Warehouse automation systems and methods

• US 10,239,694 B2
• Filed: 07/12/2018
• Issued: 03/26/2019
• Est. Priority Date: 12/07/2015
• Status: Active Grant

• Current Assignee: Ocado Innovation Limited (Ocado Group PLC)
• Original Assignee: 6 River Systems, Inc. (Shopify Incorporated)
• Inventors: Hamilton, Rylan, Dubois, Jerome, Cacioppo, Christopher, Higgins, Timothy, Chaitin-Pollak, Josh
• Primary Examiner(s): Cumbess, Yolanda R
• Application Number:
  US16/034,125
• Publication Number:
  US 20180319593A1
• Time in Patent Office: 257 Days
• Field of Search: None
• CPC Class Codes: B65G 1/0492 with cars adapted to travel in storage aisles
• CPC Class Codes: B65G 1/1373 for fulfilling orders in warehouses
• CPC Class Codes: B65G 1/1375 the orders being assembled on a commissioning stacker-crane or truck
• CPC Class Codes: G05B 19/41895 using automatic guided vehicles [AGV] control of position or course of AGV's G05D1/00
• CPC Class Codes: G05B 2219/32392 Warehouse and loading, unloading station and shop and machining centers and in out buffer
• CPC Class Codes: G06Q 10/0875 Itemisation or classification of parts, supplies or services, e.g. bill of materials
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
• CPC Class Codes: Y02P 90/60 Electric or hybrid propulsion means for production processes

Abstract

A warehouse automation system adapted to improve warehouse operating productivity includes a plurality of carts for transporting products within a warehouse and a controller. The controller is adapted to associate a first one of the plurality of carts with a first person and to control the first cart to lead the first person around the warehouse. According to one advantage, the time the first person spends restocking, picking, counting, sorting, moving, and packing product into customer orders and shipments, for example, is reduced.

Claims

1. A warehouse automation system for picking products within a warehouse, the system comprising:

a plurality of carts for transporting products within a warehouse, each cart comprising a plurality of storage receptacles for storing the products; and

a controller adapted to (i) associate a first one of the plurality of carts with a first person, (ii) dedicate each storage receptacle of the first cart to a discrete task selected from the group consisting of storing product picked for a single order, storing product picked for multiple orders, storing multiple types of picked products, storing multiple quantities of a single picked product, and storing product picked for a time sensitive order, (iii) control the first cart to lead the first person around the warehouse, (iv) instruct the first person to pick product for at least two storage receptacles of the first cart that are dedicated to different discrete tasks, and (v) move the first cart at at least one of a speed equal to a normal pace of the first person and a speed faster than a normal pace of the first person.

2. The system of claim 1, wherein the controller is further adapted to set settings of the first cart personal to the first person and to set settings of the first cart personal to a second person different from the first person when the second person is associated with the first cart.

3. The system of claim 1, wherein the controller is further adapted to assign a task to the first person based upon an ability of the first person.

4. The system of claim 1, wherein the controller is further adapted to associate a second one of the plurality of carts with the first person at the same time that the first cart is associated with the first person.

5. The system of claim 1, wherein the controller is further adapted to associate the first cart with a second person different from the first person at the same time that the first cart is associated with the first person.

6. The system of claim 1, wherein the first cart comprises a motor for propelling the first cart.

7. The system of claim 1, wherein the first cart comprises at least one of an on-screen interface and an off-screen interface for communicating information to the first person.

8. The system of claim 7, wherein the first cart comprises the on-screen interface and further wherein the on-screen interface is adapted to communicate information concerning at least one of a physical location of the first cart within the warehouse, a physical location of certain product within the warehouse, a current task assigned to the first person, time between various tasks assigned to the first person, priorities in the warehouse, and performance of the first person.

9. The system of claim 7, wherein the first cart comprises the off-screen interface and further wherein the off-screen interface comprises at least one of a lighting and an audio source.

10. The system of claim 9, wherein the first cart comprises the lighting and further wherein the lighting is adapted to identify a storage receptacle on the first cart within which a product is to be placed.

11. The system of claim 9, wherein the first cart comprises the lighting and further wherein the lighting is adapted to differ depending upon a task assigned to the first person.

12. The system of claim 9, wherein the first cart comprises the lighting and further wherein the lighting is adapted to communicate information concerning at least one of a status of the first cart, a health of the first cart, a movement speed of the first cart, and a change in direction of the first cart.

13. The system of claim 9, wherein the first cart comprises the audio source and further wherein the audio source is adapted to communicate information concerning at least one of a status of a task assigned to the first person, a proximity of the first cart to a plurality of persons, and a status of the first cart.

14. The system of claim 1, wherein the first cart comprises a sensor for, at least in part, at least one of identifying a distance of the first person from the first cart, determining a position of the first cart within the warehouse, and identifying an obstacle in a path of the first cart.

15. The system of claim 1 further comprising at least one workstation for processing the products.

16. The system of claim 15, wherein the workstation comprises a robotic arm.

17. The system of claim 15, wherein the workstation is selected from the group consisting of a sorting station, a packing station, a shipping station, a kitting station, a personalization station, and a gift wrapping station.

18. The system of claim 1 further comprising a display for displaying real-time performance metrics of the first and other persons.

19. The system of claim 1 further comprising a plurality of overhead cameras adapted to (i) monitor the plurality of carts, the first person, and material handling equipment, and (ii) determine a location of each cart.

20. A computer-controlled automated method of picking products within a warehouse, the method comprising the steps of:

associating a first person with a first one of a plurality of carts for transporting products within a warehouse, the first cart comprising a plurality of storage receptacles for storing the products, each storage receptacle being dedicated to a discrete task selected from the group consisting of storing product picked for a single order, storing product picked for multiple orders, storing multiple types of picked products, storing multiple quantities of a single picked product, and storing product picked for a time sensitive order;

controlling the first cart to lead the first person around the warehouse; and

instructing the first person to pick product for at least two storage receptacles dedicated to different discrete tasks,

wherein the controlling step comprises moving the first cart at at least one of a speed equal to a normal pace of the first person and a speed faster than a normal pace of the first person.

21. The method of claim 20 further comprising associating the first person with a second one of the plurality of carts at the same time that the first person is associated with the first cart.

22. The method of claim 20 further comprising associating a second person different from the first person with the first cart at the same time that the first person is associated with the first cart.

23. The method of claim 20 further comprising assigning a task to the first person based upon an ability of the first person.

24. The method of claim 20 further comprising illuminating a storage receptacle on the first cart to identify the storage receptacle within which a product is to be placed.

25. The method of claim 20 further comprising illuminating a storage receptacle on the first cart differently depending upon a task assigned to the first person.

26. The method of claim 20, further comprising communicating, via an audio source, information concerning at least one of a status of a task assigned to the first person, a proximity of the first cart to a plurality of persons, and a status of the first cart.

27. The method of claim 20, further comprising displaying real-time performance metrics of the first and other persons.