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US-20260125217-A1 - ORDER FULFILLMENT SYSTEM WITH AUTOMATED DISPENSING HAVING INTEGRATED TURNING DECKS

US20260125217A1US 20260125217 A1US20260125217 A1US 20260125217A1US-20260125217-A1

Abstract

An automated order fulfillment system, comprising mobile robots configured to transport containers carrying goods, the automated order fulfillment system including a storage structure having an array of storage locations configured to store containers or totes, the storage structure having a first end, a second end and a length between the first and second ends, and one or more turning decks integrated into the storage structure, between the first and second ends of the storage structure, allowing the mobile robots to change direction while in the storage structure, where a turning deck of the one or more turning decks is configured so as to engage at least one of the mobile robots so as to position and stably hold the at least one of the mobile robots in a predetermined pose on the turning deck.

Inventors

  • William J. Fosnight
  • Michael Chesna
  • Christopher J. Dancewicz
  • Alan Grant
  • Derek J. McGearty

Assignees

  • SYMBOTIC LLC

Dates

Publication Date
20260507
Application Date
20251229

Claims (20)

  1. 1 . An automated order fulfillment system, comprising mobile robots configured to transport containers carrying goods, the automated order fulfillment system comprising: a storage structure having an array of storage locations configured to store containers or totes, the storage structure having a first end, a second end and a length between the first and second ends; and one or more turning decks integrated into the storage structure, between the first and second ends of the storage structure, allowing the mobile robots to change direction while in the storage structure; wherein a turning deck of the one or more turning decks is configured so as to engage at least one of the mobile robots so as to position and stably hold the at least one of the mobile robots in a predetermined pose on the turning deck.
  2. 2 . The automated order fulfillment system of claim 1 , wherein the turning deck is arranged so that an output of the turning deck interfaces with a dispense portion.
  3. 3 . The automated order fulfillment system of claim 1 , wherein a turning deck of the one or more turning decks comprises a turning deck input/output allowing mobile robots to exit or enter the storage structure.
  4. 4 . The automated order fulfillment system of claim 1 , wherein the array of storage locations comprises a first array of storage locations, the storage structure further comprising a second array of storage locations adjacent the first array of storage locations, and an aisle defined between the first and second arrays, the one or more turning decks configured to allow the mobile robots to pass between the aisle on either side of the one or more turning decks.
  5. 5 . The automated order fulfillment system of claim 1 , wherein a turning deck of the one or more turning decks is of a modular construction configured to be inserted between the first and second ends of the storage structure.
  6. 6 . The automated order fulfillment system of claim 5 , wherein the turning deck of modular construction has as many vertical levels as the storage structure.
  7. 7 . The automated order fulfillment system of claim 5 , wherein the turning deck of modular construction comprises vertical levels configured with a same vertical spacing as levels of the storage structure.
  8. 8 . The automated order fulfillment system of claim 1 , wherein a turning deck of the one or more turning decks comprises passive bumpers allowing the mobile robot traveling along the length of the storage structure to pass through the turning deck, exit the storage structure on a first side of the storage structure and exit the storage structure on a second side of the storage structure opposed to the first side.
  9. 9 . The automated order fulfillment system of claim 1 , wherein a turning deck of the one or more turning decks comprises directed bumpers allowing the mobile robot traveling along the length of the storage structure to do one of: pass through the turning deck, exit the storage structure on a first side of the storage structure and exit the storage structure on a second side of the storage structure opposed to the first side.
  10. 10 . An automated order fulfillment system, comprising mobile robots configured to transport containers carrying goods, the automated order fulfillment system comprising: a storage structure having first and second opposed sides, and an array of storage locations configured to store containers or totes, the array having a first end, a second end and a length between the first and second ends; and one or more turning decks between first and second portions of the storage structure, and between the first and second ends of the array, the one or more turning decks being configurable to allow the mobile robot to: pass straight between the first and second portions of the storage structure, exit the storage structure through the first side, and/or exit the storage structure through the second side; wherein a turning deck of the one or more turning decks is configured so as to engage at least one of the mobile robots so as to position and stably hold the at least one of the mobile robots in a predetermined pose on the turning deck.
  11. 11 . The automated order fulfillment system of claim 10 , wherein the one or more turning decks have an input/output mechanism so that entry/exit of the mobile robot to/from each of the one or more turning deck is via the input/output mechanism of the turning deck.
  12. 12 . The automated order fulfillment system of claim 11 , wherein the input/output mechanism comprises a bumper system having bumpers on either side of the turning deck.
  13. 13 . The automated order fulfillment system of claim 12 , wherein the bumpers are passive, allowing the mobile robot to pass straight between the first and second portions of the storage structure, exit the storage structure through the first side and exit the storage structure through the second side.
  14. 14 . The automated order fulfillment system of claim 12 , wherein the bumpers are configured to position the mobile robot on the centerline of the turning deck input/output.
  15. 15 . The automated order fulfillment system of claim 12 , wherein the storage structure comprises a first set of storage locations separated by a first aisle and a second set of storage structure separated by a second aisle, and wherein the one or more turning decks comprise two contiguous turning decks, one in the first aisle and one in the second aisle, the two contiguous turning decks allowing mobile robots to pass freely between the first and second sets of storage locations between the first and second ends of the storage structure.
  16. 16 . A method of fulfilling orders with an automated order fulfillment system having mobile robots configured to transport containers carrying goods, the method comprising: providing a storage structure having an array of storage locations configured to store containers or totes, the storage structure having a first end, a second end and a length between the first and second ends; providing one or more turning decks integrated into the storage structure, between the first and second ends of the storage structure, effecting changing of direction of the mobile robots while in the storage structure; engaging at least one of the mobile robots with a turning deck of the one or more turning decks for positioning and stably holding the at least one of the mobile robots in a predetermined pose on the turning deck.
  17. 17 . The method of claim 16 , further comprising arranging the turning deck so that an output of the turning deck interfaces with a dispense portion.
  18. 18 . The method of claim 16 , wherein a turning deck of the one or more turning decks has a turning deck input/output effecting exiting or entering of the mobile robots to the storage structure.
  19. 19 . The method of claim 16 , wherein the array of storage locations has a first array of storage locations and a second array of storage locations adjacent the first array of storage locations, and an aisle defined between the first and second arrays, the one or more turning decks effecting passing of the mobile robots between the aisle on either side of the one or more turning decks.
  20. 20 . The method of claim 16 , wherein a turning deck of the one or more turning decks is of a modular construction configured to be inserted between the first and second ends of the storage structure.

Description

CROSS-REFERENCE TO RELATED APPLICATION(S) This application is a continuation of U.S. application Ser. No. 17/957,266, filed on Sep. 30, 2022, which claims priority to U.S. Provisional Patent Application No. 63/250,809, filed on Sep. 30, 2021, entitled “ORDER FULFILLMENT SYSTEM WITH AUTOMATED DISPENSING HAVING INTEGRATED TURNING DECKS”, the disclosures of each of which is hereby incorporated by reference in its entireties. BACKGROUND An order-fulfillment system for use in supply chains, for example in retail supply chains, may fulfill orders for individual product units or goods. Conventional systems may store totes including the goods in a storage structure including storage location arrays. The storage locations in the structure may be accessible by mobile robots which may for example travel within an aisle between a pair of storage location arrays. In the operation of such systems, it may be desirable to allow a mobile robot to change direction or exit the storage structure while traveling within the storage structure. BRIEF DESCRIPTION OF THE DRAWINGS Embodiments of the present technology will now be described with reference to the figures which include the following. FIG. 1A-1C show partial views of an order fulfillment facility including a storage structure, turning decks and an automated dispense portion according to embodiments of the present technology. FIGS. 2A-2D show various views of an array of turning decks according to embodiments of the present technology. FIGS. 3A-3B show views of a frame for supporting the turning decks according to embodiments of the present technology. FIGS. 4A-4B shows views of a storage structure connected to an automated dispense portion via turning decks. DETAILED DESCRIPTION Embodiments of the present technology will now be described with reference to the figures, which in general relate to an order fulfillment system with automated dispensing and customer portals having integrated turning decks. The embodiments described enable efficient routing of mobile robots, for example, by enabling the mobile robots to turn and change direction in a small area on a turning deck. Further and as will be described, the embodiments are intended to enable efficient movements of mobile robots from storage locations to the customer access portals. It is understood that the present embodiments may be embodied in many different forms and should not be construed as being limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete and will fully convey the invention to those skilled in the art. Indeed, the embodiments are intended to cover alternatives, modifications and equivalents of these embodiments, which are included within the scope and spirit of the invention as defined by the appended claims. Furthermore, in the following detailed description, specific details are set forth in order to provide an understanding of the present embodiments. The terms “top” and “bottom,” “upper” and “lower” and “vertical” and “horizontal” as may be used herein are by way of example and illustrative purposes only and are not meant to limit the description of the embodiments inasmuch as the referenced item can be exchanged in position and orientation. Also, as used herein, the terms “substantially” and/or “about” mean that the specified dimension or parameter may be varied within an acceptable manufacturing tolerance for a given application. In one non-limiting embodiment, the acceptable manufacturing tolerance is ±0.25%. For purposes of this disclosure, a connection may be a direct connection or an indirect connection (e.g., via one or more other parts). In some cases, when a first element is referred to as being connected, affixed or coupled to a second element, the first and second elements may be directly connected, affixed or coupled to each other or indirectly connected, affixed or coupled to each other. When a first element is referred to as being directly connected, affixed or coupled to a second element, then there are no intervening elements between the first and second elements (other than possibly an adhesive or weld used to connect, affix or couple the first and second elements). FIGS. 1A-1C show a partial view of an embodiment of an order fulfillment facility 100 showing a storage structure 102 including a number of bays 104 of storage locations 106 in communication with an automated dispense portion 176. In accordance with aspects of the present technology, the storage structure 102 may be formed of a number of storage modules 110 as explained below. The bays 104 defined by the storage modules 110 each include a y-z array of storage locations 106 in horizontal rows and level changing towers along the rows which in embodiments may be vertical towers. Mobile robots 148 may travel between storage levels in the z-direction within the level changing towers. The storage modules 110 form pairs of bays 104 that are ar