Autonomous mobile bin storage and retrieval system

• US 9,519,882 B2
• Filed: 07/24/2015
• Issued: 12/13/2016
• Est. Priority Date: 07/25/2013
• Status: Active Grant

• Current Assignee: Iam Robotics, Llc
• Original Assignee: Iam Robotics, Llc
• Inventors: Galluzzo, Thomas, Altman, Vladimir, Houghton, Ricky
• Primary Examiner(s): LOGAN, KYLE O
• Application Number:
  US14/808,235
• Publication Number:
  US 20150332213A1
• Time in Patent Office: 508 Days
• Field of Search: 700/218
• US Class Current: 1/1
• CPC Class Codes: B25J 11/00 Manipulators not otherwise provided for
• CPC Class Codes: B25J 15/0028 with movable, e.g. pivoting gripping jaw surfaces
• CPC Class Codes: B25J 15/0085 with means for applying an electrostatic force on the object to be gripped
• CPC Class Codes: B25J 15/06 with vacuum or magnetic holding means
• CPC Class Codes: B25J 15/0608 with magnetic holding means
• CPC Class Codes: B25J 15/0616 with vacuum
• CPC Class Codes: B25J 19/021 Optical sensing devices
• CPC Class Codes: B25J 5/007 mounted on wheels
• CPC Class Codes: B25J 9/0093 co-operating with conveyor means
• CPC Class Codes: B25J 9/162 Mobile manipulator, movable base with manipulator arm mounted on it
• CPC Class Codes: B25J 9/1692 Calibration of manipulator
• CPC Class Codes: B60P 1/5423 attached to the loading platform or similar
• CPC Class Codes: B65G 1/1373 for fulfilling orders in warehouses
• CPC Class Codes: B65G 1/1375 the orders being assembled on a commissioning stacker-crane or truck
• CPC Class Codes: B65G 2209/04 Indication location means
• CPC Class Codes: G05B 2219/37008 Calibration of measuring system, probe, sensor
• CPC Class Codes: G05B 2219/39441 Voice command, camera detects object, grasp, move
• CPC Class Codes: G05B 2219/40298 Manipulator on vehicle, wheels, mobile
• CPC Class Codes: G05B 2219/40543 Identification and location, position of components, objects
• CPC Class Codes: G05B 2219/40564 Recognize shape, contour of object, extract position and orientation
• CPC Class Codes: G05B 2219/45063 : Pick and place manipulator
• CPC Class Codes: G05D 1/0011 : associated with a remote control arrangement
• 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 1/0248 : in combination with a laser lasers per se H01S
• CPC Class Codes: G06Q 10/087 : Inventory or stock management, e.g. order filling, procurement or balancing against orders
• CPC Class Codes: Y10S 901/01 : Mobile robot
• CPC Class Codes: Y10S 901/02 : Arm motion controller
• CPC Class Codes: Y10S 901/31 : Gripping jaw
• CPC Class Codes: Y10S 901/40 : Vacuum or mangetic
• CPC Class Codes: Y10S 901/47 : Optical

Abstract

A method and system for piece-picking or piece put-away within a logistics facility. The system includes a central server and at least one mobile manipulation robot. The central server is configured to communicate with the robots to send and receive piece-picking data which includes a unique identification for each piece to be picked, a location within the logistics facility of the pieces to be picked, and a route for the robot to take within the logistics facility. The robots can then autonomously navigate and position themselves within the logistics facility by recognition of landmarks by at least one of a plurality of sensors. The sensors also provide signals related to detection, identification, and location of a piece to be picked or put-away, and processors on the robots analyze the sensor information to generate movements of a unique articulated arm and end effector on the robot to pick or put-away the piece.

Claims

1. A system for tote-picking or tote put-away within a logistics facility comprising:

a central server comprising;

a server communication interface,

one or more server processors, and

a server memory; and

at least one mobile manipulation robot comprising;

a mobile base,

a tote transport platform having a distal end portion and a proximal end, the proximal end of the tote transport platform connected to the mobile base and moveable along a vertical track on the mobile base,

an articulated manipulator arm attached to the distal end portion of the tote transport platform, the articulated manipulator arm having an end effector,

a plurality of sensors,

a remote communication interface,

a memory configured to store robot specific information, and

one or more robot processors coupled to the sensors, the memory, the mobile base, and the articulated manipulation arm,

wherein the memory comprises computer program instructions executable by the one or more robot processors to receive data from and send data to the central server, process data received from each of the sensors, and output control signals to the mobile base and the articulated manipulator arm,

wherein the plurality of sensors provide signals related to detection, identification, and location of a tote to be transferred to the tote transport platform, and the one or more robot processors analyze the sensor information to generate articulated arm control signals to guide the end effector of the articulated manipulator arm to transfer the tote.

2. The system of claim 1, wherein the server memory comprises computer program instructions executable by the one or more server processors to receive data from a warehouse management system and dispatch the at least one mobile manipulation robot.

3. The system of claim 1, wherein the server communication interface connects with the remote communication interface to send and receive tote-picking data which includes a unique identification for each tote to be picked, a location within the logistics facility of the tote to be picked, and a route for the at least one mobile manipulation robot to take within the logistics facility.

4. The system of claim 1, wherein the at least one mobile manipulation robot can autonomously navigate and position itself within the logistics facility by recognition of at least one landmark by at least one of the plurality of sensors.

5. The system of claim 4, wherein the at least one landmark comprises a vertically mounted marker placed at a specific location within the logistics facility.

6. The system of claim 1, wherein the plurality of sensors comprise 3D depth cameras, color cameras, grey scale cameras, laser ranging devices, sonar devices, radar devices, or combinations thereof.

7. The system of claim 1, wherein at least one of the plurality of sensors is positioned at a central point on the articulated manipulator arm facing a first direction, wherein rotation of the articulated manipulator arm directs the at least one of the plurality of sensors to view the tote transport platform.

8. The system of claim 7, wherein at least one of the plurality of sensors is positioned at the central point on the articulated manipulator arm facing a second direction, wherein the second direction is opposite the first direction.

9. The system of claim 7, wherein the tote transport platform comprises a calibration target which allows calibration of the at least one of the plurality of sensors located at the central point on the articulated manipulator arm.

10. The system of claim 1, wherein the end effector comprises a gripper, a suction cup, an electroadhesion end effector, a magnetic end effector, or combinations thereof.

11. The system of claim 1, wherein the end effector comprises a suction cup which is connected to a vacuum pump through a valve, wherein actuation of the valve is controlled by the one or more robot processors.

12. The system of claim 1, further comprising:

a conveyance device configured to accept the tote from the at least one mobile manipulation robot.

13. The system of claim 12, wherein the conveyance device is a conveyor belt which transfers the tote from a transfer area to a packing area.

14. The system of claim 1, wherein the at least one mobile manipulation robot further comprises:

a user interface comprising a graphical display monitor and an input device.

15. The system of claim 1, wherein more than one tote is placed on the tote transport platform by the articulated manipulator arm.

16. The system of claim 1, wherein the logistics facility is a warehouse, distribution center, manufacturing facility, or retail facility.

17. The system of claim 14, wherein the at least one mobile manipulation robot further comprises:

user information displayed on the graphical display monitor, wherein the user information includes one or more direction indicators which indicate an intended direction of movement of the at least one mobile manipulation robot, error information, or a combination thereof.

18. A method of tote transfer within a logistics facility, the method comprising:

(a) providing a tote-picking or tote put-away system comprising;

a central server including a server communication interface, one or more server processors, and a server memory; and

at least one mobile manipulation robot including a mobile base, an articulated manipulator arm having an end effector, a tote transport platform attached to the mobile base and moveable along a vertical track on the mobile base, a plurality of sensors, a remote communication interface, a robot memory configured to store robot specific information, and one or more robot processors coupled to the sensors, the memory, the mobile base, and the at least one articulated manipulation arm;

(b) receiving at the server memory via the server communication interface at least one tote-picking order including at least one tote to be picked;

(c) generating at the one or more server processors a tote-picking itinerary based on the at least one tote-picking order, wherein the itinerary includes a unique identification for the at least one tote to be picked, a location within the logistics facility of the at least one tote to be picked, and a route for the at least one mobile manipulation robot to take within the logistics facility;

(d) receiving at the robot memory the tote-picking itinerary;

(e) moving the at least one mobile manipulation robot along the route to the location within the logistics facility of the at least one tote to be picked; and

(f) picking the at least one tote to be picked from the location using the end effector of the mobile manipulation arm, wherein picking the at least one tote includes transferring the at least one tote onto the tote transport platform.

19. The method of claim 18, wherein the plurality of sensors provide signals related to detection, identification, and location of the at least one tote to be picked, and the one or more robot processors analyze the sensor information to generate articulated arm control signals to guide the end effector of the articulated manipulator arm to pick the tote.

20. The method of claim 18, wherein moving the at least one mobile manipulation robot occurs autonomously by recognition of at least one landmark by at least one of the plurality of sensors.

21. The method of claim 18, wherein the at least one tote-picking order received at the server memory is generated by a warehouse management system.

22. The method of claim 18, wherein more than one tote is transferred onto the tote transport platform, wherein the totes are stacked vertically on the tote transport platform.