Order picking systems and methods using mobile robots

Patent metadata

Field	Value
Publication number	US-11008167-B2
Application number	US-201916519395-A
Country	US
Kind code	B2
Filing date	Jul 23, 2019
Priority date	Jul 30, 2018
Publication date	May 18, 2021
Grant date	May 18, 2021

Abstract

Robotic automation and methods described herein can be used to enhance the efficiencies of order fulfillment and inventory stowage processes. For example, this document describes the use of mobile robots in conjunction with a human order picker to pick and transport items for order fulfillment processes in an efficient manner. The described systems and methods allow the elimination of human labor particularly related to transporting saleable goods and similar items. Mobile robots take over many of the tasks related to transporting the picked items. Accordingly, the efficiency of the human order picker, as measured by the number of line items picked per hour for example, is greatly enhanced.

First claim

What is claimed is:

1. An order picking system, comprising:
an order picker configured to transport a cargo holder configured for receiving items picked from storage;
a first mobile robot configured to transport the cargo holder;
a second mobile robot configured to transport the cargo holder; and
a warehouse fleet manager system in wireless communication with each of the order picker and the first and second mobile robots, the warehouse fleet manager system configured to:
control the first mobile robot to move in correspondence with movements of the order picker;
control the second mobile robot to move in correspondence with the movements of the order picker;
control the first mobile robot to move into a first cargo holder transfer position proximate to the order picker to receive a first cargo holder from the order picker;
control the first mobile robot to transport the first cargo holder received from the order picker to one or more remote locations; and
control the second mobile robot to move into a second cargo holder transfer position such that a second cargo holder can be transferred to the order picker.

2. The system of claim 1 , wherein the first and second cargo holders are each cages.

3. The system of claim 2 , wherein the order picker lowers the first cargo holder onto a floor and then the first mobile robot moves under the first cargo holder to receive it.

4. The system of claim 2 , wherein the order picker lowers the first cargo holder onto the first mobile robot and the first mobile robot receives it.

5. The system of claim 1 , wherein the cargo holders are each pallets.

6. The system of claim 5 , wherein the order picker lowers the first cargo holder onto the first mobile robot and the first mobile robot receives it.

7. The system of claim 1 , wherein the first and second cargo holder transfer positions are a same position.

8. The system of claim 1 , wherein the first and second cargo holder transfer positions are differing positions.

9. A method of order picking, the method comprising:
controlling a first mobile robot to move in correspondence with movements of an order picker that is transporting a first cargo holder configured for receiving items being picked from storage, the first mobile robot being configured to receive the cargo holder from the order picker;
controlling a second mobile robot to move in correspondence with the movements of the order picker, wherein the second mobile robot is transporting a second cargo holder;
controlling the first mobile robot to move into a cargo holder transfer position proximate to the order picker to receive the first cargo holder from the order picker;
controlling the first mobile robot to transport the first cargo holder received from the order picker to one or more remote locations; and
controlling the second mobile robot to move into the cargo holder transfer position such that the second cargo holder can be transferred to the order picker.

10. The method of claim 9 , wherein each of the controlling steps is performed by a warehouse fleet manager system.

11. The method of claim 10 , wherein the warehouse fleet manager system is in wireless communication with each of the order picker and the first and second mobile robots.

12. The method of claim 9 , wherein the first and second mobile robots are controlled to shadow the movements of the order picker.

13. The method of claim 9 , further comprising controlling a third mobile robot to move into proximity of the second mobile robot, wherein the third mobile robot is transporting a third cargo holder.

14. The method of claim 9 , further comprising controlling the second mobile robot to transport the second cargo holder received from the order picker to one or more remote locations.

15. A method of picking ordered items and stowing replenishment items, the method comprising:
a) transferring, by a worker operating an order picker, one or more first ordered items from first storage locations and putting the one or more first ordered items in or on a first cargo holder that is engaged with the order picker;
b) transferring, from the order picker to a first mobile robot, the first cargo holder with the one or more first ordered items in or on it;
c) after the transferring of the first cargo holder with the one or more first ordered items in or on it to the first mobile robot, transferring, from a second mobile robot, a second cargo holder with one or more replenishment items in or on it such that the second cargo holder with the one or more replenishment items in or on it becomes engaged with the order picker;
d) transferring, by the worker operating the order picker, the one or more replenishment items from the second cargo holder that is engaged with the order picker into storage locations; and
e) after the transferring of the one or more replenishment items into the storage locations, transferring, by the worker operating the order picker, one or more second ordered items from second storage locations and putting the one or more second ordered items in or on the second cargo holder that is engaged with the order picker.

16. The method of claim 15 , further comprising:
f) transferring, from the order picker to the second mobile robot, the second cargo holder with the one or more second ordered items in or on it.

17. The method of claim 16 , wherein, after the second cargo holder with the one or more second ordered items in or on it is transferred to the second mobile robot, the second mobile robot transports the second cargo holder with the one or more second ordered items in or on it to one or more remote locations.

18. The method of claim 15 , wherein, after the first cargo holder with the one or more first ordered items in or on it is transferred to the first mobile robot, the first mobile robot transports the first cargo holder with the one or more first ordered items in or on it to one or more remote locations.

19. The method of claim 15 , wherein the first and second cargo holders are each cages.

20. The method of claim 15 , wherein the cargo holders are each pallets.

Assignees

• Target Brands Inc

Inventors

• Lisso Gregory
• Mutarelli Gervasio

Classifications

• B65G1/0407

  using stacker cranes (constructional features of stacker cranes B66F9/06) · CPC title

• B65G1/0492

  with cars adapted to travel in storage aisles · CPC title

• B65G1/1375 Primary

  the orders being assembled on a commissioning stacker-crane or truck · CPC title