Order picking using mobile robots on elevated pathways

Patent metadata

Field	Value
Publication number	US-2021039886-A1
Application number	US-201916534181-A
Country	US
Kind code	A1
Filing date	Aug 7, 2019
Priority date	Aug 7, 2019
Publication date	Feb 11, 2021
Grant date	—

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 integration of elevated pathways that are dedicated for mobile robots to use in conjunction with a human-operated order picker lift to transport items for order fulfillment processes in an efficient manner. In some embodiments, the elevated pathways for the mobile robots can be at least partially integrated into storage systems such as pallet racking. 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 . A material handling system, comprising:
a rack storage system in a warehouse; an elevated pathway at least partially integrated into the rack storage system at a level of elevation above a floor of the warehouse, wherein the elevated pathway comprises two lanes for mobile robots; a first mobile robot configured to transport a cargo holder on the elevated pathway; and a second mobile robot configured to transport the cargo holder on the elevated pathway.

2 . The system of claim 1 , wherein one of the two lanes is a parking lane defining a plurality of mobile robot parking spots, wherein at least one of the plurality of mobile robot parking spots is associated with each aisle in the warehouse.

3 . The system of claim 2 , wherein one of the two lanes is a transport lane configured to allow the first and second mobile robots to travel along the elevated pathway, wherein the first mobile robot is configured to:
move into a first mobile robot parking spot in the parking lane; receive a first cargo holder from an order picker in the first mobile robot parking spot in the parking lane; move, in response to receiving the first cargo holder from the order picker, into the transport lane of the elevated pathway; and transport the first cargo holder to one or more remote locations in the warehouse via the transport lane of the elevated pathway.

4 . The system of claim 1 , wherein the elevated pathway is at least partially integrated into an end of the rack storage system.

5 . The system of claim 1 , wherein the elevated pathway comprises a third lane for mobile robots, wherein the third lane is another transport lane configured to allow the first and second mobile robots to travel along the elevated pathway.

6 . The system of claim 1 , wherein the elevated pathway is at least partially integrated into a middle of the rack storage system.

7 . The system of claim 6 , wherein the elevated pathway comprises three lanes for mobile robots, wherein two of the three lanes are parking lanes on opposing sides of the elevated pathway and one of the three lanes is a first transport lane positioned between the parking lanes.

8 . The system of claim 7 , wherein the elevated pathway further comprises a fourth lane for mobile robots defining a second transport lane, wherein the second transport lane is positioned between the parking lanes.

9 . The system of claim 1 , further comprising one or more elevated pathways at least partially integrated into the rack storage system at multiple levels of elevation above the floor of the warehouse.

10 . The system of claim 3 , wherein the second mobile robot is configured to move into a second mobile robot parking spot in the parking lane with a second cargo holder, such that the second cargo holder can be transferred to the order picker for picking.

11 . The system of claim 10 , wherein the second cargo holder is filled with items for stowing and the second mobile robot is further configured to:
move into the second mobile robot parking spot in the parking lane with the second cargo holder, such that the second cargo holder can be transferred to the order picker for stowing and then picking; receive, from the order picker, the second cargo holder that is filled with items from picking by the order picker; move, in response to receiving the second cargo holder from the order picker, into the transport lane of the elevated pathway; and transport the second cargo holder to one or more remote locations in the warehouse via the transport lane of the elevated pathway.

12 . The system of claim 1 , wherein the cargo holder is a cage.

13 . The system of claim 1 , wherein the cargo holder is a pallet.

14 . The system of claim 1 , wherein the cargo holder remains on a mobile robot that is parked in a mobile robot parking spot in the parking lane of the elevated pathway while an order picker transports items from one or more storage locations in the rack storage system to the cargo holder on the mobile robot.

15 . A method of material handling, the method comprising:
controlling a first mobile robot to park in a first mobile robot parking spot in a parking lane of an elevated pathway that is integrated into a rack storage system at a level of elevation above a floor of a warehouse, the first mobile robot being configured to receive a first cargo holder from an order picker, wherein the first cargo holder is configured for receiving items being picked from storage; controlling a second mobile robot to park in a second mobile robot parking spot in the parking lane of the elevated pathway, wherein the second mobile robot is transporting a second cargo holder; controlling, after receiving the first cargo holder from the order picker, the first mobile robot to move into a transport lane of the elevated pathway; and controlling the first mobile robot to transport the first cargo holder received from the order picker to one or more remote locations in the warehouse via the transport lane of the elevated pathway.

16 . The method of claim 15 , further comprising controlling the second mobile robot to move from the second mobile robot parking spot into the first mobile robot parking spot such that the second cargo holder can be transferred to the order picker.

17 . The method of claim 15 , further comprising:
controlling the second mobile robot to park in the first mobile robot parking spot, the second mobile robot being configured to receive the second cargo holder from the order picker, wherein the second cargo holder is configured for receiving items being picked from storage; controlling a third mobile robot to park in the second mobile robot parking spot in the parking lane of the elevated pathway, wherein the third mobile robot is transporting a third cargo holder; controlling, after receiving the first cargo holder from the order picker, the second mobile robot to move into the transport lane of the elevated pathway; controlling the second mobile robot to transport the second cargo holder received from the order picker to one or more remote locations in the warehouse via the transport lane of the elevated pathway; and controlling the third mobile robot to move from the second mobile robot parking spot into the first mobile robot parking spot such that the third cargo holder can be transferred to the order picker.

18 . 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 that is parked in a first mobile robot parking spot in a parking lane of an elevated pathway that is integrated into a rack storage system at a level of elevation above a floor of a warehouse, the first cargo holder with the one or more first ordered items in or on it such that the first mobile robot can move into a transport lane of the elevated pathway and transport the first cargo holder with the one or more first ordered items in or on it to one or more remote locations in the warehouse; 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 that is parked in a second mobile robot parking spot in the parking lane of the elevated pathway, a second cargo holder with o

Assignees

• Target Brands Inc

Inventors

• Lisso Gregory
• Mutarelli Gervasio
• Gardner Thomas
• Wagle Poojesh

Classifications

• B65G1/1375 Primary

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