112 may include a container transfer mechanism 124 configured to push the end container 120 following release of the end container 120 from the dispenser 122.

[0084]

[0076] As shown in Fig. 11, the container transfer mechanism 124 may include a mechanical actuator (such as a linear actuator or arm) with an end effector 125 that can be extended to push the end container 120 and that can then be retracted following the pushing operation.

[0085]

[0077] The container transfer mechanism 124 may push containers 116 one at a time, following release from the one end of the linear arrangement 118, to mobile robots 126 or to storage locations 128 for retrieval by the mobile robots 126.

[0086]

[0078] The storage locations 128 may be integrated into the ASRS and / or may be external to the ASRS and accessible by the mobile robots 126.

[0087]

[0079] The container transfer mechanism 124 may be one or more of a variety of transfer mechanisms such as mechanical actuators, conveyors, etc.

[0088]

[0080] The container transfer mechanism 124 may apply a continuous force to one of the containers 116, and / or may apply one or more intermittent forces to one of the containers 116 to transfer one of the containers 116. Aty. Docket No. 1127P017372- WO (PCT)

[0089]

[0081] As illustrated in Fig. 6, the container transfer mechanism 124 is any suitable mechanical actuator configured to push or otherwise move the end container 120 in a generally horizontal direction after release from the linear arrangement 118.

[0090]

[0082] The system 112 may include the end container 120 at the bottom of the linear arrangement 118.

[0091]

[0083] When the linear arrangement 118 is a stacked arrangement with the end container 120 at the bottom of the stacked arrangement, the dispenser 122 may release and drop the end container 120 to a transfer position 130.

[0092]

[0084] The container transfer mechanism 124 pushes (e.g., is configured to push) the end container 120 from the transfer position 130 to a secondary location.

[0093]

[0085] The container transfer mechanism 124 may one or more of (optionally): push the end container 120 directly into engagement and receipt by the mobile robots 126; and push the end container 120 to a support surface for receiving the end container 120 from the linear arrangement 118.

[0094]

[0086] The support surface may be one of the storage locations 128 described above.

[0095]

[0087] The support surface (which may be in the form of a shelf) stores the end container 120 until retrieved by a mobile robot 126.

[0096]

[0088] The support surface may be disposed between the linear arrangement 118 of the containers 116 and a mobile robot access area 132.

[0097]

[0089] As shown in Fig. 9, the system 112 may include flippers 134.

[0098]

[0090] The flippers 134 may be one or more flipper arms to retain the end container 120 on the support surface, following transfer from the linear arrangement 118. It is generally contemplated, as an alternative option to the flippers 134, that any suitable mechanism may be used to prevent the containers 116 from entering the travel path of the mobile robots 126 unintentionally. Aty. Docket No. 1127P017372- WO (PCT)

[0099]

[0091] The flippers 134 may retain the end container 120 until the end container 120 is ready to be transported by the mobile robots 126.

[0100]

[0092] When the end container 120 is ready to be engaged by the mobile robots 126, the flippers 134 may disengage to allow the mobile robots 126 access to the end container 120.

[0101]

[0093] The mobile robots 126 may engage with the end container 120 from a side of the end container 120, not adjacent to the flippers 134, and the flippers 134 may remain in an engaged state.

[0102]

[0094] Further details relating to the general structure and operation of flippers and container transfer mechanisms, such as may be used in conjunction with this disclosure, are disclosed in U.S. Patent No. 11,267,651, issued March 3, 2022, entitled “System Having Workstation with Tote Retention and Release Mechanism”, which is incorporated herein by reference in its entirety.

[0103]

[0095] As shown in Fig. 10, the system 112 may include any suitable imaging device 136. The imaging device 136 may be oriented to capture images at one end of the linear arrangement 1 18 to determine a condition of the end container 120.

[0104]

[0096] Conditions of the end container 120 may include, for example, the end container 120 being damaged, containing damaged items in the end container 120, having bale arms in an improper position, or being stuck in the dispensing frame 114.

[0105]

[0097] If undesirable conditions (e g. damaged or stuck states) are detected by the imaging device 136, the need for removal of the containers 116 with the undesirable conditions may be indicated by any suitable alert (e.g., aural, visual, electronic signal, etc.) to the system 112 and / or operator.

[0106]

[0098] The removal of the containers 116 with undesirable conditions may be done manually, or autonomously by the ASRS system.

[0107]

[0099] Where the removal of the containers 116 is done autonomously, an alternate pathway within the ASRS may be used to separate the containers 116 with undesirable conditions (such as damaged containers 116) from the other containers 116. For example, a second mechanical Aty. Docket No. 1127P017372- WO (PCT) actuator (such as a linear actuator) (e.g., the same or similar to that described above) may be used to push a damaged container to a separate area for manual inspection and / or handling by an individual.

[0108]

[0100] Transfer operations may have or be stopped in response to detection of the container with undesirable conditions, and once the imaging device 136 determines that the issue has been resolved, the system 112 may continue or resume with the transfer operations.

[0109]

[0101] The system 112 may include more than one imaging device 136, as needed, to determine the conditions of the containers 116.

[0110]

[0102] Figs. 12-13 illustrate the system 112 where the end container 120 is at the top of the linear arrangement 118 (not at the bottom of the linear arrangement, as in previous embodiments). In other words, the end container 120 may be at the top end of the stacked arrangement.

[0111]

[0103] The dispenser 122 may enable lifting of the end container 120 off of the stacked arrangement, and the container transfer mechanism 124 may move the end container 120 to the mobile robots 126 or to the storage locations 128 for retrieval by the mobile robots 126.

[0112]

[0104] The container transfer mechanism 124 may include a robot 124R, such as a Cartesian robot with a suction end effector, configured to lift the end container 120 from the top end of the stacked arrangement and move the end container 120 to the mobile robots 126, or to the storage locations 128 for retrieval by the mobile robots 126. It should be understood that other mechanisms for lifting the end container 120 may also be used as alternative options to the Cartesian robot, such as, for example, moveable platforms, robotic arms (such as illustrated in Fig. 11), etc.

[0113]

[0105] It should be understood that the system 112 may be used to transfer containers 116 onto a linear arrangement 118, such as from storage locations and mobile robots 126, as well as, or as an alternative to, transferring containers from the linear arrangement.

[0114]

[0106] A container 116 from the system 112 may be incorporated into a stack of containers 116. Aty. Docket No. 1127P017372- WO (PCT)

[0115]

[0107] To facilitate the stack of containers 116 the container transfer mechanism 124 may be configured to engage an incoming container 116, after transportation by a mobile robot 126 to a position adjacent the dispensing frame 114. The container transfer mechanism 124 may engage and move the adjacent container 116 (such as, for example, in the form of a mechanical actuator pulling it) into alignment with the dispensing frame 114, effectively aligning the incoming container 116 transported by the mobile robots 126 with a predetermined end of the dispensing frame 114.

[0116]

[0108] The dispensing frame 114 may receive the incoming container 116 at the predetermined end of the dispensing frame 114.

[0117]

[0109] Incoming containers 116 may be either stacked at the top of the stack or at the bottom of the stack.

[0118]

[0110] The incoming container 116 transported by the mobile robot 126 may be either lifted into the bottom end of the dispensing frame 114 or may be released into the top end of the dispensing frame 114.

[0119]

[0111] For example, a stacker, such as a lifting platform and / or a suction / retraction device, may receive the adjacent container at the bottom end of the dispensing frame 114 and move it into engagement with the bottom end container 120 of the stack. As another example, a stacker, such as a robot, may receive the adjacent container at the top end of the dispensing frame 114 and move it into engagement with the top end container 120 of the stack.

[0120]

[0112] It should be understood that the system 112 of transferring containers 116 may be utilized in various manners and at any of various locations in the order fulfdlment facility 100.

[0121]

[0113] Containers 116 may be stacked and then autonomously dropped (or raised) to a transfer position where they may be picked up directly by a mobile robot 126, and the next container 116 may then be lowered (or raised) to the transfer position to be picked up directly by the next mobile robot 126. Aty. Docket No. 1127P017372- WO (PCT)

[0122]

[0114] Containers 116 in the stack may be moved downwardly one at a time for eventual transfer from the stack, or the containers 116 in the stack may be moved upwardly one at a time for eventual transfer at the top end of the stack.

[0123]

[0115] The system 112 may be utilized at container processing stations 110 to introduce containers 116 into the ASRS and / or to receive containers 116 from the ASRS.

[0124]

[0116] The system 112 may be used at decks 108 to transfer containers 116 to and from mobile robots 126.

[0125]

[0117] Figs. 14-21 illustrate a system 113 for transferring containers in accordance with the present disclosure. The system 113 includes a storage array 103 (with individual storage locations 128) adjacent to the dispensing frame 114 such that a container 116 may be moved from the dispensing frame 114 directly into a storage location 128 of the storage array 103.

[0126]

[0118] Figs. 14-17 illustrate two linear arrangements 118 (e.g., in the form of stacks), of containers 116 positioned side by side within the dispensing frame 114 such that one linear arrangement 1 18 is behind the other linear arrangement 118.

[0127]

[0119] In Figs. 14-17, the containers 116 are empty and are stacked / nested inside of each other.

[0128]

[0120] There may be any number of linear arrangements 118 within the dispensing frame 114 arranged in any direction and orientation relative to each other. The linear arrangements 118 may be positioned on top of a moveable surface, such as a rollable cart, and the moveable surface may be moved into the dispensing frame 114 with containers 116 disposed upon the movable surface.

[0129]

[0121] The dispensing frame 114 may be stationary and act to transfer containers 116 at an entry point to one or more specific storage locations 128 where the transferred containers 116 may then be picked up by mobile robots 126 and transferred to other locations at the order fulfillment facility 100. Aty. Docket No. 1127P017372- WO (PCT)

[0130]

[0122] Referring to Figs. 14-21, the dispensing frame 114 may be in the form of a cabinet that includes a door 150 that can be opened to allow a linear arrangement 118 of containers 116 to be placed, manually or with any suitable automated equipment, into the dispensing frame 114.

[0131]

[0123] Two stacks of linear arrangements 118 (although there may be more or less than two stacks of linear arrangements) are arranged in the dispensing frame 114.

[0132]

[0124] The dispensing frame 114 may include an alternate door 152 either instead of or in addition to the door 150. The alternate door 152 may be placed generally near a top end of the linear arrangement 118 such that once the linear arrangement 118 is inside of the dispensing frame 114, new containers 116 can be added to the top of the linear arrangement 118 without removing the linear arrangement 118 from the dispensing frame 114.

[0133]

[0125] The dispensing frame 114 may be enclosed by walls and / or movable barriers, such as the door 150 and / or the alternate door 152, although the dispensing frame 114 may be a frame with exposed sides such that no door is needed to move the linear arrangement 118 into / out of the dispensing frame 114 or to add containers 116 to the linear arrangement 118 once inside of the dispensing frame 114.

[0134]

[0126] Referring to Figs. 14-21, the dispenser 122 may include a lifting assembly 138 configured to lift the end container 120 off of the top end of the linear arrangement 118.

[0135]

[0127] After being lifted by the lifting assembly 138, the container transfer mechanism 124 moves the end container 120 to a mobile robot 126 or to a storage location 128 (in this case, to a storage location 128).

[0136]

[0128] The lifting assembly 138 is configured to lift an end container 120 from a linear arrangement 118 within the dispensing frame 114.

[0137]

[0129] Generally, the lifting assembly 138 is above a top end of the linear arrangement 118.

[0138]

[0130] The lifting assembly 138 may be configured to lift an end container 120 from either of the two stacks and to center the end container 120 after being lifted within the dispensing frame 114. Aty. Docket No. 1127P017372- WO (PCT)

[0139]

[0131] Once a container 116 is lifted by the lifting assembly 138, the lifting assembly 138 may rotate the container 116 and align the container 116 with a storage location 128. A container 116 may be positioned in a storage location 128 with a short side of the container 116 accessible from the storage location 128; however, any orientation of a container 116 may be used. Similar positioning of the container 116 may be provided by the lifting assembly 138 where the container transfer mechanism 124 moves the end container 120 to a mobile robot 126.

[0140]

[0132] An end container 120 may be rotated 90 degrees (or any other suitable rotational amount) in order to be oriented to fit into the storage location 128. The end container 120 may need to be aligned and / or rotated after being lifted by the lifting assembly 138, although the end container 120 may not need to be aligned and / or rotated after being lifted by the lifting assembly 138.

[0141]

[0133] The lifting assembly 138 may be configured to perform any suitable functions for lifting and preparing transfer of an end container 120, such as lifting, rotating, aligning, shifting, centering, transferring, lowering, extending, retracting, etc.

[0142]

[0134] The movement and / or operation of the lifting assembly 138 (and other mechanisms described in this disclosure with respect to Figs. 1-33) may be controlled by any suitable control circuit or controller. In this context, the terms control circuit and controller refer broadly to any microcontroller, computer, or processor-based device with processor, memory, and programmable input / output peripherals, which is generally designed to govern the operation of other components and devices.

[0143]

[0135] The control circuit or controller is understood to optionally include common accompanying accessory devices, including memory, transceivers for communication with other components and devices, etc. These architectural options are well known and understood in the art and require no further description here.

[0144]

[0136] The control circuit or controller may be configured (for example, by using corresponding non-transitoiy programming code stored in a memory as will be well understood by those skilled in the art) to carry out one or more of the steps, actions, and / or functions described herein. Aty. Docket No. 1127P017372- WO (PCT)

[0145]

[0137] Referring to Figs. 14-21, the container transfer mechanism 124 may include a support plate 140 configured to support the end container 120 and move the end container 120 to a mobile robot 126 or to a storage location 128 (in this instance, a storage location 128).

[0146]

[0138] The dispensing frame 114 may include the support plate 140 such that after the end container 120 has been lifted off of the linear arrangement 118 by the lifting assembly 138, the lifting assembly 138 places the end container 120 onto the support plate 140.

[0147]

[0139] The support plate 140 (which may also be referred to as a support tray or ledge) may be moveable and move horizontally from a retracted position (e.g., at the storage location 128) to an extended position (e.g., in the dispensing frame 114).

[0148]

[0140] The lifting assembly 138 may lift the end container 120, the support plate 140 may be extended to a position underneath the end container 120, the lifting assembly 138 may release the end container 120 onto the support plate 140, and the support plate 140 may retract to the storage location 128.

[0149]

[0141] The support plate 140 may be part of the dispensing frame 114.

[0150]

[0142] The support plate 140 may be positioned in the dispensing frame 114 so that the lifting assembly 138 may maneuver the end container 120 being lifted around the support plate 140.

[0151]

[0143] The lifting assembly 138 may position the end container 120 above the support plate 140 and then release the end container 120.

[0152]

[0144] The support plate 140 may extend horizontally to deposit the end container 120 into the storage location 128 and may retract back to the dispensing frame 114.

[0153]

[0145] Figs. 14-17 show empty containers 116 nested within one another, while Figs. 18-21 depict containers 116 filled or partially filled with items. The full / partially full containers 116 are generally the same as the empty containers 116, but with bale arms, such as the bale arms 148 shown in Figs. 24-28, engaged to allow for a container 116 to be stacked on top of another container 116. Aty. Docket No. 1127P017372- WO (PCT)

[0154]

[0146] The bale arms 148 are generally used to prevent a stacked container from dropping into and crushing contents in a container underneath it.

[0155]

[0147] The bale arms 148 may be engaged in a generally horizontal position (or in a closed or locked position) to support an additional container 116 disposed on top of the bale arms 148.

[0156]

[0148] Generally, the bale arms 148 are positioned on the top edge of opposite sides of a container 116 and are moveable from an engaged position, as described above, to a disengaged position (allowing nesting of containers 116). In the disengaged position (or open or unlocked position), the bale arms 148 generally are resting vertically on the outside of a container 116 adjacent to a side of the container 116.

[0157]

[0149] The bale arms 148 may rotate towards the inside of the container 116 about an axis of rotation that is generally at the top edge of the container 116 where the bale arms 148 are coupled.

[0158]

[0150] The bale arms 148 may be configured for any suitable disengaged position that allows for a container 1 16 to be stacked / nested inside of another container 116 and for any suitable engaged position that allows for a container 116 to be stacked on top of another container 116.

[0159]

[0151] There may be any number and / or configuration of bale arms 148 disposed on the containers 116 suitable for stacking and / or nesting the containers 116. It is generally contemplated that the present disclosure is operable on or with stacks that will either be stacks of filled / partially filled containers 116 and / or stacks of empty containers 116. However, a single stack may include some combination of empty and some filled / partially filled containers 116 with bale arms 148 engaged or disengaged, as appropriate and / or there may be some stacks of empty containers 116 and other stacks of filled / partially filled containers 116. Generally, the or each stack of containers 116 includes at least one empty container 116 and / or at least one partially full container 116.

[0160]

[0152] Figs. 22-23 depict the underside of a lifting assembly 138. As can be seen, the lifting assembly 138 may be in the form of a plate 141 that is connected to, and may be raised and lowered by, a shaft 143. Aty. Docket No. 1127P017372- WO (PCT)

[0161]

[0153] The lifting assembly 138 may include adjustment member(s) 142, rail(s) 144, and / or gripper(s) 146 (e.g., of a gripper assembly 145), such as may be disposed on the underside of the plate 141. As described below, these features may enable adjustment of the bale arms 148 of the containers 116, alignment of the lifting assembly 138 with a stack of containers 116, and / or grasping of the end container 120 at the top of a stack.

[0162]

[0154] A first container 116 may include at least one bale arm 148, the bale arm 148 being moveable from a first position to allow nesting of a second container in the first container, and a second position to support the second container stacked on the first container. The first and second positions correspond to the disengaged and engaged bale arm positions described above. The second position (or engaged position) thereby enables stacking of at least partially filled containers 116 at the dispensing frame 114. Generally, the adjustment members 142 of the lifting assembly 138 are configured to move the bale arms 148 of a container 116 from the first position, allowing nesting of containers 116, to the second position, allowing stacking of the containers 116, and / or from the second position to the first position. The adjustment members 142 may include grasping members, claws, robotic arms, or any other members suitable for transferring the bale arms 148 from the first position to the second position and / or from the second position to the first position.

[0163]

[0155] The lifting assembly 138 may include rail(s) 144 (or guide(s)) to align the end container 120 relative to the lifting assembly 138.

[0164]

[0156] The rail(s) 144 may help align the gripper(s) 146 of the lifting assembly 138 relative to the end container 120. For example, if the dispensing frame 114 has two stacks of containers 116 in it, the rail(s) 144 may be used to align the gripper(s) 146 relative to one of the two stacks. The gripper assembly 145 may be moved along the rail(s) 144 to a desired position above a stack.

[0165]

[0157] The lifting assembly 138 may include gripper(s) 146 that engage or otherwise grab the end container 120.

[0166]

[0158] As shown in Figs. 22 and 23, the gripper(s) 146 may be in the form of two opposing arms with each arm including protruding tabs that are received in openings of the end container 120. The gripper(s) 146 may utilize, in addition to or in lieu of the opposing arms, other suitable Aty. Docket No. 1127P017372- WO (PCT) gripping elements such as suction cups, Velcro fasteners, clamps, suctioning forces, etc., that grip onto the end container 120 to allow for lifting of the end container 120 from the linear arrangement 118 of containers 116.

[0167]

[0159] The gripper(s) 146 may fit into a suitable female feature, such as a notch, divot, recess, etc., of the end container 120 such that while lifting, at least part of the at least one gripper 146 engages with the female feature to allow for lifting of the end container 120 by the lifting assembly 138.

[0168]

[0160] Figs. 24-25 illustrate the lifting assembly 138 and its adjustment members 142 coming into engagement with the bale arms 148 in accordance with the present disclosure. The bale arms 148 of an end container 120 being adjusted from either the first position to the second position and / or the second position to the first position by the adjustment members 142. Generally, the adjustment members 142 engage with an edge of the bale arms 148 to either lift a bale arm 148 from a position outside of the end container 120 to a position covering the surface of the end container 120, or from a position covering the surface of the end container 120 to a position on the outside of the end container 120. Where the end container 120 includes more than one bale arm 148, each bale arm 148 may be engaged by a respective adjustment member 142.

[0169]

[0161] Each bale arm 148 may be moved by a respective adjustment member 142 simultaneously, or each bale arm 148 may be moved by a respective adjustment member 142 with staggered timing. Various combinations of timing, positioning, location, etc., of the adjustment members 142 and the bale arms 148 may be used such that each bale arm 148 is moveable by an adjustment member 142. The lifting assembly 138 may not include adjustment members 142, and the bale arms 148 may be manually moved between a first and second position to allow nesting of containers 116 and / or stacking of containers 116.

[0170]

[0162] Figs. 26-28 illustrate an end container 120 engaged with grippers 146 on opposing sides of the end container 120 in accordance with the present disclosure. The grippers 146 may be in the form of the opposing arms (such as described above) with protruding tabs that are engaged with complementary recesses, or openings, on the sidewalls of the end container 120. The recesses, or Aty. Docket No. 1127P017372- WO (PCT) openings, on the sidewalls of the end container 120 are disposed near the top edges of the longer pair of opposing sidewalls near the center of the top edges.

[0171]

[0163] Other forms of grippers 146 are also possible. For example, the grippers 146 may be arranged to engage the end container 120 from outside of the end container 120 and / or from inside of the end container 120. The grippers 146 may be configured to grip the end container 120 at other locations of the end container 120. For example, the end container 120 may be gripped by the grippers 146 on various combinations of sidewalls and / or bottom walls, internally and / or externally. The grippers 146 may be any size and / or shape suitable for engaging the end container 120 for the lifting of the end container 120 off of the linear arrangement 118 of containers 116. An end container 120 may be engaged by grippers 146 while simultaneously being engaged by adjustment members 142.

[0172]

[0164] Figs. 29-33 show processes 200, 300, 400, 500, and 600 (which may be employed with what is described herein with respect to Figs. 1-28) of transferring containers 116 to or from storage locations 128 or mobile robots 126 in accordance with the present disclosure. The transfer of containers may be made to or from an ASRS at an order fulfillment facility or any other suitable facility that handles or otherwise processes containers. The processes may be used to facilitate a bulk transfer of containers. The processes may use some or all of the components described above, such as, for example, components of the transfer systems described above with respect to Figs. 1- 28.

[0173]

[0165] Figs. 29 shows a general process 200 involving transferring containers to storage locations 128 or mobile robots 126 in accordance with the present disclosure. At block 202, a plurality of containers 116 are held in a linear arrangement 118, such as by a dispensing frame 114. The plurality of containers 116 further includes an end container 120 at one end of the linear arrangement 118. As described above with respect to Figs. 1-28, the linear arrangement 118 may be in the form of a stacked arrangement, and the end container 120 may be a container at a top end or a bottom end of the stacked arrangement. Aty. Docket No. 1127P017372- WO (PCT)

[0174]

[0166] At block 204, a dispenser 122 at the dispensing frame 114 maintains the end container 120 at one end of the linear arrangement in the dispensing frame 114. For example, the dispenser 122 may be in the form of prongs 123 at the bottom end of the linear arrangement 118 that maintain the end container 120 at the bottom end of the linear arrangement 118. At block 206, the dispenser

[0175] 122 at the dispensing frame 114 enables the release of the end container 120 in a controlled manner, for example, one at a time from the end of the linear arrangement 118. As one example, prongs

[0176] 123 at the bottom end of the linear arrangement 118 may enable release of containers 116 one at a time although, a lifting assembly 138 may lift containers 116 off the top end of the linear arrangement 118 one at a time.

[0177]

[0167] At block 208, a container transfer mechanism 124 engages the end container 120 following the release of the end container 120 from the dispenser 122. The container transfer mechanism 124 may push containers one at a time following their release from the one end of the linear arrangement. The container transfer mechanism 124 may push the containers directly to mobile robots 126 or to storage locations 128 for retrieval by mobile robots 126. At block 210, the end container 120 from the linear arrangement 118 is received, such as by either a mobile robot 126 or a storage location 128. Optionally, at block 212, the end container 120 is stored until it is retrieved by a mobile robot 126. A support surface (such as described above) at a storage location 128 is disposed between the linear arrangement 118 of containers 116 and a mobile robot access area 132.

[0178]

[0168] Fig. 30 shows a process 300 involving inducting containers 116 to mobile robots 126 or storage locations 128 from a bottom end of a dispensing frame 114 in accordance with the present disclosure. At block 302, a stack of containers 116 is placed into a dispensing frame 114. At block 304, an end container 120 is released and dropped from the bottom end of the linear arrangement 118 in a controlled manner. At block 306, the released end container 120 is pushed by a container transfer mechanism 124, such as by a linear actuator. The end container 120 may be pushed directly from the transfer position to a receiving mobile robot 126. The end container 120 may be pushed from the transfer position to a storage location 128. At block 308, a mobile robot 128 retrieves the end container 120 from the storage location 128. Aty. Docket No. 1127P017372- WO (PCT)

[0179]

[0169] Fig. 31 shows a process 400 involving dispensing containers 116 from mobile robots 126 to a bottom end of a stack of containers 116 in accordance with the present disclosure. At block 402, a mobile robot 126 positions a container 116 on a support surface, which serves as a transfer position. At block 404, the container 116 is pulled into alignment below a dispensing frame 114 by a container transfer mechanism 124. At block 406, the container 116 is lifted into a bottom end the dispensing frame 114. At block 408, the container 116 joins a stack of containers in the dispensing frame 114.

[0180]

[0170] Fig. 32 shows a process 500 involving inducting containers 116 to storage locations 128 or mobile robots 126 from a top end of a dispensing frame 114 in accordance with the present disclosure. At block 502, a stack of containers 116 is placed into a dispensing frame 114. At block 504, an end container 120 is lifted from the top end of the linear arrangement 118. The end container 120 may be obtained, for example, by being lifted out of the stack by a lifting assembly 138. At block 506, the lifted end container 120 is moved by a container transfer mechanism 124. The end container 120 may be moved by a support surface to a storage location 128. At block 508, a mobile robot 126 retrieves the end container 120 from the storage location 128.

[0181]

[0171] Fig. 33 shows a process 600 involving dispensing containers 116 from mobile robots 126 to a top end of a stack of containers 116 in accordance with the present disclosure. At block 602, a mobile robot 126 positions a container 116 on a support surface (such as described above), which serves as a transfer position. At block 604, the container 116 is moved into alignment at a dispensing frame 114 by a container transfer mechanism 124. A support surface at a storage location 128 may move the container into alignment at the dispensing frame 114. At block 606, the container 116 is released into the top end of the dispensing frame 114, such as being released from a support surface to a lifting assembly 138. At block 608, the container 116 joins a stack of containers 116 at the top end of the stack.

[0182]

[0172] It should be understood that the foregoing description is only illustrative of the present disclosure. Various alternatives and modifications can be devised by those skilled in the art without departing from the present disclosure. Accordingly, the present disclosure is intended to embrace all such alternatives, modifications and variances that fall within the scope of any claims Aty. Docket No. 1127P017372- WO (PCT) appended hereto. Further, the mere fact that different features are recited in mutually different dependent or independent claims does not indicate that a combination of these features cannot be advantageously used, such a combination remaining within the scope of the present disclosure.

[0183]

[0173] What is claimed is:

Claims

Aty. Docket No. 1127P017372- WO (PCT)CLAIMS1. A system for transfer of containers, the system comprising: a dispensing frame holding a plurality of containers in a linear arrangement, the plurality of containers including an end container at one end of the linear arrangement; a dispenser at the dispensing frame enabling release of the end container in a controlled manner from the one end of the linear arrangement, the dispenser enabling release of containers one at a time from the one end of the linear arrangement; and a container transfer mechanism engaging the end container following release of the end container from the dispenser; wherein the container transfer mechanism engages and moves containers one at a time, following release from the one end of the linear arrangement, to mobile robots or to storage locations.

2. The system of claim 1, wherein the linear arrangement comprises a stacked arrangement and wherein the end container is a container at a top end or a bottom end of the stacked arrangement.

3. The system of claim 2, wherein: the end container is at the bottom end of the stacked arrangement; the dispenser releases and drops the end container to a transfer position; and the container transfer mechanism pushes the end container from the transfer position.

4. The system of claim 3, wherein the dispenser comprises a plurality of prongs to hold containers at the one end of the linear arrangement and to release one container at a time.

5. The system of claim 1 , further comprising a support surface for receiving the end container from the linear arrangement and for storing the end container until retrieved by a mobile robot, theAty. Docket No. 1127P017372- WO (PCT) support surface being disposed between the linear arrangement of containers and a mobile robot access area.

6. The system of claim 5, further comprising one or more flipper arms to retain the end container on the support surface.

7. The system of claim 1, further comprising an imaging device oriented to capture images at the one end of the linear arrangement to determine a condition of the end container.

8. The system of claim 2, wherein: the end container is at the top end of the stacked arrangement; the dispenser comprises a lifting assembly configured to lift the end container off the stacked arrangement; and the container transfer mechanism moves the end container to a mobile robot or to a storage location.

9. The system of claim 8, wherein the container transfer mechanism comprises a support plate to move the end container to the mobile robot or to the storage location.

10. The system of claim 8, wherein the lifting assembly includes one or more grippers, the one or more grippers configured to engage the end container.

11. The system of claim 10 wherein the lifting assembly includes at least one rail configured to enable alignment of the one or more grippers relative to the end container.

12. The system of claim 8, wherein a first container includes at least one bale arm, the at least one bale arm movable from a first position to allow nesting of a second container in the first container and a second position to support the second container stacked on the first container to a second position, thereby enabling stacking of either empty containers or at least partially filled containers at the dispensing frame.Aty. Docket No. 1127P017372- WO (PCT)13. The system of claim 12, wherein the lifting assembly includes adjustment members configured to move the at least one bale arm of the first container from the first position to the second position and / or from the second position to the first position.

14. The system of claim 1, wherein the plurality of containers comprise at least one empty container and / or at least one partially full container.

15. A method for transfer of containers, the method comprising: by a dispensing frame, holding a plurality of containers in a linear arrangement, the plurality of containers including an end container at one end of the linear arrangement; by a dispenser at the dispensing frame, enabling release of the end container in a controlled manner, the dispenser enabling release of containers one at a time from the one end of the linear arrangement; and by a container transfer mechanism, engaging the end container following release of the end container from the dispenser; wherein the container transfer mechanism engages and moves containers one at a time, following release from the one end of the linear arrangement, to mobile robots or to storage locations.

16. The method of claim 15, wherein the linear arrangement comprises a stacked arrangement and wherein the end container is a container at a top end or a bottom end of the stacked arrangement.

17. The method of claim 16, wherein the end container is at the bottom end of the stacked arrangement, the method further comprising: by the dispenser, releasing and dropping the end container to a transfer position; and by the container transfer mechanism, pushing the end container from the transfer position.Aty. Docket No. 1127P017372- WO (PCT)18. The method of claim 16, wherein the end container is at the top end of the stacked arrangement, the method further comprising: by the dispenser, lifting the end container off the stacked arrangement; and by the container transfer mechanism, moving the end container to a mobile robot or to a storage location.

19. The method of claim 18, wherein the dispenser comprises a lifting assembly and the container transfer mechanism comprises a support plate, the method further comprising: by the dispenser, lifting the end container from the top end of the stacked arrangement; and by the support plate, moving the end container to the mobile robot or to the storage location.

20. A system for transfer of containers, the system comprising: a dispensing frame holding a plurality of containers in a linear arrangement, the plurality of containers including an end container at one end of the linear arrangement; a container disposed adjacent the dispensing frame; a container transfer mechanism engaging the adjacent container and moving the adjacent container into alignment with the dispensing frame; and a stacker that receives the adjacent container at the one end of the dispensing frame and moves the adjacent container into engagement with the end container.

Images