Hybrid modular storage fetching system

• US 10,589,931 B2
• Filed: 01/05/2018
• Issued: 03/17/2020
• Est. Priority Date: 09/30/2016
• Status: Active Grant

• Current Assignee: Staples, Inc.
• Original Assignee: Staples, Inc.
• Inventors: Jarvis, Daniel, Amador, Paolo Gerli, Bhaskaran, Michael, Kalra, Amit, Gallaway, Rodney, Gopalakrishnan, Vikranth
• Primary Examiner(s): Jha, Abdhesh K
• Application Number:
  US15/863,050
• Publication Number:
  US 20180127211A1
• Time in Patent Office: 802 Days
• Field of Search: None
• CPC Class Codes: B65G 1/137 with arrangements or automatic control means for selecting which articles are to be removed
• CPC Class Codes: B65G 1/1373 for fulfilling orders in warehouses
• CPC Class Codes: B65G 1/1378 the orders being assembled on fixed commissioning areas remote from the storage areas
• CPC Class Codes: G01C 21/206 specially adapted for indoor navigation
• CPC Class Codes: G05D 1/0088 characterized by the autonomous decision making process, e.g. artificial intelligence, predefined behaviours using knowledge based models G06N5/00
• CPC Class Codes: G05D 1/0225 involving docking at a fixed facility, e.g. base station or loading bay parking aids B62D15/027
• CPC Class Codes: G05D 1/0274 using mapping information stored in a memory device navigation using map-matching G01C21/30
• CPC Class Codes: G05D 1/0285 using signals transmitted via a public communication network, e.g. GSM network
• CPC Class Codes: G05D 1/0297 by controlling means in a control room
• CPC Class Codes: G06Q 10/087 Inventory or stock management, e.g. order filling, procurement or balancing against orders

Abstract

A hybrid modular storage fetching system with a robot execution system (REX) is described. In an example implementation, a REX may induct, into the hybrid modular storage fetching system, an order identifying items to be fulfilled by automated guided vehicles (AGVs) at an order fulfillment facility. The REX may generate at task list including tasks for a first and second AGV, instruct the first AGV to retrieve a first item in the order from a first storage area based on the task list and deliver the first item to a pick-cell station. The REX may also instruct the second AGV to retrieve a second item of the order from a second storage area and deliver the second item to the pick-cell station. The REX may communicate with other components of the hybrid modular storage fetching system to coordinate the paths of the AGVs to fulfill the order.

Claims

1. A method comprising:

inducting an order into a robot execution system (“

REX”

) in response to receiving, by the REX, order data identifying items in the order to be fulfilled at an order fulfillment facility, the REX including one or more computing devices that communicate with a plurality of automated guided vehicles (“

AGV”

s) in the order fulfillment facility, the order fulfillment facility including an operating environment with a first storage area storing a first set of items, a second storage area storing a second set of items, and a pick-cell station at which one or more selected items from one or more of the first storage area and the second storage area are placed into a carton associated with the order;

generating, by the REX, a task list including tasks for fulfilling the order using a cart AGV of the plurality of AGVs and a picking AGV of the plurality of AGVs, the cart AGV transporting the carton associated with the order;

instructing, by the REX, the cart AGV to retrieve a first item of the order from the first storage area based on the task list, the first item being in the first set of items and being placed into the carton associated with the order that is transported by the cart AGV;

instructing, by the REX, the cart AGV to deliver the carton including the first item to the pick-cell station;

instructing, by the REX, the picking AGV to retrieve a second item of the order from the second storage area, the second item being in the second set of items; and

instructing, by the REX, the picking AGV to deliver the second item to the pick-cell station, the second item being placed into the carton associated with the order at the pick-cell station.

2. The method of claim 1, wherein inducting the order into the REX includes:

receiving, by the REX, a message from a warehouse management system (“

WMS”

), the message including the order data and labels assigned to a connectable cart, the labels representing one or more orders including the order; and

storing, by the REX, the labels in association with the connectable cart in a database.

3. The method of claim 2, wherein inducting the order into the REX includes:

instructing, by the REX, the cart AGV to couple to the connectable cart; and

outputting, by the REX, a dashboard embodied by a graphical interface presented on the one or more computing devices to indicate that the connectable cart is coupled with the cart AGV and the labels have been assigned to the connectable cart.

4. The method of claim 3, wherein inducting the order into the REX includes:

receiving, by the REX, a input from a cart picker into the dashboard, the input indicating to release the cart AGV from an induction area of the operating environment; and

instructing, by the REX, the cart AGV to navigate to a location of the first item in the first storage area in response to receiving the input by the cart picker and based on the task list.

5. The method of claim 1, further comprising:

receiving, by the REX, a confirmation message indicating that the first item has been picked from the first storage area to the cart AGV; and

updating, by the REX, the task list to indicate that the first item has been picked from the first storage area to the cart AGV.

6. The method of claim 5, further comprising:

determining, by the REX, whether an additional item is assigned to be picked to the cart AGV based on the task list, the additional item being located in the first storage area;

in response to determining, by the REX, that the additional item is assigned to be picked to the cart AGV, instructing the cart AGV to navigate to a location of the additional item in the first storage area; and

in response to determining, by the REX, that no additional item is assigned to be picked to the cart AGV, instructing the cart AGV to navigate to the pick-cell station.

7. The method of claim 1, further comprising:

selecting, by the REX, the pick-cell station from a plurality of pick-cell stations in the operating environment based on a queue of cart AGVs at the plurality of pick-cell stations.

8. The method of claim 1, further comprising:

determining, by the REX, whether the pick-cell station is available for receiving the cart AGV;

in response to determining, by the REX, that the pick-cell station is not available for receiving the cart AGV,

signaling a pick-cell picker in the pick-cell station to stay in the pick-cell station, and

instructing the cart AGV to wait in a queue for the pick-cell station; and

in response to determining, by the REX, that the pick-cell station is available for receiving the cart AGV,

instructing the cart AGV to navigate to the pick-cell station, and

outputting instructions, via an output device of the one or more computing devices, to the pick-cell picker at the pick-cell station, the instructions indicating to place the second item in the carton along with the first item.

9. The method of claim 8, further comprising:

receiving, by the REX, a confirmation message indicating that the pick-cell picker has placed the second item in the carton along with the first item; and

in response to receiving the confirmation message,

instructing, by the REX, the cart AGV to navigate to a finalizing area of the operating environment, and

detach a connectable cart coupled with the cart AGV at the finalizing area.

10. The method of claim 8, further comprising:

receiving, by the REX, a confirmation message indicating that the pick-cell picker has placed the second item in the carton along with the first item; and

in response to receiving the confirmation message, instructing one of the picking AGV and a second picking AGV to

retrieve a container from the pick-cell station, the second item having been held in the container during delivery to the pick-cell station by the picking AGV,

transport the container to the second storage area, and

place the container on a storage shelf in the second storage area.

11. A system comprising:

a plurality of automated guided vehicles (“

AGV”

s) including a cart AGV and a picking AGV; and

a robot execution system (“

REX”

) that communicates with the plurality of AGVs, the REX including one or more processors and a memory storing instructions that, when executed by the one or more processors, cause the robot execution system to;

induct an order into the REX in response to receiving order data identifying items in the order to be fulfilled at an order fulfillment facility, the REX including one or more computing devices that communicate with the plurality of AGVs in the order fulfillment facility, the order fulfillment facility including an operating environment with a first storage area storing a first set of items, a second storage area storing a second set of items, and a pick-cell station at which one or more selected items from one or more of the first storage area and the second storage area are placed into a carton associated with the order;

generate a task list including tasks for fulfilling the order using the cart AGV and the picking AGV, the cart AGV transporting the carton associated with the order;

instruct the cart AGV to retrieve a first item of the order from the first storage area based on the task list, the first item being in the first set of items and being placed into the carton associated with the order that is transported by the cart AGV;

instruct the cart AGV to deliver the carton including the first item to the pick-cell station;

instruct the picking AGV to retrieve a second item of the order from the second storage area, the second item being in the second set of items; and

instruct the picking AGV to deliver the second item to the pick-cell station, the second item being placed into the carton associated with the order at the pick-cell station.

12. The system of claim 11, wherein the instructions further cause the REX to:

determine whether an additional item is assigned to be picked to the cart AGV based on the task list, the additional item being located in the first storage area;

instruct the cart AGV to navigate to a location of the additional item in the first storage area in response to determining that the additional item is assigned to be picked to the cart AGV; and

instruct the cart AGV to navigate to the pick-cell station in response to determining that no additional item is assigned to be picked to the cart AGV.

13. The system of claim 11, wherein the instructions further cause the REX to:

determine whether the pick-cell station is available for receiving the cart AGV;

in response to determining that the pick-cell station is not available for receiving the cart AGV,

signal a pick-cell picker in the pick-cell station to stay in the pick-cell station, and

instruct the cart AGV to wait in a queue for the pick-cell station; and

in response to determining that the pick-cell station is available for receiving the cart AGV,

instruct the cart AGV to navigate to the pick-cell station, and

output instructions, via an output device of the one or more computing devices, to the pick-cell picker at the pick-cell station, the instructions indicating to place the second item in the carton along with the first item.

14. The system of claim 13, wherein the instructions further cause the REX to:

receive a confirmation message indicating that the pick-cell picker has placed the second item in the carton along with the first item; and

in response to receiving the confirmation message,

instruct the cart AGV to navigate to a finalizing area of the operating environment, and

detach a connectable cart coupled with the cart AGV at the finalizing area.

15. The system of claim 13, wherein the instructions further cause the REX to:

receive a confirmation message indicating that the pick-cell picker has placed the second item in the carton along with the first item; and

in response to receiving the confirmation message, instruct one of the picking AGV and a second picking AGV to

retrieve a container from the pick-cell station, the second item having been held in the container during delivery to the pick-cell station by the picking AGV,

transport the container to the second storage area, and

place the container on a storage shelf in the second storage area.

16. The system of claim 11, wherein the cart AGV includes a drive unit that provides motive force to the cart AGV and a guidance system that locates the cart AGV in the order fulfillment facility, the cart AGV autonomously transporting cartons, the cartons holding one or more items from the first set of items during transport of the one or more items by the cart AGV.

17. The system of claim 11, wherein the picking AGV includes a drive unit that provides motive force to the picking AGV, a guidance system that locates the picking AGV in the order fulfillment facility, and a container retrieval mechanism that retrieves containers from a first shelf in the second storage area, transports the containers to the pick-cell station, and places the containers on a second shelf at the pick-cell station.

18. A method comprising:

receiving an induction instruction from a warehouse management system, the induction instruction indicating a first item to be picked using a cart AGV and a second item to be picked using a picking AGV;

instructing the cart AGV to connect to a connectable cart;

receiving a first confirmation from one or more picker computing devices that the cart AGV is connected to the connectable cart;

selecting a pick-cell station from among a plurality of pick-cell stations;

instructing the cart AGV to propel the connectable cart to a location of the first item;

receiving a second confirmation from the one or more picker computing devices that the first item has been picked to the connectable cart;

instructing the cart AGV to propel the connectable cart to the pick-cell station;

instructing the picking AGV to

navigate to a second location of the second item,

retrieve the second item from a storage shelf at the second location, and

navigate to the pick-cell station;

presenting, for display on the one or more picker computing devices to a pick-cell picker, an instruction to place the first item and the second item in a designated carton on the connectable cart;

receiving a third confirmation from the one or more picker computing devices that the first item and the second item have been placed in the designated carton; and

instructing the cart AGV to propel the connectable cart to a finalizing area and detach from the connectable cart in the finalizing area.