Robotic induction in materials handling facilities

• US 8,639,382 B1
• Filed: 12/29/2010
• Issued: 01/28/2014
• Est. Priority Date: 12/29/2010
• Status: Active Grant

• Current Assignee: Amazon Technologies, Inc. (Amazon.com, Inc.)
• Original Assignee: Amazon Technologies, Inc. (Amazon.com, Inc.)
• Inventors: Clark, David H., Young, Eric
• Primary Examiner(s): Burgess, Ramya
• Assistant Examiner(s): Randazzo, Thomas
• Application Number:
  US12/981,172
• Time in Patent Office: 1,126 Days
• Field of Search: 700/216, 700/214, 700/218, 700/230, 700/245, 414/270, 414/807
• US Class Current: 700/214
• CPC Class Codes: G06Q 10/087 Inventory or stock management, e.g. order filling, procurement or balancing against orders

Abstract

Methods and apparatus for robotic induction in materials handling facilities. Singulation and induction of items is performed at one or more induction stations in one or more inventory areas. Each inventory area includes a stock storage area containing storage units, each storage unit including locations for stowing inventory. Mobile robotic devices deliver particular storage units from the stock storage area to particular induction stations. At the induction stations, inductors remove single units of items from locations on the storage units (singulation) and induct the units of items into a conveyance mechanism (induction). The singulated and inducted units of items are conveyed to downstream processing station(s). The operations of the robotic devices, induction stations, conveyance mechanism, and downstream processing may be controlled and/or directed by a control system.

Claims

1. A unit-level materials handling system, comprising:

a control system;

a conveyance mechanism;

a plurality of portable storage units, wherein each storage unit comprises one or more locations for stowing one or more types of items;

one or more mobile robotic devices;

one or more singulating induction stations, each singulating induction station located proximate to a portion of the conveyance mechanism, wherein each singulating induction station is configured for combined selection of items from inventory from one or more of the portable storage units and induction of single units of the items selected from the one or more portable storage units onto the conveyance mechanism;

wherein the control system is operable to;

direct each of the one or more robotic devices to transport particular storage units to and from particular singulating induction stations;

direct a combined selection and induction of one or more single units of items from a particular storage unit, wherein to direct the combined selection and induction the control system is further operable to;

direct, at a particular singulating induction station, the selection of one or more single units of items from one or more locations of the particular portable storage unit currently at the particular singulating induction station, wherein the particular portable storage unit currently at said particular singulating induction station includes units of items not needed by any of the downstream processing stations as well as the one or more single units directed for selection;

direct, at the particular singulating induction station, the induction of each selected single unit into separate locations on the conveyance mechanism at the same particular singulating induction station where each selected single unit was selected from the same particular portable storage unit; and

direct the conveyance of the inducted single units of the items to one or more downstream processing stations via the conveyance mechanism.

2. The unit-level materials handling system as recited in claim 1, wherein the robotic devices are each operable to move under a storage unit, lift the storage unit, transport the storage unit, lower the storage unit, and move out from under the storage unit.

3. The unit-level materials handling system as recited in claim 1,

wherein, to direct the induction of each selected single unit into the conveyance mechanism, the control system is operable to direct the placement of the selected single units of items into conveyance receptacles and the induction of the conveyance receptacles containing single units of items into the conveyance mechanism, wherein one and only one unit is placed in each conveyance receptacle;

and

wherein, to direct the conveyance of the inducted single units of the items to one or more downstream processing stations via the conveyance mechanism, the control system is operable to direct the conveyance of the conveyance receptacles each containing a single unit of an item to the one or more downstream processing stations via the conveyance mechanism.

4. The unit-level materials handling system as recited in claim 3, wherein the conveyance receptacles are not fixed to the conveyance mechanism.

5. The unit-level materials handling system as recited in claim 3,

wherein each conveyance receptacle includes a receptacle identifier that uniquely identifies the conveyance receptacle within a materials handling facility, and

wherein the control system is operable to associate an item identifier of each selected unit with a receptacle identifier of an empty one of the plurality of conveyance receptacles into which the unit is placed.

6. The unit-level materials handling system as recited in claim 1, further comprising one or more sorting stations each proximate to a portion of the conveyance mechanism, wherein the control system is further operable to direct the conveyance mechanism to convey the inducted single units of items from the one or more singulating induction stations to particular ones of the one or more sorting stations.

7. The unit-level materials handling system as recited in claim 6,

wherein, to direct the induction of each selected single unit into the conveyance mechanism, the control system is operable to direct the placement of the selected single units of items into conveyance receptacles and the induction of the conveyance receptacles containing single units of items into the conveyance mechanism, and

wherein each sorting station is operable to induct empty conveyance receptacles into a return path of the conveyance mechanism, wherein the return path of the conveyance mechanism is operable to return the empty conveyance receptacles to the one or more singulating inductions stations.

8. The unit-level materials handling system as recited in claim 6,

wherein each of the one or more sorting stations is operable to receive single units of items via the conveyance mechanism, and

wherein the control system is operable to direct transfer of the single units of items from the conveyance mechanism to particular locations at the sorting station associated with particular ones of a plurality of orders.

9. The unit-level materials handling system as recited in claim 8, wherein the sorting station includes one or more order sorting bins each comprising a plurality of order slots, and wherein the particular locations at the sorting station are particular ones of the plurality of order slots in the one or more order sorting bins.

10. The unit-level materials handling system as recited in claim 1, wherein the conveyance mechanism is a conveyance sorter mechanism operable to divert items off a conveyance path under control of the control system.

11. The unit-level materials handling system as recited in claim 10, wherein the conveyance sorter mechanism is a shoe sorter.

12. The unit-level materials handling system as recited in claim 1, wherein the plurality of portable storage units, the one or more mobile robotic devices, and the one or more singulating induction stations are located in an inventory area of a materials handling facility.

13. The unit-level materials handling system as recited in claim 12, wherein the materials handling facility includes at least one other inventory area comprising a plurality of portable storage units, one or more mobile robotic devices, and one or more induction stations each located proximate to a portion of the conveyance mechanism, wherein the control system is further operable to direct operations of the robotic devices and the induction stations in the at least one other inventory area.

14. A system, comprising:

at least one processor; and

a memory comprising program instructions, wherein the program instructions are executable by the at least one processor to;

direct each of one or more mobile robotic devices in an inventory area of a materials handling facility to transport particular ones of a plurality of portable storage units to and from particular ones of one or more singulating induction stations in the inventory area, wherein each portable storage unit comprises one or more locations for stowing one or more types of items, wherein each singulating induction station is proximate to a portion of a conveyance mechanism, and wherein each singulating induction station is configured for combined selection of items from inventory from one or more of the portable storage units and induction of single units of the items selected from the one or more portable storage units onto the conveyance mechanism;

direct a combined selection and induction of one or more single units of items from a particular portable storage unit, wherein to direct the combined selection and induction the program instructions are further executable to;

direct, at each singulating induction station, the selection of one or more single units of items from one or more locations of a particular portable storage unit currently at the singulating induction station, wherein the particular portable storage unit currently at said singulating induction station includes units of items not needed by any of the downstream processing stations as well as the one or more single units directed for selection;

direct, at each singulating induction station, the induction of each selected single unit into the conveyance mechanism at the same singulating induction station where each selected single unit was selected from the storage unit; and

direct the conveyance of the inducted single units of the items from the one or more singulating induction stations to one or more downstream processing stations via the conveyance mechanism.

15. The system as recited in claim 14,

wherein, to direct the induction of each selected single unit into the conveyance mechanism, the program instructions are executable by the at least one processor to direct the placement of the selected single units of items into conveyance receptacles and the induction of the conveyance receptacles containing single units of items into the conveyance mechanism, wherein one and only one unit is placed in each conveyance receptacle;

and

wherein, to direct the conveyance of the inducted single units of the items to one or more downstream processing stations via the conveyance mechanism, the program instructions are executable by the at least one processor to direct the conveyance of the conveyance receptacles each containing a single unit of an item to the one or more downstream processing stations via the conveyance mechanism.

16. The system as recited in claim 15, wherein each conveyance receptacle includes a receptacle identifier that uniquely identifies the conveyance receptacle within the materials handling facility, wherein the program instructions are executable by the at least one processor to associate an item identifier of each selected unit with a receptacle identifier of an empty one of the plurality of conveyance receptacles into which the unit is placed.

17. The system as recited in claim 14, wherein the program instructions are executable by the at least one processor to direct the conveyance mechanism to convey the single units of items from the one or more singulating induction stations to particular ones of one or more sorting stations in the materials handling facility.

18. The system as recited in claim 17, wherein the program instructions are executable by the at least one processor to, at each of the one or more sorting stations, direct transfer of the units of items from the conveyance mechanism to particular locations at the sorting station associated with particular ones of a plurality of orders.

19. The system as recited in claim 14, wherein the materials handling facility includes at least one other inventory area comprising a plurality of portable storage units, one or more mobile robotic devices, and one or more induction stations each located proximate to a portion of the conveyance mechanism, wherein the program instructions are executable by the at least one processor to direct operations of the robotic devices and the induction stations in the at least one other inventory area.

20. The system as recited in claim 14,

wherein, to direct the induction of each selected single unit into the conveyance mechanism, the program instructions are executable by the at least one processor to direct the placement of the selected single units of items into conveyance receptacles and the induction of the conveyance receptacles containing single units of items into the conveyance mechanism, and

wherein the program instructions are executable by the at least one processor to direct the conveyance of empty conveyance receptacles to the one or more inductions stations on a return path of the conveyance mechanism.

21. A method, comprising:

transporting, by one or more mobile robotic devices in an inventory area of a materials handling facility, particular ones of a plurality of portable storage units to and from particular ones of one or more singulating induction stations in the inventory area, wherein each portable storage unit comprises one or more locations for stowing one or more types of items, wherein each singulating induction station is proximate to a portion of a conveyance mechanism, and wherein each singulating induction station is configured for combined selection of items from inventory from one or more of the portable storage units and induction of single units of the items selected from the one or more portable storage units onto the conveyance mechanism;

at each singulating induction station;

direct a combined selection and induction of one or more single units of items from a particular portable storage unit, wherein directing the combined selection and induction comprises;

selecting one or more single units of items from one or more locations of a portable storage unit currently at the singulating induction station, wherein the portable storage unit currently at said singulating induction station includes units of items not needed by any of the downstream processing stations as well as the one or more selected single units; and

inducting the selected single units of items into the conveyance mechanism at the same singulating induction station where each selected single unit was selected from the portable storage unit; and

conveying the inducted single units of the items from the one or more singulating induction stations to one or more downstream processing stations via the conveyance mechanism.

22. The method as recited in claim 21,

wherein said inducting the selected single units of items into the conveyance mechanism comprises placing the selected single units of items into conveyance receptacles and inducting the conveyance receptacles containing single units of items into the conveyance mechanism, wherein one and only one unit is placed in each conveyance receptacle;

and

wherein conveying the inducted single units of the items from the one or more singulating induction stations to one or more downstream processing stations via the conveyance mechanism comprises conveying the conveyance receptacles each containing a single unit of an item to the one or more downstream processing stations via the conveyance mechanism.

23. The method as recited in claim 22,

wherein each conveyance receptacle includes a receptacle identifier that uniquely identifies the conveyance receptacle within the materials handling facility, the method further comprising associating an item identifier of each selected unit with a receptacle identifier of an empty one of the plurality of conveyance receptacles into which the unit is placed.

24. The method as recited in claim 21, wherein said conveying the inducted single units of the items from the one or more singulating induction stations to one or more downstream processing stations via the conveyance mechanism comprises directing the conveyance mechanism to convey the conveyance receptacles containing single units of items from the one or more singulating induction stations to particular ones of one or more sorting stations in the materials handling facility.

25. The method as recited in claim 24, wherein the method further comprises, at each of the one or more sorting stations, transferring the units of items from the conveyance mechanism to particular locations at the sorting station associated with particular ones of a plurality of orders.

26. The method as recited in claim 21,

wherein said inducting the selected single units of items into the conveyance mechanism comprises placing the selected single units of items into conveyance receptacles and inducting the conveyance receptacles containing single units of items into the conveyance mechanism,

the method further comprising inducting, at a downstream processing station, empty conveyance receptacles into a return path of the conveyance mechanism, wherein the return path of the conveyance mechanism is operable to return the empty conveyance receptacles to the one or more singulating inductions stations.

27. A non-transitory computer-accessible storage medium storing program instructions computer-executable to implement a materials handling facility control system operable to:

direct each of one or more mobile robotic devices in an inventory area of a materials handling facility to transport particular ones of a plurality of portable storage units to and from particular ones of one or more singulating induction stations in the inventory area, wherein each storage unit comprises one or more locations for stowing one or more types of items, wherein each singulating induction station is proximate to a portion of a conveyance mechanism, and wherein each singulating induction station is configured for combined selection of items from inventory from one or more of the portable storage units and induction of single units of the items selected from the one or more portable storage units onto the conveyance mechanism;

direct a combined selection and induction of one or more single units of items from a particular portable storage unit, wherein to direct the combined selection and induction the control system is further operable to;

direct, at each singulating induction station, the selection of one or more single units of items from one or more locations of the particular portable storage unit currently at the singulating induction station, wherein the particular portable storage unit currently at said singulating induction station includes units of items not needed by any of the downstream processing stations as well as the one or more single units directed for selection;

direct, at each singulating induction station, the induction of each selected single unit into the conveyance mechanism at the same singulating induction station where each selected single unit was selected from the storage unit, wherein induction of each selected single unit comprises singulation of each selected single unit; and

direct the conveyance of the inducted single units of the items from the one or more singulating induction stations to one or more downstream processing stations via the conveyance mechanism.

28. The non-transitory computer-accessible storage medium as recited in claim 27,

wherein, to direct the induction of each selected single unit into the conveyance mechanism, the control system is operable to direct the placement of the selected single units of items into conveyance receptacles and the induction of the conveyance receptacles containing single units of items into the conveyance mechanism, wherein one and only one unit is placed in each conveyance receptacle;

and

wherein, to direct the conveyance of the inducted single units of the items to one or more downstream processing stations via the conveyance mechanism, the control system is operable to direct the conveyance of the conveyance receptacles each containing a single unit of an item to the one or more downstream processing stations via the conveyance mechanism.

29. The non-transitory computer-accessible storage medium as recited in claim 28, wherein each conveyance receptacle includes a receptacle identifier that uniquely identifies the conveyance receptacle within the materials handling facility, wherein the control system is further operable to associate an item identifier of each selected unit with a receptacle identifier of an empty one of the plurality of conveyance receptacles into which the unit is placed.

30. The non-transitory computer-accessible storage medium as recited in claim 27, wherein the control system is further operable to direct the conveyance mechanism to convey the single units of items from the one or more singulating induction stations to particular ones of one or more sorting stations in the materials handling facility.

31. The non-transitory computer-accessible storage medium as recited in claim 30, wherein the control system is further operable to, at each of the one or more sorting stations, direct transfer of the units of items from the conveyance mechanism to particular locations at the sorting station associated with particular ones of a plurality of orders.

32. The non-transitory computer-accessible storage medium as recited in claim 27, wherein the materials handling facility includes at least one other inventory area comprising a plurality of portable storage units, one or more mobile robotic devices, and one or more induction stations each located proximate to a portion of the conveyance mechanism, wherein the control system is further operable to direct operations of the robotic devices and the induction stations in the at least one other inventory area.

33. The non-transitory computer-accessible storage medium as recited in claim 27,

wherein, to direct the induction of each selected single unit into the conveyance mechanism, the control system is further operable to direct the placement of the selected single units of items into conveyance receptacles and the induction of the conveyance receptacles containing single units of items into the conveyance mechanism, and

wherein the control system is further operable to direct the conveyance of empty conveyance receptacles to the one or more singulating inductions stations on a return path of the conveyance mechanism.