Secondary robotic catch apparatus and method

• US 9,604,358 B1
• Filed: 12/10/2015
• Issued: 03/28/2017
• Est. Priority Date: 12/10/2015
• 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): Randazzo, Thomas
• Application Number:
  US14/965,093
• Time in Patent Office: 474 Days
• US Class Current: 1/1
• CPC Class Codes: B25J 9/0084 comprising a plurality of manipulators
• CPC Class Codes: B25J 9/0096 co-operating with a working support, e.g. work-table
• CPC Class Codes: B25J 9/162 Mobile manipulator, movable base with manipulator arm mounted on it
• CPC Class Codes: B25J 9/1682 Dual arm manipulator; Coordination of several manipulators
• CPC Class Codes: B65G 1/1375 the orders being assembled on a commissioning stacker-crane or truck
• CPC Class Codes: B65G 59/00 De-stacking of articles B65G60/00 takes precedence
• CPC Class Codes: B65G 65/02 Loading or unloading machines comprising essentially a conveyor for moving the loads associated with a device for picking-up the loads

Abstract

Inventory management systems and related methods employ a catching member to selectively catch items dropped by a robotic manipulator. A related method includes controlling a robotic manipulator to move an inventory item from a first location to a second location. A catching member is selectively positioned to catch the inventory item if dropped by the robotic manipulator prior to the item reaching the second location. The catching member is moved to a suitable location for subsequent processing of one or more items dropped by the first robotic manipulator into the catching member.

Claims

1. An inventory management system, comprising:

a first robotic manipulator configured to grasp an item of a plurality of items, move the item from a first location to a second location and release the item at the second location;

the plurality of items including at least some items that differ from one another;

a catching member that is moved in coordination with the movement of the item by the first robotic manipulator to position the catching member to catch the item if dropped by the first robotic manipulator prior to the item reaching the second location;

one of

a second robotic manipulator configured to move the catching member in coordination with the movement of the item by the first robotic manipulator; and

a mobile drive unit configured to dock with the catching member and operable to move the catching member in coordination with the movement of the item by the first robotic manipulator and move the catching member independent of the first robotic manipulator to move the catching member to another location for exception processing of dropped items in the catching member so that another mobile drive unit can move another catching member into position to catch an item dropped by the first robotic manipulator; and

a management module configured to;

generate instructions to cause the first robotic manipulator to grasp the item at the first location and move the item to the second location; and

generate instructions to cause the second robotic manipulator or the mobile drive unit to move the catching member in coordination with the movement of the item by the first robotic manipulator to position the catching member to catch the item if dropped by the first robotic manipulator prior to the item reaching the second location.

2. The inventory management system of claim 1, comprising the second robotic manipulator.

3. The inventory management system of claim 1, comprising the mobile drive unit.

4. The inventory management system of claim 1, wherein the management module is configured to:

determine whether the item being moved from the first location towards the second location has been dropped by the first robotic manipulator based on input received by the management module indicative that the item has been dropped; and

in response to a determination that the item being moved from the first location towards the second location has been dropped by the first robotic manipulator, generate instructions to cause the dropped item to be moved from the catching member.

5. The inventory management system of claim 4, further comprising at least one of:

a weight sensor coupled with the catching member and configured to generate a weight sensor signal indicative of an item being caught by the catching member, wherein the input received by the management module indicative of whether the item has been dropped is based on the weight sensor signal;

a light source and a light sensor, the light source generating a light beam incident on the light sensor, the light sensor generating a light sensor signal indicative of whether an item has been dropped by the first robotic manipulator and at least temporarily blocks at least a portion of the light beam from being incident upon the light sensor, wherein the input received by the management module indicative of whether the item has been dropped is based on the light sensor signal;

a vision sensor generating a vision sensor signal indicative of whether the item being moved from the first location to the second location by the first robotic manipulator has reached or not reached the second location, wherein the input received by the management module indicative of whether the item has been dropped is based on the vision sensor signal;

or

a grasp sensor coupled with the first robotic manipulator and generating a signal indicative of whether the item is or is not being grasped by the first robotic manipulator, wherein the input received by the management module indicative of whether the item has been dropped is based on the vision sensor signal.

6. An inventory management system, comprising:

a first robotic manipulator configured to move an item from a first location to a second location;

a catching member configured to catch the item if dropped by the first robotic manipulator prior to the item reaching the second location, the catching member being configured to be moved to carry the dropped item to a suitable location for subsequent processing; and

a management module configured to;

generate instructions to cause the first robotic manipulator to grasp the item at the first location and move the item to the second location;

determine whether the item being moved from the first location towards the second location has been dropped by the first robotic manipulator based on input received by the management module indicative that the item has been dropped;

in response to determining that the item being moved by the first robotic manipulator has been dropped, generate instructions relating to subsequent processing of the dropped item; and

generate instructions to cause any items held by the catching member to be moved to a suitable location for subsequent processing.

7. The inventory management system of claim 6, further comprising at least one of:

a first weight sensor coupled with the first robotic manipulator and configured to generate a first weight sensor signal indicative of an item being dropped by the first robotic manipulator;

a second weight sensor coupled with the catching member and configured to generate a second weight sensor signal indicative of an item being caught by the catching member;

a light source and a light sensor, the light source generating a light beam incident on the light sensor, the light sensor generating a light sensor signal indicative of whether an item has been dropped by the first robotic manipulator;

a vision sensor generating a vision sensor signal indicative of whether the item being moved by the first robotic manipulator has reached or not reached the second location;

or

a grasp sensor generating a signal indicative of whether the item is or is not being grasped by the first robotic manipulator.

8. The inventory management system of claim 6, further comprising a mobile drive unit configured to move the catching member to the suitable location for subsequent processing of any items held by the catching member.

9. The inventory management system of claim 6, further comprising a mobile drive unit configured to move the catching member, and wherein the management module is configured to generate instructions to cause the mobile drive unit to move the catching member in coordination with the movement of the item by the first robotic manipulator to position the catching member to catch the item if dropped by the first robotic manipulator prior to the item reaching the second location.

10. The inventory management system of claim 6, wherein the management module is configured to generate instructions to cause the first robotic manipulator to grasp an item held by the catching member, move the item to the second location, and release the item at the second location.

11. The inventory management system of claim 6, wherein the catching member is included in a conveyance apparatus configured for continuous movement of any items dropped by the first robotic manipulator to the suitable location for subsequent processing.

12. The inventory management system of claim 6, further comprising a second robotic manipulator configured to move the catching member, and wherein the management module is configured to:

determine, based on one or more parameters for an item to be moved by the first robotic manipulator, whether to activate the second robotic manipulator to move the catching member in coordination with the movement of the item by the first robotic manipulator; and

in response to determining to activate the second robotic manipulator, generate instructions to cause the second robotic manipulator to move the catching member in coordination with the movement of the item by the first robotic manipulator.

13. The inventory management system of claim 6, further comprising a second robotic manipulator configured to move the catching member in coordination with the movement of the item by the first robotic manipulator.

14. The inventory management system of claim 13, wherein the second robotic manipulator is configured to cause an item caught by the catching member to move from the catching member to the suitable location for subsequent processing.

15. The inventory management system of claim 13, wherein the second robotic manipulator is physically integrated with the first robotic manipulator.

16. A computer-implemented method comprising:

generating instructions via a management module to control operation of a first robotic manipulator to move an inventory item within an inventory facility from a first location to a second location;

generating instructions via the management module to control operation of a second robotic manipulator to move a catching member in coordination with the movement of the inventory item by the first robotic manipulator to catch the inventory item if dropped by the first robotic manipulator prior to the item reaching the second location; and

generating instructions via the management module to control operation of the second robotic manipulator moving the catching member to a suitable location for subsequent processing of one or more items dropped by the first robotic manipulator into the catching member.

17. The computer-implemented method of claim 16, further comprising:

generating instructions via the management module to control operation of a third robotic manipulator to move a second inventory item within the inventory facility from a third location to a fourth location; and

generating instructions via the management module to control operation of the second robotic manipulator to move the catching member in coordination with the movement of the second inventory item by the third robotic manipulator.

18. The computer-implemented method of claim 17, further comprising:

selecting, by the management module, based on one or more parameters of the inventory item and the second inventory item to be moved, one of the first robotic manipulator or the third robotic manipulator; and

generating instructions via the management module to control operation of the second robotic manipulator to move the catching member in coordination with the movement of the inventory item or the second inventory item by the respective selected one of the first robotic manipulator or the third robotic manipulator.