Automated robotic replenishment system

Patent metadata

Field	Value
Publication number	US-12503308-B2
Application number	US-202217817596-A
Country	US
Kind code	B2
Filing date	Aug 4, 2022
Priority date	Aug 4, 2022
Publication date	Dec 23, 2025
Grant date	Dec 23, 2025

Abstract

An automated robotic replenishment system is described. In an example implementation, the system may include containers adapted to hold items; container transportation devices adapted to transport the containers to a replenishment station; and the replenishment station. The replenishment station may include a container receiving area, a mobile storage unit receiving space, and a robotic arm, which may pick up items from the container in the container receiving area and place the item into a mobile storage unit in the mobile storage unit receiving space. The system may also include an automated guided vehicle that transports the mobile storage unit between the replenishment station and a storage area of a fulfillment center.

First claim

What is claimed is:

1 . A method comprising:
identifying, by one or more processors communicatively coupled with a replenishment station, one or more item types of a first set of items; instructing, by the one or more processors, one or more automated guided vehicles (“AGVs”) to transport a first mobile storage unit to a first space of one or more mobile storage unit spaces at the replenishment station, the first mobile storage unit being selected from a plurality of mobile storage units based on the one or more item types; transporting, by one or more conveyance devices, the first set of items to the replenishment station, the replenishment station including a robotic arm, one or more conveyance device receiving areas, and the one or more mobile storage unit spaces; instructing, by the one or more processors, the replenishment station to move a plurality of the first set of items from the one or more conveyance devices into the first mobile storage unit including:
instructing, by the one or more processors, the replenishment station to move a first item of the first set of items from the one or more conveyance devices into the first mobile storage unit at the first space; and
counting, by the one or more processors, the plurality of the first set of items moved into the first mobile storage unit by the replenishment station.

2 . The method of claim 1 , further comprising:
receiving, by the one or more processors, scan data identifying a pallet, the pallet holding a plurality of items having a plurality of item types, the plurality of items including the first set of items; and moving one or more of the first set of items having the one or more item types from the pallet onto the one or more conveyance devices.

3 . The method of claim 2 , further comprising:
determining, by the one or more processors, the plurality of item types based on the scan data identifying the pallet; and responsive to receiving the scan data, instructing, by the one or more processors, the one or more AGVs to transport the first mobile storage unit from a storage area of a fulfillment center to a staging area associated with the replenishment station.

4 . The method of claim 2 , further comprising:
determining, by the one or more processors, a set of mobile storage units associated with the plurality of item types, the set of mobile storage units being in a storage area of a fulfillment center, each of the set of mobile storage units holding less than a full capacity of an item associated with that mobile storage unit, the set of mobile storage units including the first mobile storage unit; instructing, by the one or more processors, the one or more AGVs to transport the set of mobile storage units from the storage area to a staging area associated with the replenishment station; and instructing, by the one or more processors, the one or more AGVs to transport the first mobile storage unit from the staging area associated with the replenishment station to the first space at the replenishment station.

5 . The method of claim 2 , further comprising:
determining, by the one or more processors, a set of mobile storage units associated with the plurality of item types based on the scan data, each of the set of mobile storage units storing at least one of the plurality of item types; and determining, by the one or more processors, a subset of the set of mobile storage units based on a current quantity of items stored in each of the subset of mobile storage units, the first mobile storage unit being selected from the subset of the mobile storage units.

6 . The method of claim 1 , further comprising:
placing the first set of items in a container in a decanting area of a fulfillment center, the one or more conveyance devices including the container transported between the decanting area and the one or more conveyance device receiving areas of the replenishment station by one or more of a conveyor belt, conveyor rollers, and the one or more AGVs.

7 . The method of claim 1 , wherein identifying the one or more item types of the first set of items includes:
receiving, by the one or more processors, scan data at the replenishment station, the scan data identifying one or more of the one or more item types and the one or more conveyance devices.

8 . The method of claim 1 , wherein identifying the one or more item types of the first set of items includes:
receiving, by the one or more processors, first scan data identifying the one or more item types at a decanting area; receiving, by the one or more processors, second scan data identifying a container at the decanting area, the one or more conveyance devices including the container; associating, by the one or more processors, the container with the one or more item types in computer memory accessible to the one or more processors; placing the first set of items into the container; and identifying, by the one or more processors, the one or more item types using the association of the container with the one or more item types.

9 . The method of claim 1 , further comprising:
identifying, by the one or more processors, a second set of items having a second item type, the first set of items being transported to the replenishment station by a first conveyance device of the one or more conveyance devices, the second set of items being transported to the replenishment station by a second conveyance device of the one or more conveyance devices; based on the second item type, instructing, by the one or more processors, the one or more AGVs to transport a second mobile storage unit to a second space of the one or more mobile storage unit spaces, the second mobile storage unit being selected from the plurality of mobile storage units based on the second item type; and instructing, by the one or more processors, the replenishment station to move the one or more second items from the second conveyance device into the second mobile storage unit.

10 . The method of claim 1 , further comprising:
determining, by the one or more processors, a successful movement of the first item from the one or more conveyance devices into the first mobile storage unit; and responsive to determining the successful movement, instructing, by the one or more processors, the one or more AGVs to transport the first mobile storage unit from the first space at the replenishment station to a storage area.

11 . A system, comprising:
one or more containers adapted to hold one or more items; one or more container transportation devices adapted to transport the one or more containers to one or more container receiving areas of a replenishment station, wherein each of the one or more container transportation devices include:
a horizontal sliding mechanism supporting a container and allowing the container to slide between a decanting area and a container receiving area of the one or more container receiving areas;
the replenishment station including the one or more container receiving areas, one or more mobile storage unit receiving spaces, and a robotic arm, the robotic arm adapted to pick up the one or more items from the one or more containers in the one or more container receiving areas, move the one or more items, and place the one or more items into one or more mobile storage units in the one or more mobile storage unit receiving spaces; and one or more automated guided vehicles (“AGVs”) adapted to transport the one or more mobile storage units between the one or more mobile storage unit receiving spaces and a mobile storage unit storage area.

12 . The system of claim 11 , wherein each of the one or more container transportation devices incl

Assignees

• Staples Inc

Inventors

• Douglas Matthew Robert
• Gerli Paolo
• Cox Gregory Patrick
• Kalra Amit
• Lam Brandon
• Tewari Ruchi
• Jarvis Daniel
• Variar Nikhil
• Challapalli Naveen

Classifications

• B65G1/1371

  with data records · CPC title

• B66F9/063

  Automatically guided · CPC title

• B07C3/08

  using arrangements of conveyors {(transport of sheets B65H; transport in general B65G)} · CPC title

• B07C5/38

  Collecting or arranging articles in groups · CPC title

• G06K7/10861

  sensing of data fields affixed to objects or articles, e.g. coded labels (postal sorting B07C3/14, conveying articles B65G47/48) · CPC title