U.S. patent application number 14/034255 was filed with the patent office on 2015-03-26 for inter-facility transport in inventory management and fulfillment systems.
This patent application is currently assigned to Amazon Technologies, Inc.. The applicant listed for this patent is Amazon Technologies, Inc.. Invention is credited to Michael T. Barbehenn, Timothy Aaron Bragg, Jeremiah David Brazeau, John W. Cullen, Oleksandr Glazkov, Michael Cordell Mountz, Matthew David Verminski, Peter R. Wurman.
Application Number | 20150088302 14/034255 |
Document ID | / |
Family ID | 52575152 |
Filed Date | 2015-03-26 |
United States Patent
Application |
20150088302 |
Kind Code |
A1 |
Mountz; Michael Cordell ; et
al. |
March 26, 2015 |
INTER-FACILITY TRANSPORT IN INVENTORY MANAGEMENT AND FULFILLMENT
SYSTEMS
Abstract
In an infrastructure that uses a mobile order fulfillment
system, robotic drive units may be dispatched and instructed to
bring inventory holders to a workstation where at least one of the
inventory holders is packed and prepared for shipment. The robotic
drive units are then instructed to move the prepared inventory
holder to a transport vehicle such as a truck. Fiducial marks may
be removably placed within the transport vehicle to aid navigation
of the robotic drive units. At a destination facility, additional
robotic drive units may be instructed to move the inventory holders
from the truck and place the inventory holders at appropriate
storage locations.
Inventors: |
Mountz; Michael Cordell;
(Lexington, MA) ; Glazkov; Oleksandr; (Boston,
MA) ; Bragg; Timothy Aaron; (Woburn, MA) ;
Verminski; Matthew David; (North Andover, MA) ;
Brazeau; Jeremiah David; (Hudson, NH) ; Wurman; Peter
R.; (Acton, MA) ; Cullen; John W.; (Boston,
MA) ; Barbehenn; Michael T.; (North Reading,
MA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Amazon Technologies, Inc. |
Reno |
NV |
US |
|
|
Assignee: |
Amazon Technologies, Inc.
Reno
NV
|
Family ID: |
52575152 |
Appl. No.: |
14/034255 |
Filed: |
September 23, 2013 |
Current U.S.
Class: |
700/216 |
Current CPC
Class: |
G06Q 10/087 20130101;
G06Q 10/08 20130101; B65G 1/1373 20130101 |
Class at
Publication: |
700/216 |
International
Class: |
G06Q 10/08 20060101
G06Q010/08 |
Claims
1. An order fulfillment system, comprising: a plurality of portable
inventory holders configured to store inventory items in first and
second inventory facilities; first unmanned drive units configured
to move the portable inventory holders within the first inventory
facility; second unmanned drive units configured to move the
portable inventory holders within the second inventory facility;
control logic configured to direct the first unmanned drive units
to perform first actions comprising: moving a receiving one of the
portable inventory holders to a workstation of the first inventory
facility; moving one or more stocked ones of the portable inventory
holders to the workstation for transfer of specified inventory
items from the one or more stocked ones of the portable inventory
holders to the receiving one of the portable inventory holders; and
placing the receiving one of the portable inventory holders on an
inter-facility freight transporter for transport to the second
inventory facility by entering the inter-facility freight
transporter with one of the first unmanned drive units; and the
control logic being further configured to direct the second
unmanned drive units to perform one or more second actions, the one
or more second actions comprising: removing the receiving one of
the portable inventory holders from the inter-facility freight
transporter by entering the inter-facility transporter with one of
the second unmanned drive units.
2. The order fulfillment system of claim 1, wherein: the control
logic comprises first control logic configured to monitor inventory
of the first inventory facility and second control logic configured
to monitor inventory of the second inventory facility; the first
control logic is configured to provide inventory data indicating
inventory items held by the receiving one of the portable inventory
holders; and the second control logic is configured to receive the
inventory data for use in fulfilling orders at the second inventory
facility from the receiving one of the portable inventory
holders.
3. The order fulfillment system of claim 1, further comprising one
or more fiducial surfaces configured for placement within the
inter-facility freight transporter, the one or more fiducial
surfaces having fiducial marks for navigation by the first and
second unmanned drive units within the inter-facility freight
transporter.
4. The order fulfillment system of claim 1, wherein: the unmanned
drive units are configured to navigate based at least in part on
fiducial marks on floors of the first and second inventory
facilities; and fiducial marks are located on a floor of the
inter-facility freight transporter for navigation by the unmanned
drive units within the inter-facility freight transporter.
5. The order fulfillment system of claim 1, wherein the
inter-facility freight transporter comprises one or more of the
following: a road vehicle; a ship; an aircraft; a rail car; a
shipping container; or a cargo compartment.
6. The order fulfillment system of claim 1, wherein the receiving
one of the portable inventory holders comprises: a base portion
that docks with the first and second unmanned drive units; and a
storage portion that is detachable from the base portion for
placement on the inter-facility freight transporter.
7. The order fulfillment system of claim 1, wherein the receiving
one of the portable inventory holders comprises: a base portion
that docks with the first and second unmanned drive units; a
storage portion that is detachable from the base portion; and
wherein the storage portion is configured to be moved by a manned
lift for placement on the inter-facility freight transporter apart
from the base portion.
8. (canceled)
9. The method of claim 13, further comprising placing the receiving
one of the inventory holders on the freight transporter with one or
more of the unmanned drive units.
10. The method of claim 13, wherein the freight transporter
comprises one or more of: a road vehicle; a ship; an aircraft; a
rail car; a shipping container; or a cargo compartment.
11. The method of claim 13, wherein the receiving one of the
portable inventory holders comprises: a base portion that docks
with the unmanned drive units; and a storage portion that is
detachable from the base portion for placement in the freight
transporter.
12. The method of claim 13, wherein the receiving one of the
portable inventory holders comprises: a base portion that docks
with the unmanned drive units; and a storage portion that is
detachable from the base portion; wherein the storage portion is
configured to be moved by a manned lift for placement on the
freight transporter.
13. A method, comprising: controlling unmanned drive units to move
a plurality of portable inventory holders within a first inventory
area, wherein the unmanned drive units are configured to navigate
within the first inventory area based at least in part on fiducial
marks placed within the first inventory area; moving a receiving
one of the portable inventory holders to a workstation of the first
inventory area with at least one of the unmanned drive units;
moving one or more stocked ones of the portable inventory holders
to the workstation with at least one of the unmanned drive units
for transfer of specified inventory items from the one or more
stocked ones of the portable inventory holders to the receiving one
of the portable inventory holders; moving the receiving one of the
portable inventory holders to a freight transporter with at least
one of the unmanned drive units for transport of the receiving one
of the portable inventory holders to a second inventory area; and
based on fiducial marks placed in the freight transporter for
navigation of the unmanned drive units in the freight transporter,
navigating at least one of the unmanned drive units in the freight
transporter.
14. The method of claim 13, further comprising: placing one or more
removable fiducial surfaces in the freight transporter, wherein the
one or more removable fiducial surfaces have the fiducial marks in
the freight transporter for navigation of the unmanned drive units
in the freight transporter.
15. A method, comprising: controlling unmanned drive units to move
a plurality of portable inventory holders within a first inventory
area; moving a receiving one of the portable inventory holders to a
workstation of the first inventory area with at least one of the
unmanned drive units; moving one or more stocked ones of the
portable inventory holders to the workstation with at least one of
the unmanned drive units for transfer of specified inventory items
from the one or more stocked ones of the portable inventory holders
to the receiving one of the portable inventory holders; moving the
receiving one of the portable inventory holders to a freight
transporter with at least one of the unmanned drive units for
transport of the receiving one of the portable inventory holders to
a second inventory area; and providing inventory data for use at
the second inventory area in fulfilling orders from the receiving
one of the inventory holders, wherein the inventory data indicates
inventory items held by the receiving one of the portable inventory
holders.
16. (canceled)
17. The method of claim 21, further comprising: moving a receiving
one of the portable inventory holders to a workstation of the first
inventory area with at least one of the unmanned drive units;
moving one or more stocked ones of the portable inventory holders
to the workstation with at least one of the unmanned drive units
for transfer of specified inventory items from the one or more
stocked ones of the portable inventory holders to the receiving one
of the portable inventory holders; and moving the receiving one of
the portable inventory holders to the freight transporter with at
least one of the unmanned drive units for transport of the
receiving one of the portable inventory holders to the second
inventory area.
18. The method of claim 21, further comprising transporting the one
or more unmanned drive units and the one or more portable inventory
holders between the first and second inventory areas by the freight
transporter.
19. The method of claim 21, wherein the freight transporter
comprises one or more of: a road vehicle; a ship; an aircraft; a
rail car; a shipping container; or a cargo compartment.
20. The method of claim 21, wherein the portable inventory holder
comprises: a base portion that docks with the unmanned drive units;
and a storage portion that is detachable from the base portion for
placement in the freight transporter; and wherein the storage
portion is configured to be moved by a manned lift.
21. A method, comprising: controlling a plurality of unmanned drive
units to move a plurality of portable inventory holders within a
first inventory area, wherein the unmanned drive units are
configured to navigate within the first inventory area based at
least in part on fiducial marks placed within the first inventory
area; moving one or more of the portable inventory holders on to or
off of a freight transporter with one or more of the unmanned drive
units for transport of the one or more portable inventory holders
between the first inventory area and a second inventory area; and
based on fiducial marks placed within the freight transporter for
navigation of the unmanned drive units within the freight
transporter, navigating one or more of the unmanned drive units in
the freight transporter.
22. The method of claim 21, further comprising transferring
inventory data between control logic of the first and second
inventory areas, wherein the inventory data indicates inventory
items held by the one or more of the portable inventory
holders.
23. The method of claim 15, further comprising placing the
receiving one of the inventory holders on the freight transporter
with one or more of the unmanned drive units.
24. The method of claim 15, wherein the receiving one of the
portable inventory holders comprises: a base portion that docks
with the unmanned drive units; and a storage portion that is
detachable from the base portion for placement in the freight
transporter.
Description
BACKGROUND
[0001] Modern inventory systems, such as those used in mail order
warehouses, supply chain distribution centers, airport luggage
systems, and custom-order manufacturing facilities face significant
challenges in responding to requests for inventory items. As
inventory systems grow, the challenges of simultaneously completing
large numbers of packing, storing, and other inventory-related
tasks become non-trivial. In inventory systems tasked with
responding to large numbers of diverse inventory requests,
inefficient utilization of system resources, including space,
equipment, and manpower, can result in lower throughput,
unacceptably long response times, an ever-increasing backlog of
unfinished tasks, and, in general, poor system performance.
[0002] Increasingly, mobile order fulfillment systems are used
within inventory facilities to address these and other concerns. A
mobile order fulfillment system may provide automation for bringing
ordered items to central workstations for workers to select and
pack the ordered items in preparation for shipping. Mobile order
fulfillment systems such as this can greatly increase efficiencies
within an order fulfillment facility.
BRIEF DESCRIPTION OF THE DRAWINGS
[0003] The detailed description is set forth with reference to the
accompanying figures. In the figures, the left-most digit(s) of a
reference number identifies the figure in which the reference
number first appears. The use of the same reference numbers in
different figures indicates similar or identical items.
[0004] FIG. 1 is a figurative perspective diagram of an inventory
storage and order fulfillment system that includes two inventory
facilities.
[0005] FIG. 2 is a block diagram illustrating an example
configuration of an inventory management and order fulfillment
system that may be implemented within each of the inventory
facilities of FIG. 1.
[0006] FIG. 3 is a side view showing an example inventory holder
and robotic drive unit that may be used in the systems of FIGS. 1
and 2.
[0007] FIGS. 4a and 4b are flow diagrams illustrating handling and
transport of inventory holders in conjunction with the systems of
FIGS. 1 and 2.
[0008] FIGS. 5a, 5b, and 5c are figurative views illustrating the
use of fiducial marks for guidance and navigation of robot drive
units in conjunction with the systems of FIGS. 1 and 2.
[0009] FIG. 6 is a flowchart showing an example method of handling
inventory in conjunction with an inventory management and order
fulfillment system.
[0010] FIG. 7 is a block diagram illustrating example components of
a robotic drive unit.
[0011] FIG. 8 is a block diagram illustrating example components of
a management component.
DETAILED DESCRIPTION
[0012] Described herein is an inventory management system that uses
robotic drive units to move inventory items within and between
storage facilities. Inventory items are stored in portable
inventory holders. In order to move items from one facility to
another, robotic drive units bring various inventory holders to a
workstation where desired items are transferred to an inventory
holder that is to be shipped to another facility. One of the
robotic drive units is then instructed to move the newly stocked
inventory holder to a transport vehicle for loading. In some cases,
the robotic drive unit may be instructed to enter the transport
vehicle and to place the stocked inventory holder within the
transport vehicle. Robotic drive units may be used similarly at a
receiving facility to unload portable inventory holders from
transport vehicles and to distribute inventory items to inventory
holders throughout the receiving facility.
[0013] FIG. 1 illustrates the components of an inventory storage
and order fulfillment system or infrastructure 100 that includes a
plurality of inventory facilities 102. For purposes of discussion,
two inventory facilities 102(a) and 102(b) are illustrated,
although the infrastructure 100 may include any number of inventory
facilities or areas.
[0014] The inventory facilities 102 are used to store inventory
items that are ordered by and shipped to customers or other
entities. In the described embodiment, each of the inventory
facilities 102 uses an automated robotic mobile fulfillment system
in which inventory items are stored in portable inventory holders
104 and moved about the facility 102 by unmanned robotic drive
units 106. For example, inventory holders 104 may be moved to a
human worker 108 so that the worker can manually retrieve or "pick"
ordered items from the inventory holders 104 under the direction of
the order fulfillment system.
[0015] As a specific example, a received order may specify a
plurality of inventory items. In response to such an order, the
inventory holders 104 containing the inventory items may be moved
by the robotic drive units 106 to a workstation or other area 110.
At the workstation 110, the worker 108 may be directed by the order
fulfillment system to retrieve certain inventory items that have
been ordered. In certain embodiments, the ordered items or the
locations of the ordered items on the inventory holders 104 may be
listed or visually indicated so that the worker 108 knows which
items to retrieve. As an example, locations on the inventory
holders 104 may be indicated by illumination, such as laser
illumination, to show the worker 108 the locations from which to
retrieve items. As yet another example, the inventory holder 104
may have integral indicators or readouts that are controlled by the
system to inform the worker 108 regarding the locations from which
ordered inventory items are to be retrieved.
[0016] In some implementations, inventory items retrieved in this
manner may be placed on an additional inventory holder 104 that
contains one or more outgoing orders. Once completed, the
additional inventory holder 104 may be moved by a robotic drive
unit 106 to a shipping workstation or other processing point. As
will be described in more detail below, certain inventory holders
104 that have been loaded with specified inventory items may also
be moved to or onto a transport vehicle for shipment to a different
inventory facility.
[0017] As another example, inventory restocking may be performed
when receiving new inventory at an inventory facility 102. The
mobile fulfillment system identifies one or more inventory holders
104 that are to be used for storage of the incoming inventory
items. The robotic drive units 106 bring the identified inventory
holders 104 to the worker 108 at the location of the new inventory
items. The worker 108, under the direction of the mobile
fulfillment system, can then load the new inventory items onto the
inventory holders 104 at locations specified by the order
fulfillment system. After being loaded, robotic drive units 106 may
be used to move the inventory holders 104 to appropriate locations
within the inventory facility 102, from where they may be retrieved
for later use in fulfilling future orders.
[0018] In the illustrated embodiment, similar or identical mobile
fulfillment systems are used in each of the two inventory
facilities 102(a) and 102(b). The two inventory facilities 102(a)
and 102(b) may be separate or geographically distant facilities of
a single entity such as two order fulfillment facilities of an
online retailer. Alternatively, the two facilities may be
facilities of two different businesses, such as a retailer and a
supplier. In either case, inventory items may at times be moved
from the first inventory facility 102(a) to the second inventory
facility 102(b) using an inter-facility or inter-area freight
transporter such as a road vehicle or truck 112. Inventory items
may be loaded onto the freight transporter 112 at the first
inventory facility 102(a) and unloaded at the second inventory
facility 102(b).
[0019] In certain embodiments, the inventory holders 104 may be
used to transfer inventory items from the first inventory facility
102(a) to the second inventory facility 102(b). As an example,
existing, previously stocked inventory holders 104 may be moved
from one inventory facility to another by the freight transporter
112 in order to balance inventories between multiple locations. As
another example, an order may specify certain inventory items to be
transferred from multiple inventory holders 104 of first the
facility 102(a) to the second facility 102(b). An order such as
this may be fulfilled by stocking an inventory holder at the first
facility with the inventory items that are to be transferred, and
then moving the newly stocked inventory holder to the second
facility.
[0020] As illustrated by FIG. 1, the robotic drive units 106 may be
used to move the inventory holders 104 to and from the freight
transporter 112. The inventory holders 104 may be placed on or
within the freight transporter 112 and moved between inventory
facilities 102 with the freight transporter. In some cases, the
robotic drive units 106 may move the inventory holders 104 on to
and off of the freight transporter 112 by entering the freight
transporter 112. In other cases, the robotic drive units 106 may
move the inventory holders 104 to and from a loading dock adjacent
the freight transporter 112, and other equipment may be used to
move the inventory holders into and out of the freight transporter
112.
[0021] FIG. 2 illustrates an example configuration of an inventory
management and/or order fulfillment system 200 that may be
implemented within each of the inventory facilities 102 described
above. In the system 200 of FIG. 2, the robotic drive units 106 are
used to transport the inventory holders 104 between points within a
workspace 202 of an inventory facility. The workspace may include
workstations 110, one or more loading docks 204, and cargo
compartments 206 of one or more transport vehicles such as the
freight transporter 112 of FIG. 1. The workspace 202 may also
include designated locations 208 for placement and storage of the
inventory holders 104.
[0022] The robotic drive units 106 move the inventory holders 104
between locations within the workspace 202 under the general
direction and control of a management component 210, which is also
referred to herein as control logic 210. The management component
210 keeps track of the inventory holders 104 and their locations
within the associated workspace. In addition, the management
component 210 monitors inventory of the inventory facility, keeps
track of the inventory items held by each of the inventory holders
104, and also keeps track of the specific locations of the
inventory items within the inventory holders.
[0023] The management component 220 also assigns tasks 212 to the
robotic drive units 106 and other components of the system and
coordinates operation of the robotic drive units 106 in completing
the tasks 212. The tasks 212 may relate not only to the movement
and processing of inventory holders 104, but also to the management
and maintenance of the components of the system 200. For example,
the management component 210 may assign portions of the workspace
202 as parking spaces for the robotic drive units 106, the
scheduled recharge or replacement of robotic drive unit batteries,
the storage of empty inventory holders 104, or any other operations
associated with the functionality supported by the system 200 and
its various components.
[0024] The management component 220 also supervises or directs
manual operations, such as by indicating which items of an
inventory holder 104 are to be selected or "picked" by a worker,
and where the selected items are to be placed (such as at a
specified location in another inventory holder).
[0025] Although shown in FIG. 2 as a single, discrete component,
the management component 210 may represent multiple components and
may represent or include portions of the robotic drive units 106 or
other elements of the system 200. As a result, any or all of the
interaction between a particular robotic drive unit 106 and the
management module 210 that is described below may in particular
embodiments represent peer-to-peer communication between that
robotic drive unit 106 and one or more other robotic drive units
106. In addition, the control logic 210 may be shared between
facilities, so that multiple facilities are under the control of a
single management module or a set of cooperating management
modules.
[0026] The robotic drive units 106 may comprise any devices or
components appropriate for use in the system 200 based on the
characteristics and configuration of the inventory holders 104
and/or other elements of the system 200. In a particular
embodiment, the robotic drive units 106 are self-powered, wheeled
devices configured to move autonomously about the workspace 202
without direct human supervision. In general, the robotic drive
units 106 may be powered, propelled, and controlled in any manner
appropriate based on the configuration and characteristics of the
system 200.
[0027] The robotic drive units 106 may be capable of communicating
with the management component 210 to receive information
identifying selected inventory holders 104, to transmit the
locations of the robotic drive units 106, and/or to exchange any
other suitable information to be used by the management component
210 or the robotic drive units 106 during operation. The robotic
drive units 106 may communicate with the management component 210
wirelessly or in any other appropriate manner. As one example,
particular embodiments of the robotic drive unit 106 may
communicate with the management component 210 and/or with one
another using 802.11, Bluetooth, or Infrared Data Association
(IrDA) standards, or any other appropriate wireless communication
protocol. Furthermore, as noted above, the management component 210
may include components of individual robotic drive units 106. Thus,
for the purposes of this description and the claims that follow,
communications between the management component 210 and a
particular robotic drive unit 106 may represent communication
between components of a particular robotic drive unit 106.
[0028] The inventory holders 104 store inventory items. Inventory
items may comprise any objects suitable for storage, retrieval,
and/or processing by the system 200. In a particular embodiment,
the inventory holders 104 include multiple storage bins with each
storage bin capable of holding one or more types of inventory
items. The inventory holders 104 are capable of being carried,
rolled, and/or otherwise moved by the robotic drive units 106.
[0029] In an example implementation, the system 200 may be
implemented by a mail or online order warehouse facility, and
inventory items may comprise merchandise stored in the warehouse
facility. During operation, the robotic drive units 106 may
retrieve inventory holders 104 containing one or more inventory
items requested in an order to be packed for delivery to a
customer. Moreover, in particular embodiments of the system 200,
boxes containing completed orders may themselves represent
inventory items.
[0030] As another example, the system 200 may be implemented by a
merchandise-return facility. In such an embodiment, inventory items
may represent merchandise returned by customers. Units of these
inventory items may be stored in the inventory holders 104 when
received at the workspace 202. At appropriate times, a large number
of units may be removed from a particular inventory holder 104 and
packed for shipment back to a warehouse or other facility. For
example, individual units of a particular inventory item may be
received and stored in the inventory holders 104 until a threshold
number of units of that inventory item have been received. The
robotic drive units 106 may then be tasked with retrieving an
inventory holder 104 in this state. The inventory holder 104 may
then be shipped to another facility, such as a mail-order
warehouse.
[0031] As another example, the system 200 may be implemented by an
airport luggage facility. In such an embodiment, inventory items
may represent pieces of luggage stored in the luggage facility. The
robotic drive units 106 may retrieve inventory holders storing
luggage that is arriving and/or departing on particular flights or
luggage that is destined for particular types of processing, such
as x-ray or manual searching. The system 200 may be similarly
implemented within duties or customs facilities for tracking and
transferring freight items.
[0032] As yet another example, the system 200 may be implemented by
a manufacturing facility, and inventory items may represent
individual components of a manufacturing kit. More specifically,
inventory items may represent components intended for inclusion in
an assembled product, such as electronic components for a
customized computer system. In such an embodiment, the system 200
may retrieve particular components identified by a specification
associated with an order for the product so that a customized
version of the product can be built.
[0033] More generally, the system 200 may be implemented by or
within any facility or system for storing and processing inventory
items, and inventory items may represent objects of any type
suitable for storage, retrieval, and/or processing in a particular
system 200.
[0034] The workstations 110 may comprise locations designated for
the completion of particular tasks involving inventory items. Such
tasks may include the removal of inventory items from the inventory
holders 104, the introduction of inventory items into the inventory
holders 104, the counting of inventory items in the inventory
holders 104, the decomposition of inventory items (e.g. from pallet
or case-sized groups to individual inventory items), and/or the
processing or handling of inventory items in any other suitable
manner. In particular embodiments, the workstations 110 may
represent the physical locations where a particular task involving
inventory items can be completed within the workspace 202. In
alternative embodiments, the workstations 110 may represent both
the physical location and also any appropriate equipment for
processing or handling inventory items, such as scanners for
monitoring the flow of inventory items in and out of the system
200, communication interfaces for communicating with the management
component 210, and/or any other suitable components.
[0035] The workstations 110 can be controlled, entirely or in part,
by human workers or may be fully automated. Moreover, the human or
automated operators of the workstations 110 may be capable of
performing certain tasks with respect to inventory items, such as
packing or counting inventory items, as part of the operation of
the system 200. In the case of human operators, the system 200 may
provide detailed instructions or directions regarding activities to
be performed. Instructions may be provided verbally, though a
control panel, or by indications on the inventory holders or
inventory items themselves. Generally, a worker may be instructed
to pick an item from a specified location of an inventory holder
and to then place the item at another specified location, such as
at a specified location within another inventory holder.
[0036] The workspace 202 may include an area associated with the
system 200 in which the robotic drive units 106 can move and/or the
inventory holders 104 can be stored. For example, the workspace 202
may represent all or part of the floor of a mail-order warehouse in
which the system 200 operates. Although FIG. 2 shows an embodiment
of the system 200 in which workspace 202 includes a fixed,
predetermined, and finite physical space, particular embodiments of
the system 200 may include unmanned robotic drive units 106 and
inventory holders 104 that are configured to operate within a
workspace 202 that is of variable dimensions and/or an arbitrary
geometry. Also, while the workspace 202 may be enclosed in a
building, alternative embodiments may utilize workspaces 202 in
which some or all of the workspace 202 is located outdoors, within
a vehicle (such as a cargo ship), or otherwise unconstrained by any
fixed structure. Moreover, in particular embodiments, the workspace
202 may include multiple portions that are physically separated
from one another, including but not limited to separate floors,
rooms, buildings, and/or portions divided in any other suitable
manner.
[0037] When moving the inventory holders 104 to different locations
within the workspace 202, the robotic drive units 106 may dock with
and transport the inventory holders 104. The robotic drive units
106 may dock with the inventory holders 104 by connecting to,
lifting, and/or otherwise interacting with the inventory holders
104 or in any other suitable manner so that, when docked, the
robotic drive units 106 are coupled to and/or support the inventory
holders 104 and can move the inventory holders 104 within the
workspace 202. While the description below focuses on particular
embodiments of the robotic drive unit 106 and inventory holder 104
that are configured to dock in a particular manner, alternative
embodiments of robotic drive unit 106 and inventory holder 104 may
be configured to dock in any manner suitable to allow the robotic
drive unit 106 to move an inventory holder 104 within the workspace
202. Additionally, as noted below, in particular embodiments the
robotic drive units 106 may represent all or portions of the
inventory holders 104. In such embodiments, the robotic drive units
106 may not dock with inventory holders 104 before transporting the
inventory holders 104 and/or the robotic drive units 106 may each
remain continually docked with a particular inventory holder
104.
[0038] FIG. 3 illustrates an example implementation of an inventory
holder 104 and a robotic drive unit 106. The inventory holder 104
includes a base or base portion 302 and a storage portion 304. The
storage portion may comprise one or more bins or shelves 306. The
bins or shelves 306 may be formed integrally with the base 302 and
with each other, or may comprise separate stackable trays that are
detachable from each other and/or from the base portion 302.
[0039] In some embodiments, the storage portion may have connection
points, such as holes, hooks, etc., suitable for use by a manned
lift such as a forklift or other drive lift. For example, the
storage portion may have slots or channels 308 for engagement by a
forklift or other equipment. In embodiments where the base portion
302 and storage portion 304 are integral, lifting the storage
portion 304 by the slots or channels 308 will also lift the base
portion 302. In embodiments where the base portion 302 and the
storage portion 304 are detachable, lifting the storage portion 304
by the slots or channels 308 may separate the storage portion 304
from the base portion 302 so that the storage portion may be moved
independently of the base portion 302.
[0040] A plurality of inventory items 310 are held or stored by the
bins or shelves 306. In some cases, the bins or shelves 306 may
have adjustable dividers to provide separate spaces for different
inventory items on individual bins or shelves 306.
[0041] The inventory holder 104 or the base portion 302 of the
inventory holder 104 may have a plurality of legs 312 that extend
downward from the base 302 to support the inventory holder on a
floor or surface 314 of an inventory facility 102 and/or freight
transporter 112. The legs 312 provide a space above the floor 314
and between each other so that the robotic drive unit 106 can
maneuver itself beneath the base portion 302.
[0042] The robotic drive unit 106 may comprise a motorized lift
having a plurality of wheels 316 and a lift surface 318. One or
more of the wheels 316 may be driven to move the drive unit 106
over the floor or surface 314. One or more of the wheels 316 may be
steerable to guide the drive unit 106 in different directions or
paths.
[0043] The lift surface 318 may be configured to dock with the
inventory holder 104 by raising the lift surface 318 into
engagement with the base 302. In operation, the robotic drive unit
106 may be configured to maneuver itself beneath the inventory
holder 104, to raise the inventory holder 104 off of the surface
314 and to move the inventory holder 104 to any desired location
under the direction or in response to instructions from the
management component 210. After reaching the desired location, the
robotic drive unit 106 undocks from the inventory holder 104 by
lowering the lift surface 318 and thereby placing the inventory
holder 104 back on the floor 314.
[0044] Although FIG. 3 illustrates a particular embodiment of
robotic drive unit 106 containing certain components and configured
to operate in a particular manner, the robotic drive unit 106 may
comprise any appropriate component and/or collection of components
configured to transport and/or facilitate the transport of
inventory holders 104.
[0045] FIGS. 4a and 4b illustrate methods of transporting inventory
items from a first inventory area or facility 102(a) to a second
inventory area or facility 102(b) using an inter-area or
inter-facility freight transporter 112 such as a truck or other
road-based vehicle. The freight transporter may also comprise any
other type of transport mechanism, including road vehicles, ships,
aircraft, rail cars, shipping containers, cargo compartments, and
so forth.
[0046] FIG. 4a illustrates actions performed at the first inventory
facility 102(a). FIG. 4b illustrates actions performed at a second
inventory facility or area 102(b). Actions of the robotic drive
units 106 of the first inventory facility 102(a) are controlled by
the management component 210(a) of the first inventory facility
102(a). Actions of the robotic drive units 106 of the second
inventory facility 102(b) are controlled by the management
component 210(b) of the second inventory facility 102(b). In some
cases, the management components 210 of the first and second
inventory facilities may communicate with each other to coordinate
transfers between the facilities. Furthermore, the functionality of
the management components 210 of the respective facilities may in
some cases, in part or in whole, be implemented by a unified
controller that is responsible for controlling the robotic drive
units of both facilities.
[0047] Referring first to FIG. 4a, the first inventory facility
102(a) has a plurality of portable inventory holders 104(a)
configured to store inventory items. The first inventory facility
102(a) also has a plurality of robotic drive units 106(a) that are
controlled by a management component 210(a) of the first inventory
facility 102(a) to move the inventory holders 104(a) within and
about the first inventory facility 102(a).
[0048] In response to receiving an order or instruction to transfer
inventory items from the first inventory facility 102(a) to the
second inventory facility 102(b), one of the robotic drive units
106(a) is dispatched and instructed to move an empty one of the
inventory holders 104(a), referred to herein as a receiving
inventory holder 402 or transfer inventory holder 402, to a
workstation 110(a) of the first inventory facility 102(a).
[0049] In addition, one or more of the robotic drive units 106(a)
are dispatched and instructed to move one or more stocked inventory
holders, referred by the reference numeral 404 in FIG. 4a, to the
workstation 110(a). A human worker or automated system then moves
specified inventory items from the one or more stocked inventory
holders 404 to the receiving inventory holder 402. The selection
and placement of inventory items may be supervised or directed by
the management component 210 of the facility as described above.
For example, indications may be provided informing the operator of
the location of the stocked inventory holder 404 from which an item
should be picked and the location of the receiving inventory holder
402 into which the picked item should be placed.
[0050] When all specified inventory items have been placed on the
receiving inventory holder 402, one of the robotic drive units
106(a) is dispatched and instructed to move the receiving inventory
holder 402 to the freight transporter 112. In some implementations,
the robotic drive unit 106(a) may enter the freight transporter 112
and place the receiving inventory holder 402 on the freight
transporter 112. In other cases, the robotic drive unit 106(a) may
move the receiving inventory holder 402 to an area adjacent the
inter-facility freight transporter 112, such as to the loading dock
204 shown in FIG. 2. From there, the receiving inventory holder 402
may be moved into the freight transporter 112 by a human worker
using power equipment such as a forklift or other user-operated
driven lift.
[0051] Multiple inventory holders 104(a) may be filled and loaded
onto the freight transporter 112 in this manner, and the freight
transporter may then be driven to the second inventory facility
102(b).
[0052] In certain instances, an order may specify that an existing
stocked inventory holder 404 is to be transferred to the second
facility. In this case, one of the robotic drive units 106(a) may
be dispatched and instructed to move the stocked inventory holder
404 from its location in the facility directly into the waiting
freight transporter 112.
[0053] In certain implementations, the robotic drive unit used to
move the inventory holder to the freight transporter may remain on
the freight transporter after moving the inventory holder, and may
be transported to the destination facility for use within a
destination inventory facility.
[0054] In certain implementations, as described above with
reference to FIG. 3, an inventory holder 104 may comprise a base
portion used to dock with the robotic drive unit 106 and a
removable storage portion containing bins or storage compartments
for inventory items. In such implementations, the removable storage
portion may be removed from the base for placement into the freight
transporter 112, thereby conserving vertical space within the
storage compartment of the freight transporter 112.
[0055] Referring now to FIG. 4b, the second inventory facility
102(b) has a plurality of portable inventory holders 104(b)
configured to store inventory items. The second inventory facility
102(b) also has a plurality of robotic drive units 106(b) that are
controlled by a management component 210(b) of the second inventory
facility 102(b) to move the inventory holders 104(b) within and
about the second inventory facility 102(b).
[0056] The management component 210 of the first inventory facility
may be configured to provide transfer data to the management
component 210 of the second inventory facility. Transfer data may
identify the inventory holders contained by the freight
transporter. Transfer data may also identify inventory items held
by the inventory holders and the locations of the inventory items
on the inventory holders. In cases where drive units themselves are
transported by the freight transporter, the transfer data may also
identify the drive units.
[0057] Upon arrival of the freight transporter 112 at the second
inventory facility 102(b), the management component 210(b) may
dispatch a robotic drive unit 106(b) to move the receiving
inventory holder 402 from the freight transporter 112 to a storage
location within the second inventory facility 102(b). In some
cases, the robotic drive unit 106(b) may be configured to enter the
cargo compartment of the freight transporter 112 and to remove the
receiving inventory holder 402 from the cargo compartment of the
freight transporter 112. In other cases, a human operator may use a
forklift or other user-operated lift to remove the receiving
inventory holder 402 from the freight transporter 112 and to place
the receiving inventory holder 402 on a loading dock adjacent the
freight transporter 112. The robotic drive unit 106(b) may then be
instructed to move the receiving inventory holder 402 from the
loading dock to a storage location within the second inventory
facility 102(b). In some cases, an upper portion of an inventory
holder may be removed from the freight transporter 112 and placed
on a base portion so that the inventory holder may subsequently be
docked with and moved by the robotic drive unit 106(b).
[0058] FIGS. 5a and 5b illustrate an example technique for
navigating a robotic drive unit 106 onto and/or into a bed or
interior 502 of a freight transporter 112, so that the robotic
drive unit 106 can move an inventory holder 104 onto and/or into
the freight transporter 112.
[0059] In certain implementations, a workspace 202 may include a
number of fiducial marks 504 that mark points on a two-dimensional
grid that covers all or a portion of the floor 506 of the workspace
202 The robotic drive units 106 in such implementations may include
positioning sensors configured to detect the fiducial marks 504.
The fiducial marks 504 may be used to indicate positions of the
robotic drive units 106 within the workspace 202, and may be used
by the robotic drive units 106 to navigate through the workspace
202.
[0060] When using the robotic drive units 106 to load items such as
inventory holders 104 onto the bed or into the cargo area of the
freight transporter 112, a mat or other surface 508 that has been
prepopulated with fiducial marks may be permanently, temporarily,
or removably placed on the bed 502 of the freight transporter 112
by a human worker before the robotic drive unit 106 enters the
freight transporter 112. The robotic drive unit 106 may then sense
the fiducial marks of the mat 508 and may use the fiducial marks
for navigation and placement of the inventory holders 104 within
the cargo area of the freight transporter 112.
[0061] As illustrated in FIG. 5a, the mat 508 may in some
embodiments comprise a roll 510 of sheet-like material, which may
be unrolled onto the bed 502 of the freight transporter 112, and
which may be removed after use.
[0062] FIG. 5b shows a possible placement of the mat 508 on the bed
502 of the freight transporter 112. In this embodiment, a single
mat 508 is configured to cover all or nearly all of the bed
502.
[0063] FIG. 5c shows another possible mat configuration. In this
implementation, several fiducial mats 508 may be used within the
bed 502. For example, multiple narrow mats 508 may be placed
longitudinally, from front to rear of the bed 502, so that the legs
312 of the inventory holders 104 straddle the mats 508. Once the
freight transporter 112 has been loaded with inventory holders 104,
the mats 508 may be removed by pulling them from beneath the
inventory holders 104.
[0064] In certain other embodiments, fiducial marks may be
permanently placed on or affixed to the bed 502 of the freight
transporter 112 or on other portion of the freight transporter 112
for use by the robotic drive units 106 when entering the bed 502 of
the freight transporter 112.
[0065] Although a particular method of localizing drive units
within a freight transporter is described above, various
embodiments may utilize various different means for positioning the
drive unit within the freight transporter.
[0066] FIG. 6 illustrates an example method 600 that may be
performed in the environments described above to transfer inventory
from a first inventory facility to a second inventory facility
using elements of a mobile order fulfillment system. Actions shown
along the left side of FIG. 6 are performed at the first inventory
facility under the control or direction of first control logic such
as the management component 210 mentioned above. Actions shown
along the right side of FIG. 6 are performed at the second
inventory facility under the control or direction of second control
logic, which may similarly comprise an instance of the management
component 210.
[0067] Although the method 600 is described in the context of the
preceding figures, the method 600 may also be performed in other
environments, in conjunction with various types of equipment and
resources other than those that are specifically illustrated and
mentioned. Furthermore, certain embodiments may omit one or more of
the illustrated actions, and the actions may be ordered differently
than illustrated.
[0068] An action 602 comprises controlling a plurality of unmanned
robotic drive units to move portable inventory holders within a
first inventory area for order fulfillment and/or other inventory
management purposes. An action 604, performed by one or more of the
robotic drive units, comprises moving one or more inventory holders
to a workstation for transfer of inventory items between the
inventory holders. The inventory holders may include one or more
stocked inventory holders as well as a receiving inventory holder
that will be transported by a freight transporter to a second
inventory area.
[0069] An action 606 comprises loading the receiving inventory
holder with inventory items that are to be shipped to the second
inventory area. These inventory items may be loaded from other
inventory holders or from other sources, by a human worker or by
automated equipment as described above.
[0070] An action 608 may be performed in some situations,
comprising preparing the freight transporter for navigation by
robotic drive units. The action 608 may comprise placing fiducial
marks within the freight transporter. In some situations, the
action 608 may comprise temporarily positioning one or more
removable fiducial mats within the freight transporter.
[0071] An action 610 may comprise preparing transfer data 612
indicating information regarding the receiving inventory holder and
the items that have been placed in or on the receiving inventory
holder. Specifically, the transfer data 612 may identify the
inventory holder, such by a holder identifier (ID). In addition,
the transfer data 612 may identify the inventory items held by the
inventory holder, and the specific locations of the inventory items
on the inventory holder. In some cases where drive units themselves
are transported between facilities, the transfer data may also
include a drive unit identifier (ID).
[0072] An action 614, performed by one or more of the robotic drive
units, comprises moving the receiving inventory holder to and/or
within the freight transporter. A robotic drive unit may be used in
some situations to enter the freight transporter and place the
receiving inventory holder into or onto the transport the freight
transporter. In other situations, a robotic drive unit may place
the receiving inventory holder near the freight transporter and
other equipment may be used to move the receiving inventory holder
or a portion of the receiving inventory holder into the freight
transporter. In some cases, the robotic drive unit may remain on
the freight transporter along with the receiving inventory holder.
In other cases, the robotic drive unit may place the inventory
holder on to the freight transporter and then exit the freight
transporter for further use within the first inventory
facility.
[0073] An action 616, performed by the freight transporter,
comprises transporting the receiving inventory holder to the second
inventory facility. In some cases, the action 616 may also comprise
transporting the robotic drive unit that has been used to move the
inventory holder.
[0074] At the second inventory facility, an action 618 comprises
controlling a plurality of unmanned robotic drive units to move
portable inventory holders for order fulfillment or other inventory
management purposes. An action 620 may comprise receiving the
transfer data that has been prepared and provided by the first
inventory facility.
[0075] An action 622, performed upon arrival of the freight
transporter, comprises removing the receiving inventory holder from
the freight transporter. The action 622 may include entering the
freight transporter with a robotic drive unit and removing the
receiving inventory holder with the robotic drive unit.
Alternatively, the inventory holder may be removed from the freight
transporter by other means, such as by other types of manned and/or
automated equipment, and the robotic drive unit may be used to move
the inventory holder from the area of the freight transporter. In
cases where the robotic drive unit has accompanied the inventory
holder on the freight transporter, the action 622 may comprise
using that robotic drive unit to remove the inventory holder from
the freight transporter.
[0076] An action 624 comprises moving the inventory holder with a
robotic drive unit to a storage area within the second inventory
facility, from where it may be accessed to fulfill future orders at
the second inventory facility. The management component of the
second inventory facility may utilize the received transfer data to
determine the identification of the inventory holder, its inventory
items, and any robotic drive unit that has accompanied the
inventory holder.
[0077] FIG. 7 shows relevant operational components of an example
robotic drive unit 106 that may be used in conjunction with the
techniques and systems described above. In a very basic
configuration, an example drive unit 106 may have control logic in
the form of one or more processors 702 and memory 704. Depending on
the configuration of the drive unit and its control logic, the
memory 704 may be a type of computer storage media and may include
volatile and nonvolatile memory. Thus, the memory 704 may include,
but is not limited to, RAM, ROM, EEPROM, flash memory, or other
memory technology.
[0078] The memory 704 may be used to store any number of executable
components 706 that are executable by the processor(s) 702. In many
embodiments, these executable components comprise instructions or
programs that are executable by the processor(s) 702, and that when
executed implement operational logic for performing the actions and
functions described above.
[0079] Executable components stored in the memory 704 may include
navigational components, communication components, components,
power management components, device drivers, and other software or
firmware. Generally, the drive unit 106 is configured through by
means of the executable components 706 to receive and act upon
instructions from the management component 210 and to provide
status information back to the management component 210.
[0080] The drive unit 106 may have communication components 708
such as wireless networking components or other components for
providing wireless communications between the drive unit 106 and
the management component 210.
[0081] Physical components of the drive unit 106 may include
multiple sensors 710 such as optical sensors, cameras, position
sensors, gyroscopes, compasses, position receivers, accelerometers,
microphones, and so forth. The sensors 710 may be used for
navigational purposes or for other purposes such as identifying
inventory holders 104, determining status of various system or
device elements and subsystems, and so forth.
[0082] Physical components may also include one or more actuators
and/or motors 712, which may be used for engaging or docking with
inventory holders 104, moving the drive unit over a surface, and so
forth. The drive unit 106 may also include batteries 714 or another
type of energy storage device for operating the various components
described above.
[0083] The drive unit 106 may of course include many other elements
and components that are not shown.
[0084] FIG. 8 shows relevant operational components of an example
management component 210 that may be used in conjunction with the
techniques and systems described above. In a very basic
configuration, an example management component 210 may have control
logic in the form of one or more processors 802 and memory 804.
Depending on the configuration of the management component 210 and
its control logic, the memory 804 may be a type of computer storage
media and may include volatile and nonvolatile memory. Thus, the
memory 804 may include, but is not limited to, RAM, ROM, EEPROM,
flash memory, or other memory technology.
[0085] The memory 804 may be used to store any number of executable
components 806 that are executable by the processor(s) 802. In many
embodiments, these executable components comprise instructions or
programs that are executable by the processor(s) 802, and that when
executed implement operational logic for performing the actions and
functions described above.
[0086] Executable components stored in the memory 804 may be
configured to manage multiple robotic drive units. For example, the
management component may specify instructions, locations, paths,
inventory holders, and other information to the robotic drive
units. In addition, the management component may implement a
database or other type of logic for managing inventory items and
their storage within an inventory facility. In some embodiments,
the management component 210 may be configured to coordinate and
direct all or most automated activities relating to robotic drive
units and associated inventory holders.
[0087] The management component 210 may have communication
components 808 such as wireless networking components or other
components for providing wireless communications between robotic
drive units and the management component 210.
[0088] The management component 210 may of course include many
other elements, components, and functionalities that are not
specifically illustrated.
[0089] Although the subject matter has been described in language
specific to structural features, it is to be understood that the
subject matter defined in the appended claims is not necessarily
limited to the specific features described. Rather, the specific
features are disclosed as illustrative forms of implementing the
claims.
* * * * *