CN117098713A - Object handling system and method including a pallet positionable mobile carrier - Google Patents

Abstract

An object handling system is disclosed, the object handling system comprising a plurality of remotely actuatable carriers for controlled movement in at least two mutually orthogonal directions, each carrier including a base and for controlled movement in at least two mutually orthogonal directions. Carrier shelf portions for receiving containers, each said carrier portion being adapted to move in a lifting direction and in a rotational direction about an axis of rotation, said rotational axis being substantially parallel to said lifting direction.

Description

Object handling system and method including rack positionable mobile carrier

priority

This application claims priority from U.S. Provisional Patent Application No. 63/163,342 filed on March 19, 2021 and U.S. Provisional Patent Application No. 63/256,395 filed on October 15, 2021. The disclosures are hereby incorporated by reference in their entirety.

Background technique

The present invention relates generally to object handling systems, and specifically to robotic and other physical handling systems for, for example, sorting objects, storing and retrieving objects, and redistributing objects for various purposes, wherein said systems are intended to require systems It is suitable for use in dynamic environments where various objects are processed.

Current distribution center processing systems, for example, typically adopt an inflexible sequence of operations in which a disorganized incoming object stream is first segmented into a stream of individual isolated objects, presented one at a time to a scanner that identifies the objects. Induction elements (eg, conveyors, tilt pallets, or manually moved bins) transport the objects to a desired destination or another processing station, which may be a bin, chute, bag, or conveyor, etc.

For example, in some sorting systems, human workers or automated systems typically remove packages in the order of arrival and sort each package or object into collection bins based on a given set of heuristics. For example, all objects of a similar type might go into a collection bin, or all objects in a single customer order, or all objects destined for the same shipping destination, etc., could be processed similarly. Human workers or automated systems may be required to receive objects and move each object to their designated collection bin. If the number of input (received) objects of different types is large, a large number of collection bins will be needed.

Since the desired goal is to match incoming objects to designated collection bins, such systems are inherently inefficient and inflexible. Such a system would likely require a large number of collection bins (and therefore a large amount of physical space, a large capital cost, and a large operating cost), in part because sorting all objects to all destinations at once is obviously not simple or efficient. Specifically, there are several major things to consider when automating the sorting of objects: 1) overall system throughput (packages sorted per hour), 2) number of lane transfers (i.e., the number of lanes an object may be delivered to) number of discrete locations), 3) the total area of the sorting system in square feet, and 4) the annual cost of operating the system (labor hours, power costs, cost of disposable parts).

Current state-of-the-art sorting systems rely to some extent on human labor. Most solutions rely on workers, who perform the sorting by scanning objects coming from induction areas (chutes, workbenches, etc.) and placing the objects in staging locations, conveyors, or collection bins. When a bin is full or the control software system determines it needs to be emptied, another worker empties the bin into a bag, box, or other container and sends the container to the next processing step. Such systems perform well on throughput (i.e., how quickly human workers can sort bins or empty bins this way) and lane number (i.e., only so many bins can be scheduled for a given bin size) There are limitations in the practical reach of human workers).

Other partially automated sorting systems involve the use of circulating conveyors and tilt pallets, where the tilt pallets receive objects through manual sorting and each tilt pallet moves past a scanner. Each object is then scanned and moved to the predefined position assigned to that object. The pallet is then tilted so that the object falls into that position. In addition, partially automated systems, such as bomb bay type circulating conveyors, involve having a number of pallets with an opening floor (door) at the bottom of each pallet, where the door opens when the pallet is positioned over a predefined chute, and then the object Drop from the pallet into the chute. Again, the object is scanned while it is in the pallet, assuming the scanner can see any identification code.

Such partially automated systems are lacking in critical areas. As described, these conveyors have discrete pallets that can be loaded with objects; they then pass through a scanning tunnel that scans the objects and associates them with the pallets they are on. When the pallet passes the correct bin, a trigger mechanism causes the pallet to dump the object into the bin. However, the disadvantage of this system is that each turn requires an actuator, which increases the mechanical complexity and the cost per turn can be very high.

The alternative is to use manpower to increase the number of diverters or collection bins available in the system. This reduces system installation costs but increases operating costs. Multiple units can then work in parallel, effectively linearly multiplying throughput while keeping the number of expensive automated diverters to a minimum. Such redirectors cannot identify bins or redirect bins to specific locations, but instead work with beam interrupters or other sensors to try to ensure that indiscriminate piles of objects are properly redirected. The lower cost of such diverters, combined with the fewer number of diverts, keeps overall system divert costs low.

Unfortunately, these systems do not address limitations regarding the total number of boxes in the system. The system simply routes the same share of all objects to each parallel manual unit. Therefore, each parallel sorting unit must have all the same collection bin names; otherwise, an object may be delivered to a unit that does not have the bin to which the object is mapped.

Other systems provide access to various input objects through storage and retrieval systems. Automated storage and retrieval systems (AS/RS), for example, typically include computer control systems for automatically storing (placing) items into and retrieving items from defined storage locations. Traditional AS/RS usually uses storage bags (or boxes), which are the smallest loading units of the system. In these systems, the glove bag is brought to the person who selects individual items from the glove bag. When the person selects the required number of items from the glove bag, the glove bag is reintroduced back into the AS/RS.

In these systems, the glove bag is brought to the person, who can remove items from the glove bag or add items to the glove bag. Then return the storage bag to its storage position. Such systems can be used in libraries and warehouse storage facilities. AS/RS does not involve handling the contents of the glove bag because the person handles the objects when the glove bag is brought to them. This separation of tasks allows any automated transport system to do what it does best, which is move the glove compartment, and allows humans to do what they do better, which is sort through the clutter of the glove compartment. This also means that when the transportation system brings the storage bag to the person, the person can stand in one place, which increases the speed at which people pick items. However, this is problematic in terms of the time and resources required to move the glove bags to and subsequently away from each person, and how quickly people can dispose of the glove bags in this manner in an application that may require each person to handle a large number of glove bags. Traditional systems have limitations.

While automated handler systems exist for moving shelves, boxes, or objects, such systems are limited in their ability to efficiently and economically interact with existing equipment, such as conveyors or other handling equipment in some applications. May not be flexible enough. There remains a need for a more efficient and cost-effective object sorting system that sorts objects of various sizes and weights into appropriate fixed-size collection bins or pallets and has the capability to handle objects of varying sizes and weights. The object aspect is also efficient.

Contents of the invention

According to one aspect, the invention provides an object handling system comprising a plurality of remotely actuable carriers for controlled movement in at least two mutually orthogonal directions, each carrier Comprising a base and a carrier portion for receiving a container, each carrier portion is adapted to move in a lifting direction and in a rotational direction about an axis of rotation that is substantially parallel to the lifting direction.

According to another aspect, the invention provides an object handling system comprising at least one remotely actuatable carrier for controlled multi-directional movement, said carrier including a base and for receiving a container a carrier shelf portion, the carrier shelf portion is adapted to move relative to the base in a lifting direction and a rotation direction, and the system is adapted to place any container and any object on the container onto a plurality of protrusions .

According to another aspect, the present invention provides an object handling system including a plurality of remotely actuatable carriers for controlled multi-directional movement, each carrier including a carrier for receiving a container. a rack portion and a base for supporting said carrier, said base including a pair of independently actuable wheels for moving a respective carrier in either of two mutually orthogonal directions, and said carrier The rack is coupled to a carrier rotation system for rotating the carrier relative to the base.

According to another aspect, the invention provides an object handling system for handling objects, said object handling system comprising a plurality of remotely actuatable carriers for controlled multi-directional movement, each remotely actuatable The carrier includes a carrier shelf portion for receiving containers and a base for supporting the carrier shelf, the base includes a carrier shelf lifting system including a rotation-linear motion converter, and includes a carrier shelf portion for relative movement of the carrier shelf. A carrier rotation system that rotates on the base.

Description of the drawings

The following description may be further understood with reference to the accompanying drawings, in which:

Figure 1 shows an illustrative diagrammatic view of an object handling system according to one aspect of the invention;

FIG. 2 shows an illustrative diagrammatic enlargement of a portion of the object handling system of FIG. 1 , the portion including an input conveyor and an input station;

3A-3F show illustrative diagrammatic side views of the input station of the system of FIG. 1 showing carrier alignment with the support structure (FIG. 3A), confirmation of alignment with the support structure (FIG. 3B), support structure Receiving the object (Fig. 3C), the carrier carrier engaging the object (Fig. 3D), the carrier moving the object away from the support structure (Fig. 3E), and the carrier lowering the carrier and object or transferring (Fig. 3F);

4A-4D show illustrative diagrammatic front views of a support structure and a carrier, showing the carrier approaching the support structure (FIG. 4A), underneath the support structure (FIG. 4B), and the support structure receiving an object (FIG. 4C). and the transporter's load-carrying rack engaging objects (Fig. 4D);

Figure 5 shows an illustrative diagrammatic view of an input station including a narrow conveyor belt in the form of a protrusion according to another aspect of the invention;

Figure 6 shows an illustrative, liberated view of the conveyor belt protrusion of the input station of Figure 5;

Figure 7 shows an illustrative diagrammatic plan view of the input conveyor tab of the input station of Figure 5;

Figure 8 shows an illustrative diagrammatic side view of the input conveyor protrusion of the input station of Figure 5;

Figures 9A-9D show illustrative diagrammatic views of the mid-shelf position of the system of Figure 1, showing a carrier with objects on the carrier aligned with the support structure (Fig. 9A), the carrier lifting the carrier and the objects (Fig. 9B), the carrier moves the carrier between the protrusions of the shelf position (Fig. 9C), and the carrier lowers the carrier to place the object on the protrusion of the shelf position (Fig. 9D);

10A and 10B show an illustrative before view of a carrier moving a carrier shelf between ledges at a shelf location (FIG. 10A) and lowering a carrier shelf to place an object onto the ledge at a shelf location (FIG. 10B). view;

FIG. 11 shows an illustrative diagram of a portion of the system of FIG. 1 showing an object processing location;

Figure 12 shows an illustrative diagrammatic plan view of the object handling location of Figure 11;

Figure 13 shows an illustrative diagrammatic side elevation view of the object handling location of Figure 12;

Figure 14 shows an illustrative diagrammatic exploded view of the automated mobile handler of the system of Figure 1;

Figure 15 shows an illustrative diagrammatic isometric view of the top of the carrier rack of Figure 14;

Figure 16 shows an illustrative diagrammatic isometric view of the bottom of the carrier rack of Figure 14;

Figure 17 shows an illustrative diagrammatic isometric first side view of the position control system of the carrier of Figure 14;

Figure 18 shows an illustrative diagrammatic isometric second side view of the position control system of the carrier of Figure 14;

Figure 19 shows an illustrative diagrammatic isometric third side view of the position control system of the carrier of Figure 14;

20 shows an illustrative diagrammatic isometric third side view of the position control system of the carrier of FIG. 19 with the rotor belt housing removed;

21A and 21B show illustrative diagrammatic views of the position control system within the carrier of FIG. 14 without carrier shelves, showing the position control system in a raised position (FIG. 21A) and a lowered position (FIG. 21B). ;

Figures 22A and 22B show illustrative diagrammatic views of the position control system within the carrier of Figure 14 without carrier shelves and without intermediate portions, shown in a raised position (Fig. 22A) and a lowered position (Fig. 22B) position control system;

23A and 23B show illustrative diagrammatic views of an enlarged portion of the position control system of FIGS. 22A and 22B, showing the position control system in a raised position (FIG. 23A) and a lowered position (FIG. 23B);

24A and 24B show illustrative diagrammatic views of the carrier of FIG. 14 with the carrier and objects thereon in a first rotational position (FIG. 24A) and a second rotational position (FIG. 24B);

Figure 25 shows an illustrative diagrammatic top view of the automated mobile carrier of Figure 14;

Figure 26 shows an illustrative diagrammatic bottom view of the automated mobile carrier of Figure 14;

Figure 27 shows an illustrative diagrammatic isometric side view of an object handling system in accordance with another aspect of the invention;

28 shows an illustrative diagrammatic isometric view of a portion of the system of FIG. 27 showing a vertical output portion and an output sorting system including packaged shipping containers loaded onto a shipping bin;

Figures 29A-29D show illustrative enlarged views of a shipping container being loaded onto a support pallet, showing the shipping container being loaded onto the tongue extension (Figure 29A), showing the tongue extension portion retracted with the shipping container over the support pallet (Figure 29B), the tongue extension is shown fully retracted to drop the shipping container onto the support pallet (Figure 29C), and the shipping container and support pallet are shown The combination is removed for further processing (Fig. 29D);

Figure 30 shows an illustrative diagrammatic exploded view of the transport bin of Figure 27;

Figure 31 shows an illustrative diagrammatic view of the shipping bin of Figure 30 after assembly;

Figure 32 shows an illustrative diagrammatic view of the two shipping bins of Figure 30 stacked on top of each other for shipping;

33 shows an illustrative diagrammatic isometric view of a portion of the system of FIG. 27 showing a vertical output portion and an output sorting system including objects loaded into a transport bin;

34 shows an illustrative diagrammatic isometric view of a portion of the system of FIG. 27 showing a vertical output portion and an output sorting system including packaged goods loaded by humans onto an automated mobile carrier. Box;

Figure 35 shows an illustrative diagrammatic isometric view of a portion of the system of Figure 27 showing a vertical output section and an output sorting system including automated loading onto an automated mobile carrier via a multi-level stacking system. packed boxes;

Figure 36 shows an illustrative diagrammatic rear isometric view of the multi-layer stacking system of Figure 35;

Figures 37A-37D show illustrative diagrammatic side views of an enlarged portion of the multi-layer stacking system of Figure 36, showing the shipping container approaching the carrier (Figure 37A), showing the shipping container being placed on the tongue element (Figure 37A) Figure 37B), showing the transport container moving on the tongue element above the carrier (Figure 37C), and showing the tongue element being retracted and the transport container being placed on the carrier (Figure 37D);

Figures 38A and 38B show an illustrative enlarged view of the transport container and support pallet on the tongue element above the carrier (Figure 38A), and showing the tongue element retracted and the transport container and support pallet being removed Put it on the carrier (Figure 38B);

Figure 39 shows an illustrative diagrammatic front view of the multi-layer stacking system of Figure 35;

Figure 40 shows an illustrative diagrammatic view of an object handling system involving handling objects with and without a shipping container in accordance with another aspect of the present invention;

41A and 41B illustrate illustrative diagrammatic views of an enlarged portion of the object handling system of FIG. 40 showing objects on a carrier approaching a support structure storage shelf (FIG. 41A) and placing the object onto the support structure storage. (Fig. 41B);

42A and 42B illustrate illustrative diagrammatic views of an enlarged portion of the object handling system of FIG. 40 showing non-rigid objects on a carrier approaching a support structure storage rack (FIG. 42A) and placing the non-rigid objects onto Support structure storage shelves in front of previously placed non-rigid objects (Figure 42B);

43 shows an illustrative diagram of an expanded front isometric view of the automated mobile handler of the system of FIG. 40;

Figure 44 shows an illustrative diagram of a large bottom isometric view of the automated mobile handler of the system of Figure 40;

45A and 45B show an illustrative diagrammatic enlarged front view of a portion of the mobile carrier of FIG. 40 with a carrier rack positioned beneath discrete objects to be engaged (FIG. 45A) and only engaging said discrete objects (FIG. 45B);

46 shows an illustrative diagrammatic front view of the carrier rack of the system of FIG. 40 engaging a non-rigid object; and

Figure 47 shows an illustrative diagrammatic elevation view of a carrier rack of the carrier of the system of Figure 40 engaging a large non-rigid object that extends beyond the width of the carrier rack.

The drawings are for illustrative purposes only.

Detailed ways

In certain aspects, the present invention generally relates to object handling systems, wherein objects are initial containers (e.g., boxes, bins, storage bags, etc.) in a pre-processed state by various automated handlers capable of freely moving within the environment. Carried in processed containers (e.g., boxes, bins, storage bags, etc.) and in a post-processing state. According to other embodiments, the system may assume that the objects themselves (eg, boxes, bags, shipping bags, etc.) are carried directly by automated handlers (as disclosed below with reference to Figures 14-26, 43, 44). The carriers may each include multi-purpose racks for receiving containers (e.g., boxes, bins, or totes) that allow the containers to be moved to conveyors or other handling equipment using a cost-effective handling system and Removed from conveyors or other handling equipment. Container racking and retrieval mechanisms associated with each automated carrier assume that bags or boxes are carried by each carrier having bag storage area carriers.

For example, FIG. 1 illustrates an object handling system 10 that includes an input conveyor system 12 that includes an input conveyor 14 that selectively transfers containers 20 at a bidirectional converter 18 (eg, boxes, bins, totes, or pallets of various sizes) are routed toward any of the various input stations 16 . Each input station 16 includes a capped support structure 22 that includes a plurality of tabs 24 (discussed in more detail below). Multiple automated mobile handlers 30 may be engaged to move containers from any of the multiple input stations 16 , between any of the multiple intermediate racking locations 40 , and at any of the multiple object handling locations 50 Move from one to the other, and finally move to any one of a plurality of output stations 60 of the output conveyor system 62 . The system can dynamically move containers 20 along the input conveyor 14, including empty containers as well as containers containing objects to be processed.

Objects can be homogeneous within a container (all objects of the same type) or heterogeneous within a container (including objects of different types). The system moves the containers 20 to any of a number of intermediate rack locations, noting where each container is located. The system dynamically allocates certain containers to transfer one or more objects out of the corresponding container, and allocates other containers to receive objects, ultimately satisfying the object allocation list. For example, a set of containers for input objects may include objects that are to be processed by placing each input object into a specifically assigned target container for the plurality of objects. The target container of the allocation does not have to be empty when an object is initially allocated to the corresponding container. Likewise, for example, a container containing one or more objects to be included in an assigned target container may be assigned a corresponding target container assignment such that the one or more objects may simply remain in the container. When processing of the container is complete, the completed container is moved to the output station 60 of the output conveyor system 62 where it can be further processed, for example for transportation. In this way, objects can be introduced into the system into the same container that is ultimately used for shipping. Each container includes a unique identification mark (eg, 23 discussed below), and the contents of each container can be known at the outset. The system essentially moves objects between containers, and as each container becomes full or complete for shipping, the containers are directed to an output station 60 for further processing.

The movement of each container within the system is monitored, and the movement of each object between containers is also monitored. Each container 20 may be marked with a unique identification mark 23 on each vertical side thereof, and each input conveyor system 12 , mobile rack 30 , storage rack 40 , programmable motion device 50 and output conveyor system 62 may each include Associated detection units 11, 21, 31, 41, 51 and 61 respectively for monitoring the position of all containers (as discussed further herein) by detecting identification marks 23 (shown in Figures 3A to 3F). FIG. 2 shows an enlarged view of a portion of the system 10 of FIG. 1 , showing in greater detail the capped support structure 22 of the input station 16 and the intermediate racking location 40 including the detection unit 41 . The system is controlled by one or more processing systems 100 that communicate with each conveyor, mobile handler, intermediate racking location, processing station, and output conveyor system (e.g., via cable or wireless land).

The systems and methods of various embodiments of the invention may be used in a wide variety of object handling systems, such as sorting systems, automated storage and retrieval systems, and distribution and redistribution systems. For example, according to other embodiments, the present invention provides a system capable of automating the outbound process of a processing system. The system may provide a novel goods-to-picker system that uses a fleet of small mobile carriers to carry individual inventory totes and outbound containers to and from picking stations. According to one aspect, the system includes an automated picking station that picks goods in inbound containers and loads them into outbound containers. Containers can be dynamically assigned incoming and outgoing names. The system involves combining machine vision, task and motion planning, control, error detection and recovery, and artificial intelligence based on sensor-enabled hardware platforms to enable real-time and robust systems for sorting items from cluttered containers. solution.

Figures 3A to 3F show side views of containers 20 being moved from the input station 16 onto the carrier 30. Referring to FIGS. 3A and 3B , the carrier 30 moves beneath the support structure 22 of the input station 16 . Support structure 22 includes a plurality of protrusions 24 (also shown in FIGS. 4A and 4B ), each protrusion being supported by a bracket 26 . As mentioned above, the sensing unit 11 captures a unique identification mark 21 on each container 20 (and the identification mark of each container may be provided on all sides of the container). Each sensing unit (11, 21, 31, 41, 51, 61) identifies containers, always confirming their location in the system.

Specifically, and referring again to Figure 3A, when the carrier moves adjacent to the support structure 22, the carrier uses the sensing unit 29 (shown in Figure 26) on the underside of the carrier 30 or the bottom side of the carrier 230. Multiple sensing units 227 on the side (shown in Figure 44) find/confirm their position via position markers 27 (shown in Figures 3B to 3D). If the carrier is not positioned completely over the mark 27 in the desired orientation, the carrier may drive away from the support structure. According to other aspects, the carrier may be moved forward toward the support structure in a manner that steers the carrier to adjust the lateral position of the carrier relative to the support structure, for example, by first moving one of the two wheels 34 faster than the other. (to cause the carrier to turn) and then move the other of the two wheels 34 faster than the first (to cause the carrier to turn in the opposite direction so that it is guided to the support structure again). The carrier may then return to the support structure in an attempt to better position itself above the mark 27 with the proper carrier position and orientation relative to the support structure. Once the sensing unit on the underside of the carrier 30 is properly positioned above the position mark 27, it is confirmed that the carrier 30 has the desired orientation relative to the support structure 22. Then, if the carrier 30 is not already under the support structure 22, the system moves it there. The carrier 30 keeps moving until the sensing unit 29 on the bottom side of the carrier 30 confirms that the carrier 30 is centered above the position mark 25, as shown in Figure 3B. While the system may always know the location and orientation of each carrier 30 , the use of markers (eg, 25 , 27 ) and sensing units 29 confirms the precise location and orientation of each carrier 30 in the environment beneath the support structure 22 .

Referring to FIG. 3C , the container 20 then moves along the input station 16 and onto a support structure 22 that includes a protrusion 24 supported by a bracket 26 . Each carrier 30 includes a base 32 having a pair of drive wheels 34 that can be driven independently (in the same or opposite directions of rotation and at different speeds) to move the carrier in a linear direction around the floor work surface. and rotation direction movement. Two sets of casters 35 may also be provided on the bottom side of each carrier 30 (on the side orthogonal to the side containing the drive wheel 34) to maintain a generally horizontal orientation of each carrier 30. Depending on other aspects, a caster may be provided at each end of the carrier in place of each pair of casters.

Each carrier 30 also includes an intermediate portion 36 and a load carrier 38 that includes a plurality of upwardly extending support ridges 37 . The support ridges 37 are sized and spaced such that when aligned with the tabs 24 of the support structure 22 , the support ridges 37 pass between the tabs as the carrier rack 38 is raised from under the support structure 22 . The use of markers 25, 27 and sensing unit 29 (again, shown in Figure 26) allows the handler to accurately confirm alignment with the support structure 22. Referring to Figure 3D, the carrier rack 38 is raised relative to the base 32 using an actuatable lift system 39, as discussed in greater detail below. Referring to Figures 3C and 3D, the container 20 is moved onto the support structure 22 (Figure 3C, e.g., by gravity from the input station conveyor 17 or using a drive belt as discussed below), and the carrier rack is raised from beneath the support structure ( when aligned), as shown in Figure 3D. The elevated carrier engages the container and then exits the input station 16, as shown in Figure 3E. The carrier 30 can then lower the lift system 39 to return the carrier (and now the containers) to the lowered position on the carrier as shown in Figure 3F.

If the carriage 38 of the carrier 30 is not aligned with the tab when the carrier is over mark 27, the carrier will try to correct the lateral orientation of the carrier when the carrier moves to mark 25, or the carrier may move completely from The support structure 22 is removed (and moved to a different location or tried again at the current location). As the carrier moves between marks 27 and 25, the lateral orientation of the carrier can be corrected by powering each wheel 34 on the carrier differently (first on one side, then on the other).

According to other aspects, as shown in FIGS. 4A and 4B , the detection unit 31 may also be used to confirm the alignment with the protrusions 24 of the support structure 22 by detecting the marks 81 on the underside of some of the protrusions 24 . Figure 4A shows the carrier approaching the support structure, and Figure 4B shows the carrier below the support structure with the detection unit 31 aligned between corresponding pairs of markers 81, which may be reflective markers or markers such as LEDs. type of lighting source. When the detection units 31 are each located between a corresponding pair of marks 81, the carrier is aligned with the support structure.

4C and 4D illustrate that the carrier shelf 38 is aligned with the support structure 22 (as shown in FIG. 4C ) such that the support ridges 37 alternate with the protrusions 24 of the support structure 22, thereby allowing the support ridges to move as the carrier shelf is raised. 37 passes between the protrusions 24. Near the end of the lifting range (as shown in FIG. 4D ), the container 20 is lifted off the support structure 22 and is instead supported by the support ridges 37 of the carrier shelf 38 . The central area of the two outermost support ridges can also employ sensing units 31 (in addition to the above-mentioned mark detection) to detect any marks 23 on the container 20, again confirming the identity of the container 20.

As mentioned above, the input station 16 may include an input station conveyor that slopes downward to utilize gravity to provide containers 20 onto the support structure. According to another aspect, as shown in Figures 5-8, the support structures 22' may instead include protrusions formed by narrow conveyor belts that pull objects toward the open end of each support structure. Specifically, Figure 5 shows a support structure 22' extending at the end of the input station conveyor 17 of the input station 16, and as shown in the enlarged area of Figure 6, each protrusion 24' is comprised between a pair of Rollers 29' travel over a narrow conveyor belt 27' and are supported by (eg, I-beam) support brackets 26' (shown in Figure 6). Referring to Figure 7, each protrusion 24' is sized and spaced apart (shown in Figure 7) such that when the carrier rack is raised from beneath the support structure 22', the carrier's support ridge 37 can be lifted from the protrusion. Passed between 24'. Each support bracket 26' is located within the ring of each band 27' as shown in Figures 6 and 8. The actuatable belt 27' may assist in moving the containers onto the support structure 22' (and, in accordance with other aspects discussed below, may assist in moving the containers onto the output station conveyor of the output station). As discussed above with reference to Figures 3A-3F, the power applied to the wheels 34 can be adjusted independently as the carrier moves from mark 27 to mark 25 (again, by applying more power to one side first and then to the other. The other side applies more power) to provide any alignment correction between the carrier and the support structure 22'. Additionally, when the strap 27' is formed of a highly reflective material, the sensing unit 31 may be used to detect the tab 24'

Containers 20 may be moved from the carrier 30 to an intermediate racking location 40 that includes one or more container support structures 42 . Referring to Figures 9A and 9B, the carrier racks of the carrier 30 are raised and moved toward the support structure 42 at the intermediate rack position, and the lift system 39 can be engaged to raise the racks and containers, as shown in Figure 9B. Support structure 42 includes a plurality of protrusions 44 (also shown in FIGS. 10A and 10B ), each protrusion being supported by a bracket 46 . As the carrier 30 travels toward the support structure 42, the sensing unit 29 on the underside of the carrier 30 (again, shown in Figure 26) detects the position mark 43 on the floor near the support structure 22 (as shown in Figure 9C and Figure 26). shown in 9D). Although the system may always know the position and orientation of each carrier 30 , the use of markers 43 and sensing units 29 confirms the precise position and orientation of each carrier 30 in the vicinity of the support structure 42 .

Likewise, each carrier 30 also includes a carrier frame 36 that includes a plurality of upwardly extending support ridges 37 . The support ridges 37 are sized and spaced such that when aligned with the protrusions 44 of the support structure 42, the support ridges 37 pass between the protrusions when the carrier shelf 38 is moved into the support structure 42 as shown in Figure 9C. . The use of markers 25 and sensing units 29 (again, shown in FIG. 25 ) allows the handler to confirm precise alignment with the support structure 42 . As discussed above, the carrier rack 38 is lowered relative to the base 34 using a remotely actuatable lift system 38 . Referring to Figure 9D, the container 20 is placed on the support structure 42 (Figure 9D), and the carrier 30 then drives away from the input station 16, leaving the container in the intermediate rack position.

According to other aspects, each protrusion 44 may include markings 81 on its underside for detection by the sensing unit 31 when the object is removed from the shelf location, as discussed above with reference to Figures 4A-4C. Each shelf location may also include highly reflective material 85 at the end of each tab 44, as shown in Figures 10A and 10B. Each carrier rack 38 may also include a detection unit 83 on each end of each support ridge 37 (shown in Figures 10A and 10B), and using the detection units 83, the system may also detect when the corresponding carrier is oriented Confirm the alignment of the corresponding carrier with the rack position when the rack position is advanced, with the carrier rack in the raised position and the object on the carrier rack.

10A and 10B illustrate that the carrier rack 38 is aligned with the support structure 42 (as shown in FIG. 10A ) such that the support ridges 37 alternate with the protrusions 44 of the support structure 42 as the carrier rack moves between the support structures 42 , allowing the support ridge 37 to pass between the protrusions 24 . The carrier rack is then lowered away from the support structure 42 and the containers 20 are instead supported by the support structure 42 at the intermediate rack position (as shown in Figure 10B). As mentioned above, the sensing unit 41 (shown in Figure 2) captures a unique identification mark 21 on each container 20 (and the identification mark of each container may be provided on all sides of the container). Each sensing unit (11, 31, 41, 51, 61) identifies containers, always confirming their location in the system.

If the carriage 38 of the carrier 30 is not aligned with the tab 44 when the carrier is over mark 43, the carrier will try to correct the lateral orientation of the carrier when the carrier moves to mark 45, or the carrier may completely Remove from shelf location 40 (and move to a different location or try again at the current location). The lateral orientation of the carrier can also be corrected by powering each wheel 34 on the carrier differently (first on one side, then on the other) as the carrier moves between marks 43 and 45.

Automated picking systems use multi-modal sensing units to sense the contents of containers and use robotic arms equipped with automated programmable motion grippers and integrated software in the handling system to pick goods from inbound and processed containers and place them on outbound shelves. in the library container. These systems communicate with work cells that are connected to automated mobile handlers to keep the automated picking system continuously supplied with containers. Automated handlers can easily remove or replace containers from or to storage locations. Because a carrier can only carry one container at a time, it could potentially be smaller, lighter and consume less power than a larger robot while being faster. These features improve the price-performance ratio.

Unlike shuttle- or crane-based cargo picking systems where the moving parts of the system are restricted to a single lane, handlers can move forward, backward, left or right to travel around each other and reach any location in the system . This flexibility allows the handler to play multiple roles in the system by (a) transporting inventory totes to the picking station, (b) transporting outbound containers to the picking station, (c) transporting inventory totes To and from the bulk warehouse, (d) transporting complete outbound containers to the unloading lane, and (e) emptying outbound containers into the system. Additionally, movers can be added incrementally as needed to scale as your facility grows.

For example, FIG. 11 shows an object handling location 50 that includes a programmable motion device 52 with an end effector 54 for grasping an object 55 . Each programmable motion device may be floor mounted or may be suspended from the programmable motion device support 56 . Multiple sensing units 51, 58 may be employed to monitor the movement of the carrier 30 within the field of view of the sensing unit and for guiding the end effector 54 to a selected location and moving objects from one container to another. Likewise, the sensing system 51 can also identify/confirm the identity of the container 20 . The system operates, for example, wirelessly, under the control of, for example, one or more computer processing systems 100.

A pick order is a request to move a specified number of SKUs from inventory bags to outbound containers. Outbound containers may contain SKUs from many different pick orders that are destined for similar locations in the store and have mutually compatible shipping requirements. For example, a pick order might call for two packages of brand

A sequence order is a request to deliver a set of containers in sequence to a feed station for assembly into carts. The carts are assembled from a mix of VCPs (for SKUs replenished in full case quantities) and outbound containers (filled to pick orders) and are used to replenish adjacent picking points within the store. For example, a sequence order might require two additional outbound containers and five VCPs to be loaded onto a cart destined for the health and beauty department of a specific store.

The carriers 30 move so that two selected carriers at a time appear beneath the articulated arms 52 of the processing station 50, as further shown in Figure 12 (showing a top view) and Figure 13 (showing an end view). The carriers are selected such that a specified object (eg, 55) in a container on one carrier is designated to be moved to a container on the other of the two carriers. In this way, objects are moved between containers on the carrier in order to provide completed containers according to the overall inventory. Likewise, containers including one or more groups of homogeneous or heterogeneous objects may be introduced into the system, and additionally, when additional containers are required, empty containers may be introduced into the system. Because each container and each carrier is uniquely identified, the system always knows the contents and location of each container and carrier. Detection unit 29 on the underside of carrier 30 (shown in Figure 26) can confirm that the carrier is aligned above position mark 53, detection unit 51 can confirm that a known container 20 is present on carrier 30, detection unit 59 is available To assist the programmable motion device in positioning and grasping the object, and the detection unit 58 can be used to confirm the grasping of the object and the position of the container 20 in the vicinity of the programmable motion device.

All orders required to fill a trailer form a wave that must be completed before the cutoff time for that trailer. Each wave begins with the introduction of the necessary inventory containers and VCPs from the bulk warehouse into the module. These containers remain on the carrier until the wave is completed, at which time they are either (i) sorted onto the output conveyor system 62, (ii) returned to the bulk warehouse, or (iii) retained for use in future waves. Multiple waves are processed simultaneously and seamlessly: one wave may be bringing in inventory, while two waves are processing picking orders, and a fourth wave is sorting. Operations for bringing inventory into the system, fulfilling picking orders, and sequencing output can also include the following operations. Inventory is introduced into the system at the feed station, which is close to the external bulk warehouse solution. Items intended to go through the individual-based process must be dumped and cleared into inventory containers containing homogeneous goods before being loaded into the system. VCPs intended to be transported through the system must be compatible with the carrier or placed in a compatible container (such as a pallet). Each container is scanned during the ingestion process to determine its identity, which is used to identify its contents and track its location within the module system. Once all pick orders requiring an incoming wave have been completed - and no upcoming waves are expected to require it - then the container is unloaded from the system by completing the ingestion process in reverse.

Picking orders are processed by automated and manual picking stations. Each pick order is completed by requesting two handlers to meet at the pick station: one carries the inventory container for the requested SKU, while the second carries the required outbound container. As soon as the two handlers arrive, the picking station transfers the requested quantity of goods from the stock container to the outbound container. At this point, the handler can transport the container back to the warehouse or to the container's next destination. System scheduling software optimizes the allocation of storage locations, order sequencing, scheduling of arrival times and queuing of handlers to keep picking stations fully utilized, and optimizes the scheduling and use of grids to avoid traffic jams and collisions. Orders not suitable for automated processing are assigned to manual picking stations. Inventory containers and outbound containers are stored near the picking stations designated to process these orders. If possible, organize multiple orders requiring the same container to minimize storage and retrieval operations. Once all containers required to build an order are available, i.e. the required VCPs are introduced and the picking order is completed, then these containers are eligible for sequencing. Containers are sequenced by requesting a handler to transport the container from its current location to any one of multiple programmable motion devices.

Alignment of each carrier (and carrier rack) to each output station 60 may also be accomplished using markings on the floor (as discussed above with reference to Figures 3A-3F and 9A-10B) and through the use of support from the carrier racks. Sensing units 83 on ridge 37 are identified together with highly reflective strips at the ends of each protrusion of the support structure of each output station (as discussed above with reference to Figures 10A and 10B). Additionally, the tabs of each output station may include conveyor tabs as discussed above with reference to Figures 5-8, wherein the conveyor pulls objects away from the open end of each support structure.

FIG. 14 shows an exploded view of a carrier 30 including a base 32 , wheels 34 (one is shown), casters 35 , a middle section 36 , a position control system 39 and a carrier shelf 38 including support ridges 37 . The position control system 39 is mounted on top of the base 32 and is protected by an intermediate portion 36 in the form of a shroud. As discussed in more detail below, the underside of the carrier shelf 38 includes a mounting plate 33 for attachment to a rotary system drive, optionally disposed within a recessed area. Figure 15 shows a top view of the carrier shelf 38 including the support ridge 37 and the detection unit 31, and Figure 16 shows the bottom of the carrier shelf including the rotor attachment unit 33 for coupling to the drive rotor of the rotating system discussed below. Side view. A rotor attachment unit may optionally be provided in a recess in the bottom side surface.

Figures 17 and 18 illustrate opposing views of the position control system 39, showing the base plate 70, the top plate 72, and the scissor stabilizer arms 75 with one end connected to the pivot mount 76 and the other The corresponding end is connected to the sliding mount 77 . The lifting action of the top plate 72 relative to the bottom plate 70 is achieved by a lift motor 74 (shown in FIG. 17 ) mounted on the bottom plate 70 , the output shaft of which is coupled to the top plate 72 via a link arm, as referenced below. Figures 23A and 23B are discussed further. The lift control system also includes two pairs of scissor stabilizing arms 75 that move together with the top plate 72 relative to the bottom plate 70 .

The position control system 39 also includes a rotation control system including a rotation motor 78 (shown in Figures 18, 19 and 20) that controls the rotational movement of the drive rotor 73 relative to the top plate 72. With further reference to Figures 19 and 20, the output shaft of the rotating electrical machine 78 is coupled to the drive portion of the drive rotor 73 via a belt (as shown in Figure 20, in which the rotor belt housing 71 of Figure 19 is removed. The lift control system can be independent of The rotation control system is operated. Figures 21A and 21B illustrate the carrier 30 with the lift system engaged to raise the top plate 72 (Figure 21A) and engaged to lower the top plate 72 (Figure 21B). Figures 22A and 21B 22B respectively shows the carrier 30 with the lifting system similarly engaged, with the middle section shield 33 removed.

As mentioned above, the lift control system includes link arms 86, 88 as shown in Figures 23A and 23B, and the link arms are driven by the output shaft of the lift motor 74 to lift the top plate relative to the bottom plate (as shown in Figure 22A), Or lower the top plate toward the bottom plate (as shown in Figure 22B). Specifically, when the rotor shaft rotates in the first direction, the link arms extend (as shown in Figure 23A), thereby driving the top plate upward. Rotation in the opposite direction allows the linkage arm to return to the lower portion (shown in Figure 23B) with linkage arm 86 adjacent fixed mounting element 82. A portion 80 of the sensor system (eg, a Hall effect sensor) may be mounted on the fixed mounting element 82, and a second portion 84 of the sensor system (eg, a magnet) may be mounted on the linkage arm (eg, 86). As the linkage arm moves adjacent to fixed mounting 82, the sensor system will detect the presence of portion 84 adjacent portion 80, indicating that the top plate is in the lowered position.

Figure 24A shows the carrier 30 including the carrier 38 and the container 20 in a rotated position, and Figure 24B shows the carrier 30 using a rotation system with the carrier 38 and the container 20 in a rotated position (90 degrees). Figure 25 shows a top view of the carrier shelf 38 with support ridges 37 and sensing unit 31, and Figure 26 shows a bottom view of the base 32 of the carrier 30, showing the drive wheels 34, casters 35 and Sensing unit 29.

In addition to the nominal operating mode, the system of the present invention is designed with the following exceptions in mind. Pick orders containing SKUs that are not suitable for automated processing (such as violating weight and size standards) will be sent to manual picking for manual processing. In the manual picking station, team members transfer the required quantity of goods from the stock container to the outbound container. Any VCP that is incompatible with the mover's transport (such as violating weight and size standards) will bypass the track system. Containers detected as being out of place, unexpectedly empty, or prematurely full are automatically flagged as anomalies. When such an exception occurs, the work management system is notified of the fault and can send the container to the feed station for special handling.

During use, containers can be introduced into the system at the input conveyor system and when emptied, these containers can then be assigned an output name and used as output containers. Empty containers can be introduced into or removed from the system as needed to maintain a ready and reasonable supply of usable containers. According to other aspects, the system may employ input storage bags and output boxes, each of which may be moved by the carriers and support structures discussed above. By distributing commands to other stations, static system parts can be maintained while the system is online without hampering operations. This is true for both manual and automated processing stations. By commanding the carrier to move to a location on the perimeter of the system that is accessible to maintenance personnel, the carrier can be serviced without affecting system operation. If a carrier encounters a malfunction that renders it inoperable, the system maintains degraded operation by passing other carriers around the disabled carrier until maintenance personnel can remove the carrier for repairs. Auto scan is expected for IVC and OBC sensing. VCP sensing is expected to require a manual scanning step by team members, as vendor tags may be positioned inconsistently on the VCP.

Control of each of the systems discussed above may be provided by one or more computer processing systems 100 in communication, such as wirelessly, with programmable motion devices, carriers, and other equipment. The computer system also contains knowledge of the location and identification of each storage bin (continuously updated), and contains knowledge of the location and identification of each target bin (also continuously updated). The system therefore directs the movement of storage bins and target bins and retrieves objects from the storage bins and assigns them to the destination bins based on an overall manifest indicating which objects must be provided in which destination bins, e.g. for shipping to distribution or retail locations. In systems according to aspects of the invention, throughput and storage can be scaled independently, and all inventory SKUs can reach all outbound containers. The system is robust to failures due to redundancy, and stock storage bags (storage bins) and outbound boxes (destination bins) can be handled interchangeably.

According to other aspects, the present invention provides a system 110 including a plurality of layers 103, 105, 107 of a processing system, each of the layers including an input conveyor system 12, an automated mobile handler 30, an input station 16 The end capping support structure 22, the intermediate racking location 40, and the output station 60, as discussed above, are shown in Figure 27. Additionally, the system 110 includes an output conveyor system 62 on each level coupled to a plurality of container support insertion stations 120; and a vertical output section 130 including a plurality of vertical conveyors 132, such as screws. conveyor; and an output sequencing series 140 as shown in Figure 28, leading to any of a variety of types of output sequencing systems 140, 140', 140", 140"', as discussed below. Each pallet insertion section 120 provides completed containers 20 on a container support 21 on a conveyor section 128 traveling towards a vertical merge conveyor 132 . Each vertical conveyor 132 feeds a vertical output section conveyor 134 in which completed containers are provided in the desired order on the support 21 to be packed. For example, objects in containers may be provided for packaging (eg, by a person) into shipping bin 141 . Objects are arranged to arrive at specific conveyor sections 134 in a specific order, for example to facilitate the provision of organized groups of objects for processing at a local section or other facility, such as a storage facility or aisles or shelves of a retail store. More efficient handling, such as storage. Other output systems are discussed below.

Referring to FIGS. 29A to 29D , the completed containers 20 on the carrier rack 38 of the automated mobile carrier 30 are loaded onto the end-capping support structure 25 of the output conveyor 62 . Similar to the system described above, the completed container 20 is raised from the plurality of support ridges 37 of the carrier rack 38 (by raising the carrier rack 38) such that the support ridges 37 pass through the plurality of tabs 27 of the end capping support structure 25, e.g. As shown in Figure 29A. The carrier rack is then lowered and the capping support structure 25 is retracted into the capping support structure control system 122 so that the supports 21 pass underneath the completed container 20 along the output conveyor 62 . At this point (shown in Figure 29B), the end-capping support structure 25 is then fully retracted (shown in Figure 29C), allowing the completed container to fall onto the support 21 (shown in Figure 29D). The combined completed container 20 and support 21 may then be directed to the desired conveyor section 128 via a bi-directional conveyor section including a transverse belt 126 .

As described above, completed containers may be provided in shipping bins 141 and each shipping bin 141 includes a pallet-profiled bottom 142, a wall portion 144 with an opening, a wall insert 146, and a top 148, as shown in FIG. 30 . When assembled, the bin 141 can house the container 20 (or object, as discussed below) within the container in a securely closed state, as shown in FIG. 31 . As further shown in Figure 32, the top 148 is adapted to receive the bottom 142 of the pallet profile so that the completed bins 141 can be stacked as shown in Figure 32.

According to other aspects, the system includes an output conveyor system 62 on each level coupled to a plurality of container support insertion stations 120; and a vertical output portion 130 including a plurality of vertical conveyors machine 132, such as a screw conveyor; and an output sorting system 140', as shown in Figure 33. Likewise, each pallet insertion section 120 provides completed containers 20 on container supports 21 on a conveyor section 128 traveling towards the vertical merge conveyor 132 . Each vertical merge conveyor 132 feeds a vertical output section conveyor 134 in which completed containers are provided in the desired order on the support 21 to be packaged. For example, the objects in the container may be unloaded from the container 20 (eg, by a person) and loaded into the transport bin 141 . Containers 20 (as well as supports 21) can be stacked nearby. Objects are arranged to arrive at specific conveyor sections 134 in a specific order, for example to facilitate the provision of organized groups of objects for processing at a local section or other facility, such as a storage facility or aisles or shelves of a retail store. More efficient handling, such as storage. Similar to the system discussed above, the system includes an output conveyor system 62 on each level coupled to a plurality of container support insertion stations 120; and a vertical output section 130 including A plurality of vertical conveyors 132, such as screw conveyors, are shown in Figure 33. Likewise, each pallet insertion section 120 provides a completed container 20 on a container support 21 on a conveyor section 128 traveling towards a vertical conveyor 132 . Each vertical merge conveyor 132 feeds a vertical output section conveyor 134 where completed containers are provided in the desired order on the support 21 to be packaged at the conveyor section 134.

According to other aspects and with reference to Figure 34, completed containers may be provided at the conveyor section 128 (again in a scheduled order) for loading onto additional automated handlers 150. For example, completed containers 20 may be stacked in groups using supports 21 for transport to another processing location in a desired arrangement. For example, each container may be associated with a different shelf, with the group of containers all associated with the same aisle area of a storage facility or retail store. Likewise, the system includes an output conveyor system 62 on each level coupled to a plurality of container support insertion stations 120; and a vertical output section 130 including a plurality of vertical merge conveyors 132, such as a screw conveyor; and an output sorting system 140", as shown in Figure 34.

Referring to Figures 35-39, completed containers may be provided (again in a scheduled order) at the conveyor section 128 for automatic loading onto additional automated handlers 150. Likewise, completed containers 20 may be stacked in groups, for example using supports 21, for transport to another processing location in the desired arrangement. For example, each container may be associated with a different shelf, with the group of containers all associated with the same aisle area of a storage facility or retail store. Likewise, the system includes an output conveyor system 62 on each level coupled to a plurality of container support insertion stations 120; and a vertical output section 130 including a plurality of vertical merge conveyors 132, such as a screw conveyor, as shown in Figure 35.

With further reference to Figure 36, the system can further automatically stack completed containers. The system includes an output conveyor system 62 on each level coupled to a plurality of container support insertion stations 120; and a vertical output section 130 including a plurality of vertical conveyors 132, such as screw conveyor; and output sorting system 140"', as shown in Figure 36. Likewise, each pallet insertion section 120 provides completed containers 20 on the container support 21 on the conveyor section 128, which is oriented Vertical merge conveyors 132 travel. Each vertical merge conveyor 132 feeds a vertical output section conveyor 134 in which completed containers are provided on the support 21 in the desired order to be packed. In Figures 36 to 39 In the system, completed containers can be loaded onto additional automated handlers 150 in the desired order for delivery to a specific location.

Specifically, each vertical output conveyor section 134 leads to a multi-level stacking system 160 that includes a lowest level conveyor 162, a first intermediate level conveyor 164, a second higher intermediate level conveyor 166 and top conveyor 168, as shown in Figures 36 and 39. The system can sequence the delivery of completed containers so that not only one group (e.g., four) goes to a localized distribution location (e.g., an aisle and/or shelf area of a storage facility or retail store), but further provides a stacking sequence. To facilitate the delivery of objects, for example, by providing an upper container for delivery to an upper shelf and a lower container for delivery to a lower shelf.

With further reference to Figures 37A-37D, each conveyor 162, 164, 166, 168 includes a placement system for placing containers 20 and supports 21 onto (either directly or indirectly) an automated handler 150. Referring to Figure 37A, as the containers 20 and supports 21 move along the conveyor (eg, 162), the tongue elements 172 of the stack placement system 170 extend with the moving containers and supports. When reaching the end of the conveyor, the carrier and support move onto the moving tongue element 172 (shown in Figure 37B) and continue to move together until exiting the conveyor 162 (shown in Figure 37C). Tongue elements 172 are movable along opposing tracks 174 . Once resting on tongue element 172 and parked above carrier 150 (again, as shown in Figure 37C), tongue element 172 is rapidly retracted, allowing the container and supports to drop onto automated carrier 150 (or onto already on another container on the automated handler 150, as provided at conveyors 164, 166, 168). According to other aspects, and as shown in Figures 38A and 38B, the system can also employ a fixed alignment bracket 180 over which the support 21 can be easily moved to the tongue element 172, but when the tongue When the shaped element 172 is retracted below the support member 21, the support member 21 will be supported on the fixed alignment bracket. Accordingly, a variety of systems are provided that facilitate the provision of objects that are all associated with the same aisle area of a storage facility or retail store, and even in a specific order to facilitate further processing, such as stacking the objects to the shelves.

According to other embodiments, the system described above can be combined with automated handlers that move the objects themselves, racks that accommodate various placements and removals of objects in close proximity to each other, and along directions that include directional components on both mutually perpendicular grid directions. Used together with automated carrier moves.

For example, FIG. 40 illustrates a portion of an object handling system 210 that includes an input conveyor system 212 that includes an input conveyor 214 that selectively transports containers 220 (e.g., boxes, bins, bags or trays) as well as the objects themselves (such as boxes 206 and bags 208 ), which containers and objects may be of different sizes, are diverted at the bidirectional converter 218 to any of the various input stations 216 . Each input station 216 includes a capped support structure 222 that includes a plurality of tabs 224 (as described above). A plurality of automated mobile handlers 230 may be engaged to move containers and objects from any of a plurality of input stations 216 , between any of a plurality of intermediate racking locations 240 , between a plurality of object handling locations (e.g., , move between any one of 50 shown in Figure 1), and finally move to multiple output stations (e.g., 60 shown in Figure 1) of the output conveying system (e.g., 62 shown in Figure 1) ) any one. The system can dynamically move containers 220 and objects 206, 208 along an input conveyor 214 that also includes empty containers for processing by the system, as described above. The system may be used with the object handling location 50, output station 60, and output conveyor system 62 as described above.

Likewise, the objects within a container can be homogeneous (all objects of the same type) or heterogeneous (including objects of different types). The system 410 of Figure 40 moves containers 220 and objects 206, 208 to any of a plurality of intermediate rack locations 240, noting where each container is located, and allowing any number of objects to be positioned along each rack location, As discussed in more detail below. The system dynamically allocates certain containers to transfer one or more objects out of the corresponding container, and allocates other containers to receive objects, ultimately satisfying the object allocation list. For example, a set of containers for input objects may include objects that are to be processed by placing each input object into a specifically assigned target container for the plurality of objects. The target container of the allocation does not have to be empty when an object is initially allocated to the corresponding container. Likewise, for example, a container containing one or more objects to be included in an assigned target container may be assigned a corresponding target container assignment such that the one or more objects may simply remain in the container. When processing of the container is complete, the completed container is moved to an output station of the output conveyor system, where it can be further processed, for example, for transportation, as discussed above with reference to Figure 1 . In this way, objects can be introduced into the system, in the same containers that will ultimately be used for shipping. Each container includes a unique identification mark (eg, 223 discussed above), and the contents of each container may be known initially. Similarly, each object may include a unique identification mark 205, 207. The system essentially moves objects and containers, as well as objects between containers. As each container becomes full or complete ready for shipping, the container is directed to an output station for further processing.

The movement of each container within the system is monitored, and the movement of each object between containers is also monitored. Each container 220 may be tagged with a unique identification mark 223, and each object (eg, 206, 208) may be tagged with a unique identification mark (eg, 205, 207). Each of the input conveyor system 212, the moving rack 230, the storage rack 240, the programmable motion device (eg, 50 in FIG. 1), and the output conveyor system (eg, 62 in FIG. 1) may each include an associated Detection units (for example, 211, 221, 231, 241) are used to monitor the positions of all containers and objects by detecting identification codes 205, 207, 223. The system is controlled by one or more processing systems 200 that communicate (e.g., via cables or wireless land).

Referring to FIGS. 41A and 41B , each storage shelf 240 includes a sensing unit 241 and an overhead sensing system 243 . The racks are formed by the tabs 224 as discussed above with reference to Figures 1-4B, and the carrier rack support ridges on the automated carrier 230 are spaced to fit between the tabs 224 as described above. However, in the system of Figure 40, the objects themselves (eg, boxes, bags, etc.) are carried by the carrier, and further, the objects can be placed at any position on the shelf formed by the protrusion (eg, on a surface with a surface size smaller than position on the carrier and remove the object from any location on the shelf. As discussed in more detail below, Figure 42B shows object 206 along the width of the shelf next to another already on the shelf protrusion. Object placement. Figures 42A and 42B show an object 408 (in the form of a bag) being placed along the shelf depth next to another object (also a bag) already on the shelf protrusion. Carriers 230 can also be placed between each other Movement over the system of markers 245 that are closely spaced to provide a high-resolution grid. This allows the carrier 230 to move not only along directions aligned with the grid pattern (e.g., the X or Y direction), but also along directions including the X and directional movement of the Y component. This also allows the carrier 230 to move in non-linear directions on a high-resolution grid. Figure 44 shows that each carrier 230 may also include multiple sensing units 227 on its underside, Used to detect marks 245 on a grid pattern, allowing movement in angular and non-linear directions.

Figure 43 shows an automated carrier 230 that includes a base 232 with wheels 234 and casters 235, a middle portion 236 and a load carrier 238. The carrier shelf 236 includes a first set of support ridges 237 having a first height that is higher than a second set of support ridges 239 . The second height of the second set of ridges 239 is higher than the third height of the third set of support ridges 233 . The profile of the carrier shelf 236 is therefore coronal (higher in the centre), with outer support ridges 229 being provided to hold any object thereon, and optionally also including a sensing unit 231 as described above. Likewise, FIG. 44 shows the underside of an automated carrier 239 with multiple tracking sensing units 227 . The carrier 238 is mounted on a position control system (eg, 39) as disclosed above with reference to Figures 17-24B, wherein rotation of the carrier 238 relative to the base 232, and incremental lift control of the carrier 238 relative to the base 232 are provided. .

For example, Figure 45A shows an object 206 next to another object 206' on a set of shelf protrusions 224, the two objects being closely spaced from each other. A set of coronal support ridges of the carrier 238 of the automated handler 230 may be used to selectively remove the object 206 but not the object 206'. Referring to Figure 45B, the carrier rack 236 is raised such that only the support ridges 237 are raised above the tabs 224, thereby lifting the object 206. The remaining support ridges 239, 233 do not rise above the protrusion 224 and therefore do not lift adjacent objects. The height of the outer ridge 229 may be lower than the lowest ridge (eg, 233), or may be formed to a more intermediate height (as shown) to help inhibit objects from sliding out of the carrier during movement of the carrier 230. Figure 46 shows the carrier 236 engaged with an object 208 in the form of a bag, with support ridges 237 and 239 engaging the object. Figure 47 shows the carrier 236 engaged with a larger object 208 bearing a label 207, with the object 208 extending between support ridges 229.

Those skilled in the art will appreciate that many modifications and changes can be made to the embodiments disclosed above without departing from the spirit and scope of the invention.

Claims (40)

1. An object handling system comprising a plurality of remotely actuatable carriers for controlled movement in at least two mutually orthogonal directions, each carrier including a base and a Carrier shelf portions for receiving containers, each said carrier portion being adapted to move in a lifting direction and in a rotational direction about an axis of rotation, said rotational axis being substantially parallel to said lifting direction. 2. The object handling system of claim 1, wherein the carrier portion of each carrier includes a plurality of support ridges. 3. The object handling system of claim 2, wherein the plurality of support ridges are adapted to pass through a container support structure. 4. The object handling system of any one of claims 2 or 3, wherein the plurality of support ridges terminates at a plurality of heights. 5. An object handling system as claimed in any one of claims 2 to 4, wherein each of the plurality of support ridges of each carrier is adapted to engage a plurality of support members of the conveyor. 6. The object handling system of any one of claims 2-5, wherein the plurality of support members includes a plurality of conveyor rollers. 7. The object handling system of any one of claims 2-6, wherein the plurality of support members includes a plurality of conveyor belts. 8. The object handling system of any one of claims 1 to 7, wherein the carrier portion is adapted to move in the lifting direction by a lifting system and in the rotational direction by a rotating system , the rotating system moves in the lifting direction through the lifting system. 9. The object handling system of any one of claims 1-8, wherein the carrier portion is adapted to remain engaged with the rotation system when raised. 10. The object handling system of any one of claims 1-9, wherein the plurality of remotely actuatable carriers are provided for engaging a plurality of containers and a plurality of conveyors to interface with the plurality of Any of the remotely actuatable carriers exchanges containers. 11. An object handling system comprising at least one remotely actuatable carrier for controlled multi-directional movement, said carrier including a base and a carrier portion for receiving containers, said The carrier portion is adapted to move relative to the base in a lifting direction and a rotation direction, and is adapted to place any container and any object on the container onto a plurality of protrusions. 12. The object handling system of claim 11, wherein the carrier portion of the carrier includes a plurality of support ridges. 13. The object handling system of claim 12, wherein the plurality of support ridges are adapted to pass through a container support structure. 14. The object handling system of any one of claims 11-13, wherein the plurality of support ridges are provided on the carrier rack at a plurality of different heights. 15. The object handling system of any one of claims 11-14, wherein each of the plurality of support ridges of the carrier is adapted to engage a plurality of support members of a conveyor. 16. The object handling system of any one of claims 11-15, wherein the plurality of support members includes a plurality of conveyor belts. 17. An object handling system as claimed in any one of claims 11 to 16, wherein the carrier portion is adapted to move up and down by a lifting system and in a rotational direction by a rotation system. 18. The object handling system of claim 17, wherein the carrier portion is adapted to remain engaged with the rotation system when raised. 19. The object handling system of any one of claims 17-18, wherein the carrier portion is adapted to remain engaged with the lifting system while rotating. 20. An object handling system as claimed in any one of claims 11 to 19, wherein the remotely actuatable carrier is provided for engaging with at least one container and at least one conveyor to interface with the remotely actuatable carrier. A moving carrier exchanges the at least one container. 21. An object handling system comprising a plurality of remotely actuatable carriers for controlled multi-directional movement, each carrier including a carrier portion for receiving a container and for supporting a base of said carrier, said base comprising a pair of independently actuable wheels for moving a respective carrier in either of two mutually orthogonal directions, and said carrier being coupled to a A carrier rotation system in which the carrier rotates relative to the base. 22. The object handling system of claim 21, wherein the base further includes a plurality of casters. 23. The object handling system of any one of claims 21-22, wherein the carrier portion includes a plurality of support ridges. 24. The object handling system of claim 23, wherein the plurality of support ridges are coronal such that the support ridges are positioned at different heights. 25. The object handling system of any one of claims 23-24, wherein the plurality of support ridges are adapted to pass through the container support surface. 26. The object handling system of claim 25, wherein the container support surface includes a plurality of conveyor belts. 27. The object handling system of any one of claims 21-26, wherein the object handling system further includes a carrier lifting system for moving the carrier portion in a lifting direction relative to the base. 28. The object handling system of claim 27, wherein the carrier lift system is adapted to remain engaged during actuation of the carrier rotation system. 29. The object handling system of any one of claims 27-28, wherein the carrier rotation system is adapted to remain engaged during actuation of the carrier lift system. 30. The object handling system of any one of claims 27-29, wherein the carrier lift system is independent of the carrier rotation system. 31. An object handling system for handling objects, said object handling system comprising a plurality of remotely actuatable carriers for controlled multi-directional movement, each remotely actuatable carrier comprising: A carrier shelf portion for receiving a container and a base for supporting said carrier shelf, said base including a carrier shelf lifting system including a rotational-to-linear motion converter, and including a means for rotating said carrier shelf relative to said base Carry rack rotation system. 32. The object handling system of claim 31, wherein the base further includes a pair of independently actuable wheels. 33. The object handling system of any one of claims 31-32, wherein the carrier portion includes a plurality of support ridges. 34. The object handling system of claim 33, wherein the plurality of support ridges provide heat dissipation. 35. The object handling system of any one of claims 33-34, wherein the plurality of support ridges are adapted to pass through a container support structure. 36. The object handling system of claim 35, wherein the container support surface includes a plurality of conveyor belts. 37. The object handling system of any one of claims 31 to 36, wherein the object handling system further includes a carrier lifting system for moving the carrier in a lifting direction relative to the base. 38. The object handling system of claim 37, wherein the carrier lift system is adapted to remain engaged during actuation of the carrier rotation system. 39. The object handling system of any one of claims 37-38, wherein the carrier rotation system is adapted to remain engaged during actuation of the carrier lift system. 40. The object handling system of any one of claims 37-39, wherein the carrier lift system is independent of the carrier rotation system.