Shuffling inventory holders

• US 9,111,251 B1
• Filed: 03/31/2014
• Issued: 08/18/2015
• Est. Priority Date: 03/31/2014
• Status: Active Grant

• Current Assignee: Amazon Technologies, Inc. (Amazon.com, Inc.)
• Original Assignee: Amazon Technologies, Inc. (Amazon.com, Inc.)
• Inventors: Brazeau, Jeremiah David
• Primary Examiner(s): CUMBESS, YOLANDA RENEE
• Application Number:
  US14/231,692
• Time in Patent Office: 505 Days
• Field of Search: None
• US Class Current: 1/1
• CPC Class Codes: B65G 1/1373 for fulfilling orders in warehouses
• CPC Class Codes: B65G 43/00 Control devices, e.g. for safety, warning or fault-correcting
• CPC Class Codes: G05B 15/02 electric
• CPC Class Codes: G06Q 10/087 Inventory or stock management, e.g. order filling, procurement or balancing against orders

Abstract

An inventory system has mobile drive units that freely and independently move about a facility to transport inventory holders. The mobile drive units may operate through communications with other drive units, or under a more centralized control of a management module. For various operating scenarios, the mobile drive units are directed to shuffle the inventory holders in a manner that minimizes travel of the mobile drive units, thereby improving overall system efficiency. One or more single mobile drive units may be used to transport inventory holders to and from a region, and one or more other mobile drive units may be used to reposition or slide each of the inventory holders back and forth within the region to efficiently place inventory holders before an operator on an as-needed basis.

Claims

1. A method comprising:

positioning multiple inventory holders at multiple locations at a station of an inventory system, the multiple locations including a set of multiple primary locations and a set of multiple staging locations;

repositioning a first inventory holder, a second inventory holder, a third inventory holder, and a fourth inventory holder of the multiple inventory holders among the multiple primary locations and the multiple staging locations at the station using multiple mobile drive units, the repositioning comprising;

following a first inventory operation when the first inventory holder is positioned in a first primary location of the multiple primary locations,

receiving a first inventory task;

determining from the first inventory task that the second inventory holder contains one or more items of interest for a second inventory operation;

in response to determining that the second inventory holder contains items of interest for the second inventory operation, repositioning, using a first mobile drive unit, the first inventory holder from the first primary location to a first staging location of the multiple staging locations and repositioning, using a second mobile drive unit, the second inventory holder from a second staging location of the multiple staging locations to the first primary location;

following a third inventory operation when the third inventory holder is positioned in a second primary location of the multiple primary locations,

receiving a second inventory task;

determining from the second inventory task that the fourth inventory holder contains one or more items of interest for a fourth inventory operation;

in response to said determining that the fourth inventory holder contains items of interest for the fourth inventory operation, repositioning, using a third mobile drive unit, the third inventory holder from the second primary location to a third staging location of the multiple staging locations and repositioning, using a fourth mobile drive unit, the fourth inventory holder from a fourth staging location of the multiple staging locations to the second primary location;

following a fifth inventory operation when the second inventory holder is positioned in the first primary location,

receiving a third inventory task;

determining from the third inventory task that the first inventory holder contains one or more items of interest for a sixth inventory operation;

in response to said determining that the second inventory holder contains items of interest for the sixth inventory operation, repositioning, using the second mobile drive unit, the second inventory holder from the first primary location to either the second staging location or another unoccupied location of the multiple staging locations and repositioning, using the first mobile drive unit, the first inventory holder from the first staging location back to either the first primary location or another unoccupied primary location of the multiple primary locations;

following a seventh inventory operation when the fourth inventory holder is positioned in the second primary location,

receiving a fourth inventory task;

determining from the fourth inventory task that the third inventory holder contains one or more items of interest for an eighth inventory operation;

in response to said determining that the third inventory holder contains items of interest for the eighth inventory operation, repositioning, using the fourth mobile drive unit, the fourth inventory holder from the second primary location to either the fourth staging location or another unoccupied staging location of the multiple staging locations and repositioning, using the third mobile drive unit, the third inventory holder from the third staging location back to the second primary location or another unoccupied primary location of the multiple primary locations.

2. The method as recited in claim 1, further comprising:

determining that the first inventory holder and the second inventory holder no longer contain items of interest and subsequently transferring away from the station the first inventory holder and the second inventory holder; and

transferring in to at least one of a primary location or a staging location of the station, one or more new inventory holders.

3. The method as recited in claim 2, wherein the transferring is performed by one or more additional mobile drive units separate from the first mobile drive unit, the second mobile drive unit, the third mobile drive unit, and the fourth mobile drive unit.

4. The method as recited in claim 1, wherein:

the first primary location and the second primary location are proximally closest to an operator;

the first staging location and the second staging location are adjacent to the first primary location; and

the third staging location and the fourth staging location are adjacent to the second primary location.

5. The method as recited in claim 1, further comprising controlling movement of the multiple mobile drive units from a central control module.

6. A method comprising:

positioning a first inventory holder at a first location near an operator;

positioning a second inventory holder at a second location proximal to the first location, but spaced from the operator;

determining that one or more items on the second inventory holder should be placed for access by the operator;

in response to said determining, repositioning, using a mobile drive unit, the first inventory holder from the first location to a third location and repositioning, using the mobile drive unit, the second inventory holder from the second location into the first location vacated by the repositioning of the first inventory holder;

subsequently determining that one or more items on the first inventory holder should be placed for access by the operator;

in response to said subsequently determining, repositioning, using the mobile drive unit, the second inventory holder from the first location back to the second location and repositioning, using the mobile drive unit, the first inventory holder from the third location back to the first location.

7. The method as recited in claim 6, wherein the second and third locations are proximal to the first location.

8. The method as recited in claim 6, further comprising:

after repositioning the first inventory holder back into the first position,

repositioning, using the mobile drive unit, the first inventory holder from the first location to the third location; and

repositioning, using the mobile drive unit, the second inventory holder from the second location into the first location.

9. The method as recited in claim 6, further comprising transferring, using another mobile drive unit, a new inventory holder into an unoccupied location proximal to the first location.

10. The method as recited in claim 6, wherein the first inventory holder is repositioned to the third location for a temporary period of time and further comprising transporting, using another mobile drive unit, the first inventory holder away from the third location.

11. The method as recited in claim 6, further comprising controlling movement of the mobile drive unit from a central control module.

12. The method as recited in claim 6, wherein determining that one or more items on the second inventory holder should be placed for access by the operator comprises receiving an inventory task that is generated in response to an inventory operation involving the one or more items and ascertaining, based on the inventory task, which inventory holder contains the one or more items.

13. The method as recited in claim 12, wherein the inventory task is selected from a set of inventory tasks comprising order fulfillment tasks, restocking tasks, storage tasks, and counting tasks.

14. An inventory system comprising:

a plurality of mobile drive units that are remotely controllable to move inventory holders about a warehouse; and

a management module configured to receive instructions pertaining to handling of inventory items and in response to create inventory tasks that, in part, direct movement of the plurality of mobile drive units to move the inventory holders throughout the warehouse and position the inventory holders at primary locations accessible by human or machine operators, the management module being further configured to direct at least a first mobile drive unit and a second mobile drive unit from the plurality of mobile drive units to perform a process within a region of the warehouse wherein the first mobile drive unit and the second mobile drive unit move at least a first inventory holder and a second inventory holder between operational locations for access by an operator and staging locations proximal to the operational locations but spaced from the operator, wherein during the process, the management module is configured to at least;

receive a first request related to one or more items on the second inventory holder while the first inventory holder is positioned at an operational location;

in response to the first request, create one or more inventory tasks to move the second inventory holder into the operational location by directing the first mobile drive unit to reposition the first inventory holder from the operational location to a first staging location that is proximal to the operational location and directing the second mobile drive unit to reposition the second inventory holder from a second staging location into the operational location vacated when the first inventory holder is repositioned to the first staging location, wherein the second inventory holder is positioned such that the operator can place one or more items onto or remove one or more items from the second inventory holder;

receive a second request related to one or more items on the first inventory holder while the second inventory holder is positioned at the operational location; and

in response to the second request, create one or more inventory tasks to move the first inventory holder into the operational location by directing the second mobile drive unit to reposition the second inventory holder from the operational location back to the second staging location or to another unoccupied staging location and directing the first mobile drive unit to reposition the first inventory holder from the first staging location back to the operational location, wherein the first inventory holder is positioned such that the operator can place one or more items onto or remove one or more items from the first inventory holder.

15. The method as recited in claim 14, wherein the management module is further configured to direct the first mobile drive unit and the second mobile drive unit to both be in motion at least part of the time during repositioning of the first inventory holder and the second inventory holder.

16. The method as recited in claim 14, wherein the management module is further configured to direct the first mobile drive unit and the second mobile drive unit to move at different times during repositioning of the first inventory holder and the second inventory holder.

17. The inventory system as recited in claim 14, wherein the management module is further configured to direct another mobile drive unit to remove the first inventory holder from the region of the warehouse.

18. The inventory system as recited in claim 17, wherein the management module is further configured to direct said another mobile drive unit to remove the first inventory holder location after the first mobile drive unit is disengaged and moved away from the first inventory holder.

19. The inventory system as recited in claim 14, wherein the management module is further configured to direct another mobile drive unit to bring a new inventory holder and deposit the new inventory holder in an unoccupied staging location.

20. The inventory system as recited in claim 19, wherein the management module is further configured to direct the second mobile drive unit to move to the unoccupied staging location to engage and reposition the new inventory holder.

21. A method comprising:

determining an order set for a plurality of items to be picked from a plurality of inventory holders, wherein the plurality of inventory holders comprise at least a first inventory holder, a second inventory holder, a third inventory holder, and a fourth inventory holder;

determining a sequence for a plurality of inventory tasks to be performed by an operator at a station to pick each of the plurality of items;

positioning the first inventory holder at a first primary location based at least in part on a first task of the sequence of the plurality of inventory tasks, the first task including a pick of one or more items from the first inventory holder by the operator;

positioning a second inventory holder at a second primary location based at least in part on a second task of the sequence of the plurality of inventory tasks, the second task including a pick of one or more items from the second inventory holder by the operator;

positioning a third inventory holder at a first staging location based at least in part on a third task of the sequence of the plurality of inventory tasks, the third task including a pick of one or more items from the third inventory holder by the operator;

positioning a fourth inventory holder at a second staging location based at least in part on a fourth task of the sequence of the plurality of inventory tasks, the fourth task including a pick of one or more items from the fourth inventory holder by the operator;

determining that the first task has been performed by the operator;

determining that a first subsequent task in the sequence of the plurality of inventory tasks includes a picking of an item from the first inventory holder;

repositioning, using at least one mobile drive unit, the first inventory holder from the first primary location to a third staging location;

repositioning, using at least one mobile drive unit, the third inventory holder from the first staging location to the first primary location to enable picking of the item associated with the third task;

determining that the second task has been performed by the operator;

determining that a second subsequent task in the sequence of the plurality of inventory tasks includes a picking of an item from the second inventory holder;

repositioning, using at least one mobile drive unit, the second inventory holder from the second primary location to a fourth staging location; and

repositioning, using at least one mobile drive unit, the fourth inventory holder from the second staging location to the second primary location to enable picking of the item associated with the fourth task.

22. The method as recited in claim 21, wherein the order set for a plurality of items includes a plurality of orders, where each order includes one or more items to be picked for fulfillment of the order.

23. The method as recited in claim 21, further comprising:

determining that the third task has been performed by the operator;

repositioning, using at least one mobile drive unit, the third inventory holder from the first primary location to the first staging location or another unoccupied staging location; and

repositioning, using at least one mobile drive unit, the first inventory holder from the third staging location to the first primary location to enable picking of the item associated with the first subsequent task.

24. The method as recited in claim 23, further comprising:

determining that the first inventory holder no longer contain items of interest following the first subsequent task; and

subsequently transferring away from the station the first inventory holder.

25. The method as recited in claim 24, wherein the transferring is performed by one or more additional mobile drive units separate from the at least one mobile drive unit used to reposition the first inventory holder at the station.

26. The method as recited in claim 24, further comprising:

transferring in to at least one of a primary location or a staging location of the station, one or more new inventory holders.

27. The method as recited in claim 23, further comprising:

determining that the fourth task has been performed by the operator;

repositioning, using at least one mobile drive unit, the fourth inventory holder from the second primary location to the second staging location or another unoccupied staging location; and

repositioning, using at least one mobile drive unit, the second inventory holder from the fourth staging location to the second primary location to enable picking of the item associated with the second subsequent task.