Flexible processing module for use in order fulfillment centers
First Claim
1. An order-processing module, comprising:
- a receiving station configured to receive one or more inventory items that are to be processed for shipment;
a pre-packaging station configured to receive the one or more inventory items from the receiving station and to perform pre-packaging operations to produce a pre-packaged unit, wherein the pre-packaging operations include disposing the one or more inventory items onto a pre-packaging substrate, and wherein the pre-packaged unit includes the one or more inventory items and the pre-packaging substrate;
an inspection station configured to receive the pre-packaged unit from the pre-packaging station and to perform automated inspection operations that include verification that one or more dimensions of the pre-packaged unit conform to specifications required for successful automated construction of outer packaging around the pre-packaged unit;
a packaging station configured to receive the pre-packaged unit from the inspection station and to perform packaging operations to produce a particular packaged unit, wherein the packaging operations include automated construction of carton-based outer packaging around the pre-packaged unit while the pre-packaged unit is within the carton-based outer packaging, and wherein the particular packaged unit includes the one or more inventory items, the pre-packaging substrate, and the outer packaging;
wherein the order-processing module is configured to;
produce various packaged units conforming to a particular size, wherein the various packaged units comprise the particular packaged unit and at least one other packaged unit that includes a different item from the one or more inventory items of the particular packaged unit; and
facilitate conveyance of the various packaged units to a shipping module.
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Abstract
Methods and apparatus for material handling in an order fulfillment center. Embodiments may include one or more flexible, modular processing modules that may be configured to receive one or more inventory items that are to be processed for shipment. The received inventory items may correspond to single-item customer orders, or to multi-item customer orders. A pre-packaging station of the processing module may be configured to receive the one or more inventory items and to perform pre-packaging operations to produce a pre-packaged unit. The pre-packaged unit may include the one or more inventory items and a pre-packaging substrate. The processing module may also include an inspection station configured to automatically verifying one or more dimensions of the pre-packaged unit. The processing module may further include a packaging station configured to perform packaging operations to produce a packaged unit.
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Citations
19 Claims
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1. An order-processing module, comprising:
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a receiving station configured to receive one or more inventory items that are to be processed for shipment; a pre-packaging station configured to receive the one or more inventory items from the receiving station and to perform pre-packaging operations to produce a pre-packaged unit, wherein the pre-packaging operations include disposing the one or more inventory items onto a pre-packaging substrate, and wherein the pre-packaged unit includes the one or more inventory items and the pre-packaging substrate; an inspection station configured to receive the pre-packaged unit from the pre-packaging station and to perform automated inspection operations that include verification that one or more dimensions of the pre-packaged unit conform to specifications required for successful automated construction of outer packaging around the pre-packaged unit; a packaging station configured to receive the pre-packaged unit from the inspection station and to perform packaging operations to produce a particular packaged unit, wherein the packaging operations include automated construction of carton-based outer packaging around the pre-packaged unit while the pre-packaged unit is within the carton-based outer packaging, and wherein the particular packaged unit includes the one or more inventory items, the pre-packaging substrate, and the outer packaging; wherein the order-processing module is configured to; produce various packaged units conforming to a particular size, wherein the various packaged units comprise the particular packaged unit and at least one other packaged unit that includes a different item from the one or more inventory items of the particular packaged unit; and facilitate conveyance of the various packaged units to a shipping module. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9)
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10. An order-processing module, comprising:
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a receiving station configured to receive one or more inventory items; a pre-packaging station configured to receive the one or more inventory items from the receiving station and to perform pre-packaging operations on the one or more inventory items to produce a pre-packaged unit; an inspection station configured to receive the pre-packaged unit from the pre-packaging station and to perform automated inspection operations that include verification that one or more dimensions of the pre-packaged unit conform to specifications required for successful automated construction of outer packaging around the pre-packaged unit; and a packaging station configured to receive the pre-packaged unit from the inspection station and to perform packaging operations to produce a particular packaged unit, wherein the packaging operations include automated construction of carton-based outer packaging around the pre-packaged unit while the pre-packaged unit is within the carton-based outer packaging; wherein the order-processing module is configured to produce a plurality of types of packaged units conforming to a particular size, wherein the plurality of types comprises a type corresponding to the particular packaged unit, and a type corresponding to at least one other packaged unit that includes a different item from the one or more inventory items of the particular packaged unit. - View Dependent Claims (11, 12, 13, 14, 15, 16)
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17. A method, comprising:
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receiving one or more inventory items at a receiving station of an order-processing module in an order fulfillment center; performing pre-processing operations at a pre-packaging station of the order-processing module, wherein the pre-processing operations produce a pre-packaged unit that includes a pre-packaging substrate and the one or more inventory items, and wherein the pre-packaged unit corresponds to a particular order; performing automated inspection operations at an inspection station of the order fulfillment center prior to performing packaging operations, wherein the inspection operations include verifying that dimensions of the pre-packaged unit conform to requirements associated with packaging operations performed at a packaging station; and performing the packaging operations, at the packaging station of the order-processing module, to produce a particular packaged unit, wherein the packaging operations include automatically constructing carton-based outer packaging around the pre-packaged unit while the pre-packaged unit is within the carton-based outer packaging, and wherein the particular packaged unit includes the one or more inventory items, the pre-packaging substrate, and the outer packaging; wherein the order-processing module is configured to; produce various packaged units conforming to a particular size, wherein the various packaged units comprise the particular packaged unit and at least one other packaged unit that includes a different item from the one or more inventory items of the particular packaged unit; and
facilitate conveyance of the various packaged units to a shipping module in the order fulfillment center. - View Dependent Claims (18, 19)
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Specification