Patent Application
20230028034
The embodiments herein, in general, relate to automated storage and retrieval systems, order fulfillment, and supply chain logistics. More particularly, the embodiments herein relate to a multi-zone automated storage and retrieval system and auto-induction processes employing consolidation and exchange of storage units.
A conventional supply chain comprises a series of discrete transactional entities, for example, manufacturers, producers, suppliers, vendors, warehouses, transportation companies, distribution centers, order fulfillment centers, retailers, etc. Supply chain management allows sourcing and delivery of inventory from manufacturers and producers to end customers and end users. Several technologies have emerged that are altering conventional methods of managing a supply chain. Customer demand for individualized products and stronger granularization of orders are growing. Customers also rely on the availability of product items that can be purchased in different temperature states, for example, chilled, refrigerated and frozen states. As electronic commerce (e-commerce) continues to grow at a significant rate and overtake conventional brick and mortar retail practices, many businesses are facing notable challenges of maintaining or gaining relevance in an online marketplace and being able to compete with prominent players in the space.
Supply chain management require systems that execute storage and retrieval of a large number of different products. For example, e-commerce and retail platforms that sell multiple product lines require systems that are able to store hundreds of thousands of different product lines having different temperature requirements. Different product items need to be maintained at different prescribed temperatures within a storage system, while the product items are stored and/or transported, and/or while orders are fulfilled. Some product items need to be maintained in a chilled or frozen environment to ensure freshness, while other product items can be stored or transported at ambient temperature. Conventional systems typically require a walk-in cooler or freezer to be pre-constructed or additional components to be installed around a storage system, which substantially expands a two-dimensional (2D) footprint of the storage system and increases the cost and complexity of installing and operating the storage system across multiple environmentally controlled zones. There is a need for a freestanding, high density, automated storage and retrieval system with multiple integrated, environmentally controlled zones that eliminates construction of walk-in, environmentally controlled zones to buildings and installation of separate storage systems operating independently within each environmentally controlled zone.
Moreover, supply chains and warehouse operations of conventional e-commerce and retail platforms are substantially dependent on their ability to organize, control, store, retrieve, and return product items to various storage units. In some of these implementations, robotic or automated mechanisms are used for managing the storage units and operations related to the contents of the storage units. These mechanisms navigate through one or more grids of conveyor systems and transportation paths to access the storage units for a variety of different operations, for example, inducting a storage unit into a storage system, retrieving a storage unit from the storage system, moving the storage unit from one location or workstation to another for handling, conducting operations upon the storage unit, returning the storage unit to a location or a workstation in a warehouse or to the storage system, etc. There is a need for optimally coordinating the movement of one or more robotic or automated mechanisms with respect to a storage system for improving storage and retrieval of a large number of different product items having different temperature requirements. Some systems require different groups or classes of robotic handlers that are configured to operate in different environmentally controlled zones of a storage system. There is a need for a common class of robotic handlers that are configured to operate in all the different environmentally controlled zones with optimized buffering of the robotic handlers within the storage system when the robotic handlers transition between the different environmentally controlled zones.
Furthermore, there is a need for providing convenient access to storage units within a storage system and maintaining the prescribed temperature of the storage units containing product items that require a cooled temperature by avoiding exposure of the storage units to an uncooled environment which may affect the quality and freshness of these product items. Some conventional storage facilities comprise storage systems and a fleet of robotic handlers disposed in a cooled, chilled or freezer environment. In these facilities, the robotic handlers reside and operate in the cooled, chilled or freezer environment on a full-time basis, which may substantially affect the operating characteristics of the robotic handlers. Other conventional systems allow robotic handlers to traverse only an upper track of a storage system, thereby allowing operation of the robotic handlers in generally ambient temperature conditions when riding atop the track, and exposure to colder temperatures of cooled storage columns when operating over the cooled storage columns from which insulating covers have been removed to access the storage units therein. There is a need for reducing exposure of robotic or automated mechanisms to non-ambient, cooled, chilled or freezer environments while these mechanisms operate in a storage system, as increased exposure may adversely affect their circuitry and componentry and reduce their throughput performance. Moreover, there is a need for optimal positioning of workstations with respect to a storage system, continuous to all environmentally controlled zones, such that all robotic or automated mechanisms and therefore all storage units from each environmentally controlled zone are accessible at all workstations, thereby allowing order pickers to work in the comfort of ambient temperatures while picking product items that are chilled or frozen. Furthermore, storage units are typically stacked on top of each other and accessed with an unstacking method. The stacking method constrains air flow and requires a plenum to circulate cold air throughout the storage units in storage and a large number of air circulating devices.
Furthermore, a conventional supply chain does not incorporate material handling equipment in all its entities for performing various supply chain activities and inventory exchanges between the entities. There is a need for an exchange technique of forward and reverse storage units during auto-induction at a transactional entity, for example, a micro-fulfillment center from a servicing distribution center during a replenishment process. There is a need for improving shipping and receiving processes and eliminating associated staging areas in micro-fulfillment and distribution center sites to substantially reduce labor, real estate and resource requirements while streamlining logistics, and to make operations predictable, orderly, and easier to monitor in real time over disorderly, chaotic approaches used in conventional supply chains.
Hence, there is a long-felt need for a self-contained, freestanding, multi-zone automated storage and retrieval system having different, vertically delineated, environmentally controlled zones for storing multiple different product items requiring varying degrees and types of environmental control parameters, and optimally controlled robotic storage/retrieval vehicles and conveniently accessible storage units configured to operate in these different environmentally controlled zones, which address the above-recited problems associated with the related art.
This summary is provided to introduce a selection of concepts in a simplified form that are further disclosed in the detailed description. This summary is not intended to determine the scope of the claimed subject matter.
The embodiments herein address the above-recited need for a self-contained, freestanding, multi-zone automated storage and retrieval system (ASRS) having different, vertically delineated, environmentally controlled zones for storing multiple different product items requiring varying degrees and types of environmental control parameters, and optimally controlled robotic storage/retrieval vehicles (RSRVs) and conveniently accessible storage units configured to operate in these different environmentally controlled zones. The environmentally controlled zones are temperature zones, for example, ambient, chilled and freezer zones of varying environmental control parameters. The environmentally controlled zones in the multi-zone ASRS do not share the same footprint. The multi-zone ASRS maintains different product items at different prescribed temperatures therewithin, while the product items contained within storage units are stored and/or transported, and/or while orders are fulfilled. The multi-zone ASRS is a freestanding, high density, ASRS with multiple integrated, environmentally controlled zones.
The multi-zone ASRS disclosed herein comprises a plurality of storage locations configured to accommodate placement and storage of storage units therein. The multi-zone ASRS further comprises a first storage zone, a second storage zone, at least one barrier, one or more portals, at least one track layout, and one or more RSRVs. The first storage zone comprises a first group of storage locations. The second storage zone comprises a second group of storage locations. In an embodiment, the first storage zone and the second storage zone differ from one another in environmental control equipment installed therein or operating characteristics of the environmental control equipment. In another embodiment, the first storage zone or the second storage zone is a cooled storage zone having a lower environmental operating temperature than the other of the first storage zone and the second storage zone.
The barrier(s) isolates the second storage zone from the first storage zone. The portal(s) opens through the barrier(s) between the first storage zone and the second storage zone. The track layout(s) comprises a first track area occupying the first storage zone, a second track area occupying the second storage zone, and one or more connective track segments interconnecting the first track area and the second track area through the portal(s) configured in the barrier(s). In an embodiment, the track layout comprises an upper track layout positioned above the storage locations. In this embodiment, the barrier(s) comprises an upper portion standing upright from the upper track layout, and the portal(s) is configured to open through the barrier(s) at the upper portion thereof to accommodate a connective track segment of the upper track layout that interconnects the first track area and the second track area of the upper track layout. In an embodiment, the barrier isolating the second storage zone from the first storage zone comprises an upright barrier wall separating the first storage zone and the second storage zone. The connective track segment(s) spans through the portal(s) from one side of the upright barrier wall to another side of the upright barrier wall.
In another embodiment, the track layout comprises a lower track layout positioned below the storage locations. In this embodiment, the barrier(s) comprises a lower portion standing upright from the lower track layout, and the portal(s) is configured to open through the barrier(s) at the lower portion thereof to accommodate a connective track segment of the lower track layout that interconnects the first track area and the second track area of the lower track layout. In an embodiment, the storage units stored in the first group of storage locations and the second group of storage locations are accessible by any one of a plurality of workstations attached to the lower track layout that extends continuous to the first storage zone and the second storage zone. The multi-zone ASRS provides convenient access to the storage units and maintains a prescribed temperature of the storage units containing product items that require a cooled temperature by avoiding exposure of the storage units to an uncooled environment. The embodiments herein implement optimal positioning of workstations with respect to the multi-zone ASRS, continuous to all environmentally controlled storage zones, such that all RSRVs and therefore all storage units from each environmentally controlled storage zone are accessible at all workstations, thereby allowing order pickers to work in the comfort of ambient temperatures while picking product items that are chilled or frozen.
In an embodiment, the track layout(s) is positioned above the storage locations of the multi-zone ASRS. In this embodiment, the second storage zone comprises an enclosed attic space positioned above the track layout(s) and isolated from the first storage zone. The enclosed attic space is delimited by boundary walls of the second storage zone. At least one of the boundary walls is separate and discrete from building walls of a facility that accommodates the multi-zone ASRS. The enclosed attic space is isolated from the first storage zone and from a surrounding space of the facility. In an embodiment, the boundary walls of the enclosed attic space are separate and discrete from the building walls of the facility. In an embodiment, the boundary walls are mounted to frame members of a gridded storage structure of the multi-zone ASRS that delimits the second group of storage locations. In another embodiment, the first storage zone is free of the enclosed attic space and is open to a surrounding environment of the facility that accommodates the multi-zone ASRS. In this embodiment, the environmental control equipment is mounted in the enclosed attic space of the second storage zone.
The multi-zone ASRS comprises a common class of robotic handlers or RSRVs that are configured to operate in all the different environmentally controlled storage zones with optimized buffering of the RSRVs within the multi-zone ASRS when the RSRVs transition between the different environmentally controlled storage zones. The upper track layout and the lower track layout of the multi-zone ASRS allow transitioning of the RSRVs to the different environmentally controlled storage zones. The RSRV(s) is configured to deposit and retrieve the storage units to and from the storage locations. The RSRV(s) is further configured to travel on the track layout(s) on both the first track area and the second track area to respectively access the first group of storage locations and the second group of storage locations therefrom. The RSRV(s) is further configured to travel between the first track area and the second track area via the connective track segments connected therebetween. In an embodiment, the storage locations of the multi-zone ASRS are arranged in storage columns configured to receive the placement of the storage units therein. The RSRV(s) is configured to travel on at least one track layout between access locations at which different storage columns are accessible by the RSRVs to deposit and retrieve the storage units into and from the storage columns. In an embodiment, the access locations comprise unoccupied access shafts around which the storage columns are clustered and through which the RSRVs are configured to travel to access multiple levels of the storage columns. Each of the unoccupied access shafts is neighbored by at least one of the storage columns to and from which the storage units are placeable and retrievable by the RSRVs from within each of the unoccupied access shafts.
In an embodiment, the multi-zone ASRS further comprises a third storage zone isolated from both the first storage zone and the second storage zone by at least one additional barrier. The third storage zone comprises a third group of storage locations. The multi-zone ASRS further comprises at least one additional portal opening through the additional barrier(s) between the third storage zone and at least one of the first storage zone and the second storage zone. The additional portal(s) is configured to accommodate travel of the RSRV(s) therethrough. In an embodiment, the additional portal(s) comprises portals opening to both the first storage zone and the second storage zone. In an embodiment, the additional barrier(s) comprises an upper portion standing upright from the upper track layout of the multi-zone ASRS. In this embodiment, the additional portal(s) comprises at least one upper portal opening through the additional barrier(s) at the upper portion thereof. The first storage zone, the second storage zone, and the third storage zone differ from one another in environmental control equipment installed therein or operating characteristics of the environmental control equipment. The first storage zone, the second storage zone, and the third storage zone are accessible by the RSRV(s).
In an embodiment, the multi-zone ASRS further comprises one or more buffer spots. Each of the buffer spots is positioned at a location on the track layout(s) and accessible by the RSRV(s) from the track layout(s). Each of the buffer spots is configured to temporarily hold one of the storage units thereon. In an embodiment, at least one of the buffer spots is positioned proximal to a respective one of the portals. In an embodiment, one or more buffer spots comprise a plurality of buffer spots. In this embodiment, at least one of the buffer spots is positioned in each of the first storage zone and the second storage zone.
The multi-zone ASRS further comprises a computerized control system (CCS) in operable communication with the RSRVs. The CCS comprises a network interface coupled to a communication network, at least one processor coupled to the network interface, and a non-transitory, computer-readable storage medium communicatively coupled to the processor(s). The non-transitory, computer-readable storage medium of the CCS is configured to store computer program instructions, which when executed by the processor(s) of the CCS, cause the processor(s) to control operation of the RSRVs in the multi-zone ASRS. As part of a retrieval task associated with the second storage zone requiring retrieval of a targeted one of the storage units stored in the second storage zone, the CCS assigns the retrieval task associated with the second storage zone to a first RSRV selected from among the RSRVs located in the first storage zone; and issues commands to the first RSRV to: (a) travel into the second storage zone via one of the portals opening thereinto from the first storage zone; and (b) during the travel, prior to entering the second storage zone through that portal, drop off one of the storage units currently carried on the first RSRV at one of the buffer spots in the first storage zone.
In additional steps of the retrieval task associated with the second storage zone, the CCS further issues commands to the first RSRV to: upon entry into the second storage zone, pick up a buffered storage unit from one of the buffer spots in the second storage zone; travel from that buffer spot in the second storage zone toward an access location in the second storage zone from which the targeted storage unit stored in the second storage zone is retrievable; and prior to retrieving the targeted storage unit at the access location, deposit the picked up storage unit into an available one of the storage locations in the second storage zone. In an embodiment, the CCS selects the available storage location in the second storage zone from among any of the storage locations available upstream and positioned en route from the buffer spot in the second storage zone to the access location, and/or any of the storage locations available downstream and positioned en route from the access location to an exit portal.
The CCS completes the retrieval task associated with the second storage zone by issuing commands to the first RSRV to retrieve the targeted storage unit stored in the second storage zone and perform delivery of the targeted storage unit to a workstation to facilitate picking of product from the targeted storage unit at the workstation. Subsequent to the completion of the retrieval task associated with the second storage zone and picking of the product from the targeted storage unit carried by the first RSRV, the CCS issues commands to the first RSRV or a different RSRV to deposit the targeted storage unit onto one of the buffer spots in the second storage zone and then exit the second storage zone. As part of a subsequent retrieval task associated with the second storage zone and assigned to a second RSRV selected from among the first RSRV and a different RSRV, to retrieve another targeted storage unit stored in the second storage zone, the CCS issues commands to the second RSRV to: (a) enter the second storage zone; (b) pick up the deposited storage unit from the buffer spot in the second storage zone; (c) travel from the buffer spot in the second storage zone toward an access location in the second storage zone from which the other targeted storage unit is retrievable; and (d) prior to retrieving the other targeted storage unit at the access location, deposit the picked up storage unit from the buffer spot in the second storage zone into an available one of the storage locations in the second storage zone. In an embodiment, the CCS selects the available storage location in the second storage zone from among any of the storage locations available upstream and positioned en route from the buffer spot in the second storage zone to the access location, and/or any of the storage locations available downstream and positioned en route from the access location to an exit portal.
In an embodiment, the CCS assigns a task of depositing an unneeded one of the storage units stored in the second storage zone into one of the storage locations in the second group, to one of the RSRVs that is assigned to retrieve a needed one of the storage units stored in the second storage zone from the second group of the storage locations.
In an embodiment, the second storage zone is characterized by a harsher operating environment for the RSRVs than the first storage zone. In this embodiment, during the selection of one of the RSRVs to assign to any retrieval task associated with the second storage zone, the CCS prioritizes the RSRVs of a longer absence from the second storage zone over the RSRVs of a more recent presence in the second storage zone. In an embodiment, the CCS records an exit time at which any of the RSRVs last exited the second storage zone. In this embodiment, during the selection of the RSRVs for any retrieval task associated with the second storage zone, the CCS compares exit times of the RSRVs for prioritizing the RSRVs of the longer absence from the second storage zone over the RSRVs of the more recent presence in the second storage zone. The embodiments herein reduce exposure of the RSRVs to non-ambient, cooled, chilled or freezer environments while the RSRVs operate in the multi-zone ASRS, thereby protecting their circuitry and componentry and maintaining their throughput performance.
In an embodiment, the storage units containing product inventory are received at a receiving facility on a transport vehicle from a supply facility and automatically inducted into an ASRS, for example, the multi-zone ASRS or a single-zone ASRS, at the receiving facility. The multi-zone ASRS or the single-zone ASRS is of a type compatible with a predetermined type of each of the storage units. In this embodiment, the storage units containing the product inventory are exchanged for outgoing storage units, for example, empty storage units, from the receiving facility, thereby loading the outgoing storage units onto the transport vehicle for transit from the receiving facility. Both the storage units containing the product inventory and the outgoing storage units are of the same predetermined type compatible with the ASRS of the receiving facility. The embodiments herein implement a 1:1 exchange technique of forward and reverse storage units during auto-induction at the receiving facility, that is, a micro-fulfillment center, during a replenishment process. The embodiments herein improve shipping and receiving processes and eliminate associated staging areas in micro-fulfillment and distribution center sites to substantially reduce labor, real estate and resource requirements while streamlining logistics, thereby making operations predictable, orderly, and easier to monitor in real time.
The multi-zone ASRS optimally coordinates the movement of the RSRVs for improving storage and retrieval of a large number of different product items having different temperature requirements. Disclosed herein is also a computer-implemented method for controlling operation of the RSRVs in the multi-zone ASRS disclosed above. The method disclosed herein employs the CCS configured to operably communicate with the RSRVs. In the method disclosed herein, for a deposit process in the second storage zone involving a deposit of a first storage unit in the second storage zone to a first storage location in the second storage zone, the CCS divides the deposit process into a first entrance task of carrying the first storage unit into the second storage zone and a second placement task of placing the first storage unit into the first storage location. The CCS then assigns the first entrance task and the second placement task to a first RSRV and a second RSRV respectively, selected from among the RSRVs positioned outside the second storage zone. The CCS then issues commands to the first RSRV and the second RSRV to execute the first entrance task and the second placement task. In an embodiment, the first entrance task comprises a drop-off of the first storage unit in the second storage zone by the first RSRV, and a prompt exit of the first RSRV from the second storage zone after the drop-off. The drop-off performed by the first RSRV in the first entrance task comprises placement of the first storage unit at a buffer spot in the second storage zone for later retrieval of the first storage unit from the buffer spot by the second RSRV.
In an embodiment, the CCS assigns a retrieval task associated with the second storage zone to the second RSRV. In this embodiment, the second storage zone is characterized by a harsher operating environment for the RSRVs than the first storage zone. For example, the second storage zone is a cooled storage zone having a lower environmental operating temperature than the first storage zone. The retrieval task comprises retrieving a second storage unit from a second storage location in the second storage zone. The second storage location from which to retrieve the second storage unit is selected from among any of the storage locations available upstream and positioned en route from a buffer spot in the second storage zone to the second storage locations in the second storage zone, and/or any of the storage locations available downstream and positioned en route from the second storage location in the second storage zone to an exit portal of the second storage zone.
In an embodiment of the computer-implemented method disclosed herein, the CCS assigns a retrieval task associated with the second storage zone to a first RSRV selected from among the RSRVs positioned outside the second storage zone. The CCS then issues commands to the first RSRV to travel into the second storage zone; retrieve a first storage unit from a first storage location in the second storage zone; and exit the second storage zone and carry the first storage unit to a workstation positioned outside the second storage zone. After performance of product placement to or product extraction from the first storage unit at the workstation, the CCS commands the first RSRV or a different RSRV to transport the first storage unit from the workstation back into the second storage zone, and to drop off the first storage unit at a buffer spot in the second storage zone that is distinct from the storage locations of the second storage zone. The CCS issues commands to the first RSRV or the different RSRV to promptly exit the second storage zone after dropping off the first storage unit at the buffer spot in the second storage zone. The CCS issues commands to another RSRV to enter the second storage zone from the first storage zone, pick up the first storage unit from the buffer spot in the second storage zone, and deposit the first storage unit into one of the storage locations in the second storage zone. The CCS issues commands to the other RSRV to, after depositing the first storage unit into one of the storage locations in the second storage zone, retrieve a second storage unit from a second storage location in the second storage zone different from that in which the first storage unit was deposited. The CCS selects one of the storage locations in the second storage zone into which to deposit the first storage unit from among any of the storage locations in the second storage zone available upstream and positioned en route from the buffer spot to the second storage location in the second storage zone from which the second storage unit is to be retrieved, and any of the storage locations available downstream and positioned en route to an exit of the second storage zone from the second storage location from which the second storage unit is to be retrieved.
In one or more embodiments, related systems comprise circuitry and/or programming for executing the methods disclosed herein. The circuitry and/or programming are of any combination of hardware, software, and/or firmware configured to execute the methods disclosed herein depending upon the design choices of a system designer. In an embodiment, various structural elements are employed depending on the design choices of the system designer.
The foregoing summary, as well as the following detailed description, is better understood when read in conjunction with the appended drawings. For illustrating the embodiments herein, exemplary constructions of the embodiments are shown in the drawings. However, the embodiments herein are not limited to the specific structures, components, and methods disclosed herein. The description of a structure, or a component, or a method step referenced by a numeral in a drawing is applicable to the description of that structure, component, or method step shown by that same numeral in any subsequent drawing herein.
Various aspects of the present disclosure may be embodied as a system of components and/or structures, methods, and/or non-transitory, computer-readable storage media having one or more computer-readable program codes stored thereon. Accordingly, various embodiments of the present disclosure may take the form of a combination of hardware and software embodiments comprising, for example, mechanical structures along with electronic components, computing components, circuits, microcode, firmware, software, etc.
The barrier 104 isolates the second storage zone 102 from the first storage zone 101. The portals 108a, 109a, 108b, and 109b open through the barrier 104 between the first storage zone 101 and the second storage zone 102. The track layout, for example, 122 comprises a first track area 122a occupying the first storage zone 101, a second track area 122b occupying the second storage zone 102, and one or more connective track segments 122d illustrated in
In an embodiment where the track layout 122 is positioned above the storage locations of the multi-zone ASRS 100, the second storage zone 102 comprises an enclosed attic space 102a positioned above the track layout 122 and isolated from the first storage zone 101. The enclosed attic space 102a is delimited by boundary walls 104, 105, 106, and 107a of the second storage zone 102. At least one of the boundary walls 106 is separate and discrete from building walls of a facility that accommodates the multi-zone ASRS 100. The enclosed attic space 102a is isolated from the first storage zone 101 and from a surrounding space of the facility. In an embodiment, the boundary walls 104, 105, 106, and 107a of the enclosed attic space 102a are separate and discrete from the building walls of the facility. In an embodiment, the boundary walls 104, 105, 106, and 107a are mounted to frame members of the 3D gridded storage structure 100a of the multi-zone ASRS 100 illustrated in
In an embodiment as illustrated in
In an embodiment, the multi-zone ASRS 100 further comprises one or more buffer spots, for example, 112a, 112b, and 112c. In an embodiment, buffer spots 112a, 112b, and 112c are storage shelves configured to temporarily hold storage units when the RSRVs 128 transition between the storage zones 101, 102, and 103. The buffer spots 112a, 112b, and 112c allow the storage units to be segregated and be stored in only one environmentally controlled storage zone 101, 102, or 103, while allowing an RSRV 128 to transition between the environmentally controlled storage zones 101, 102, and 103 during performance of a single storage and retrieval task. Each of the buffer spots 112a, 112b, and 112c is positioned at a location on the track layout 122 and accessible by the RSRV(s) 128 from the track layout 122. Each of the buffer spots 112a, 112b, and 112c is configured to temporarily hold one of the storage units thereon. In an embodiment, at least one of the buffer spots 112a, 112b, and 112c is positioned proximal to a respective one of the portals 108a, 109a, 108b, 109b, or 110. In an embodiment, one or more buffer spots comprise multiple buffer spots. In this embodiment, at least one of the buffer spots 112a, 112b, and 112c is positioned in each of the first storage zone 101, the second storage zone 102, and the third storage zone 103.
The boundary walls comprise a full-span barrier wall 104 spanning vertically through a full height of the 3D gridded storage structure 100a from a ground level beneath the lower track layout 126 up to, and past, the upper track layout 122. As illustrated in
A partial-span barrier wall 105 spans vertically through the full height of the 3D gridded storage structure 100a from a ground level beneath the lower track layout 126 up to, and past, the upper track layout 122, while not fully spanning the 3D gridded structure 100a in either horizontal direction. The partial-span barrier wall 105 spans in the Y-direction of the 3D gridded storage structure 100a from the full-span barrier wall 104 to the outer perimeter wall 106 of the 3D gridded storage structure 100a at a side of the full-span barrier wall 104 opposite the ambient first storage zone 101, and therefore, physically and thermally isolates the second storage zone 102 and the third storage zone 103 from one another in the X-direction of the 3D gridded storage structure 100a. As exemplarily illustrated in
In an embodiment as illustrated in
In the embodiment illustrated in
Regardless of the particular configuration of the storage zones 101, 102, and 103, when multiple cooled storage zones are included in the multi-zone ASRS 100, each cooled storage zone 102 and 103 is configured to share at least one barrier wall 104 with the ambient storage zone 101, and have at least one access portal, for example, 108a, 109a, 108b, 109b, that opens through this barrier wall 104 to allow travel of the robotic storage/retrieval vehicles (RSRVs) 128 illustrated in
Since the second storage zone 102 and the third storage zone 103, for example, are environmentally controlled or temperature-controlled, chilled and freezer storage zones requiring physical and thermal isolation from the surrounding environment of the facility, the boundary walls of these storage zones 102 and 103 comprise not only the internal harrier walls 104 and 105 that cut through the interior of the 3D gridded storage structure 100a, but also outer perimeter walls 106, 107a, and 107b that cooperate with the internal barrier walls 104 and 105 to completely surround each of the storage zones 102 and 103 on all sides thereof. The full-span perimeter wall 106 spans the full X-direction of the 3D gridded storage structure 100a at the outer perimeter side thereof and is positioned opposite the full-span barrier wall 104, and is therefore, shared by the second storage zone 102 and the third storage zone 103 to close off the sides thereof opposite the first storage zone 101. Partial-span perimeter walls 107a and 107b for the second storage zone 102 and the third storage zone 103 respectively, span a partial dimension of the 3D gridded storage structure 100a in the Y-direction thereof between the full-span perimeter wall 106 and the full-span barrier wall 104, and thereby closes off a fourth and final side of each of the storage zones 102 and 103 in opposite and opposing relation to the partial-span barrier wall 105.
Similar to the barrier walls 104 and 105, the perimeter walls 106 and 107a, 107b span a full height of the 3D gridded storage structure 100a from a ground level beneath the lower track layout 126 up to, and past, the upper track layout 122. Accordingly, all of the boundary walls 104, 105, 106, 107a, and 107b reach upwardly beyond the upper track layout 122 of the 3D gridded storage structure 100a. At an upper portion of the full-span barrier wall 104 standing upright from the upper track layout 122, a pair of access portals 108a and 109a penetrate horizontally through the full-span barrier wall 104 at the upper portion thereof denoting the boundary between the first storage zone 101 and the second storage zone 102. A respective pair of Y-direction rails 130 of the upper track layout 122 of the 3D gridded storage structure 100a as illustrated in
Within each pair of access portals, in an embodiment, one access portal 108a, 108b is used as a dedicated entrance portal by which the RSRVs 128 enter the cooled, second storage zone 102 or third storage zone 103 from the ambient, first storage zone 101 by riding over the respective connective track segment 122d, while the other access portal 109a, 109b is used as a dedicated exit portal by which the RSRVs 128 exit the cooled, second storage zone 102 or third storage zone 103 back into the ambient, first storage zone 101. In another embodiment, either of the two access portals 108a, 108b or 109a, 109b is used as either an entrance portal or an exit portal at any given time. In another embodiment, a singular entrance/exit portal is employed at each of the cooled storage zones 102 and 103 for two-way travel thereto and therefrom. As illustrated in
The multi-zone ASRS 100 comprises environmental control equipment, for example, chillers or coolers 111a, fans 111b, heaters, etc., for controlling the temperature or environmental parameters and conditions in one or more of the storage zones, for example, 102 and 103. The number, size, and locations of the environmental control equipment are configured based on the size of the multi-zone ASRS 100. As exemplarily illustrated in FIGS. 1-2, each of the second storage zone 102 and the third storage zone 103 comprises a respective chiller 111a installed therein to cool the internal space of the respective storage zone 102, 103 to a targeted operational temperature range for chilled or frozen storage of product items or goods. In an embodiment, the chillers 111a are installed at the upper portion of one of the boundary walls surrounding the respective storage zone 102, 103. For example, the chillers 111a are installed in the enclosed attic space 102a, 103a on the outer perimeter wall 106 of the respective storage zone 102, 103. The chillers 111a are, for example, evaporators or evaporative coolers configured with a wide range of capacities to support cooling applications in the multi-zone ASRS 100. These evaporative coolers cool air through the evaporation of water within the multi-zone ASRS 100. In another embodiment, one or more fans 111b are positioned in the enclosed attic spaces 102a and 103a of the storage zones 102 and 103 respectively and in the basement 103b illustrated in
As illustrated in
To fully enclose the cooled storage zones 102 and 103, in an embodiment, zone ceilings (not shown) made of suitable thermally insulative materials are installed over the top ends of the boundary walls 104, 105, 106, 107a, and 107b. The zone ceilings are omitted in
Through the above disclosed division of the 3D gridded storage structure 100a of the multi-zone ASRS 100 into storage zones 101, 102, and 103 isolated by the internal barrier walls 104 and 105, and the cooperative relation of the perimeter walls 106, 107a, and 107b and zone or facility ceilings and floors therewith to fully enclose the cooled, second storage zone 102 and third storage zone 103, a first group or a subset of the storage columns 123 of the overall 3D gridded storage structure 100a therefore reside in an ambient environment in the environmentally exposed first storage zone 101, while second and third groups or subsets of the storage columns 123 of the overall 3D gridded storage structure 100a reside in cooled environments within the chilled, second storage zone 102 and the freezer, third storage zone 103. In an embodiment, to maintain a substantially complete isolation between the cooled storage zones 102 and 103 and the ambient storage zone 101, each of the access portals 108a, 109a, 108b, 109b, and 110 is equipped with a strip curtain through which an RSRV 128 is configured to push. In another embodiment, each of the access portals 108a, 108b, 109a, 109b, and 110 is equipped with a normally-closed, selectively-openable, electronically-operated door configured to automatically open upon approach or arrival of an RSRV 128, for example, under an automated control either at a system level by a computerized control system (CCS) of the multi-zone ASRS 100 configured to wirelessly command movements and operations of the RSRVs 128 within the 3D gridded storage structure 100a, or at a vehicular level by an actuator, remote control system, or other means. Neither the storage columns 123 nor the access shafts 124 inside the cooled, second storage zone 102 and third storage zone 103 need to be capped with individual insulation covers and, in an embodiment, are left uncapped at all times. The access shafts 124 are left uncapped at all times such that any RSRV 128 entering the cooled, second storage zone 102 or third storage zone 103 at the upper track layout 122 can readily travel down any access shaft 124 in the cooled storage zone 102 or 103 without having to first perform or await removal of such an insulative cover.
As disclosed above, the upper track layout 122 further comprises a plurality of buffer spots, including a plurality of buffer spots 112a in the first storage zone 101, at least one buffer spot 112b in the second storage zone 102, and at least one buffer spot 112c in the third storage zone 103. Each of the buffer spots 112a, 112b, and 112c is positioned proximal to a respective one of the access portals 108a, 109a, 108b, 109b, and 110 in the barrier walls 104 and 105 respectively. Each of the buffer spots 112a, 112b, and 112c is equipped with a shelving assembly sized to accommodate placement of one of the storage units thereon. As illustrated in
During a subsequent pickup of the storage unit 127, the reverse process is performed, that is, extending the arm 136 of the RSRV 128 between the shelf rails 125a, raising an upper support platform 138 of the RSRV 128 illustrated in
The multi-zone ASRS 100 further comprises at least one neighboring workstation 114, 115. For example, two workstations 114 and 115 are attached to a perimeter side of the 3D gridded storage structure 100a of the multi-zone ASRS 100 as illustrated in
In an embodiment as illustrated in
In an embodiment as illustrated in
The second leg 115b of the multi-point workstation 115 comprises a placement port 118 opening through the countertop Hob of the workstation 115 in overlying relation to an access spot, which instead of overlying an RSRV-carrying extension of the lower track layout 126 of the 3D gridded storage structure 100a, overlies a short conveyor (not shown) to which storage units are dropped off by the RSRVs 128 operating on the lower track layout 126 of the 3D gridded storage structure 100a. Accordingly, a storage unit into which an order is to be placed, herein referred to as an “order bin”, is dropped off at the conveyor-based path of the second leg 115b of the workstation 115, and advanced by the conveyor to the placement port 118, where product items picked from different RSRV-carried storage units circulating through the track-based path of the first leg 115a of the workstation 115 are placed into the order bin waiting at the placement port 118. Once the order bin has been filled with the prescribed product items for the order being filled, the filled order bin is advanced on the conveyor-based path to a pickup point from where the filled order bin is retrieved by an RSRV 128 on the lower track layout 126 of the 3D gridded storage structure 100a. This RSRV 128, alone or in cooperation with another RSRV 128, is tasked with placement of the order bin into a storage location of the 3D gridded storage structure 100a for temporary storage or buffering of the filled order bin for later retrieval during a customer pickup or delivery.
In an embodiment of the multi-point workstation 115 as illustrated in
As illustrated in
Furthermore, in an embodiment, the multi-zone ASRS 100 further comprises a bin exchange area 119 as illustrated in
Similar to the upper track layout 122, the lower track layout 126 comprises connective track segments 126b running through the lower access portals 108a, 109a, 108b, and 109b to connect the first track area 126a of the lower track layout 126 positioned in the first storage zone 101 with the second track area and the third track area 126c of the lower track layout 126 positioned respectively inside the second storage zone 102 and the third storage zone 103. Accordingly, by riding through the lower access portals 108a, 109a, 108b, and 109b on the connective track segments 126b of the lower track layout 126, the RSRVs 128 travel into and out of the second storage zone 102 and the third storage zone 103 from and back into the first storage zone 101. In various embodiments of RSRV routing techniques disclosed herein, both the entrance and exit of the RSRVs 128 to and from the second storage zone 102 and the third storage zone 103 are employed at the upper track layout 122, and hence both entrance and exit access portals 108a, 108b, and 109a, 109b are implemented in the 3D gridded storage structure 100a, while transitions of the RSRVs 128 between the storage zones 101, 102, and 103 at the lower track level is limited to a one-way travel in an exiting direction from the second storage zone 102 and the third storage zone 103 back into the first storage zone 101, in which case a singular lower access portal between the ambient, first storage zone 101 and each of the cooled storage zones 102 and 103 are employed. In an embodiment similar to the access portal 110 at the upper track layout 122, an additional access portal (not shown) between the second storage zone 102 and the third storage zone 103 is optionally included at the lower portion of the partial-span barrier wall 105 to allow transition of the RSRVs 128 directly between the second track area and the third track area 126c of the lower track layout 126. In an embodiment, the storage units stored in the first group of storage locations of the first storage zone 101 and the second group of storage locations of the second storage zone 102, and in an embodiment, the third group of storage locations of the third storage zone 103, are accessible by any one of a plurality of workstations, for example, 114 and 115 illustrated in
The multi-zone ASRS 100 disclosed herein comprises a common class of robotic handlers or robotic storage/retrieval vehicles (RSRVs) 128 that are configured to operate in all the different environmentally controlled storage zones, for example, 101, 102 and 103, of the multi-zone ASRS 100 illustrated in
The RSRVs 128 are further configured to travel between the first track area 122a, the second track area 122b, and the third track area 122c of the upper track layout 122 via the connective track segments 122d connected therebetween as illustrated in
Each of the upper track layout 122 and the lower track layout 126 comprises a set of X-direction rails 129 lying in the X-direction of the respective horizontal plane, and a set of Y-direction rails 130 perpendicularly crossing the X-direction rails 129 in the Y-direction of the same horizontal plane. The crossing rails 129 and 130 define a horizontal reference grid of the 3D gridded storage structure 100a, where each horizontal grid row is delimited between an adjacent pair of the X-direction rails 129 and each horizontal grid column is delimited between an adjacent pair of the Y-direction rails 130. Each intersection point between one of the horizontal grid columns and one of the horizontal grid rows denotes a two-dimensional position of a respective vertical storage column 123 or a respective vertical access shaft 124. That is, each storage column 123 and each access shaft 124 are positioned at a respective X, Y Cartesian coordinate point of the reference grid at a respective area bound between two of the X-direction rails 129 and two of the Y-direction rails 130. Each such area bound between four rails 129 and 130 in either the upper track layout 122 or the lower track layout 126 is referred to herein as a respective “spot” of the track layout 122 or 126. The 3D address of each storage location in the 3D gridded storage structure 100a is, therefore, a combination of the X, Y coordinates of the storage column 123 in which that storage location is positioned, plus the vertical level or Z coordinate at which the storage location is positioned within that storage column 123.
A respective upright frame member 131 spans vertically between the upper track layout 122 and the lower track layout 126 at each intersection point between the X-direction rails 129 and the Y-direction rails 130, thereby cooperating with the track rails 129 and 130 to define a skeletal framework of the 3D gridded storage structure 100a for containing and organizing the 3D array of storage units 127 within the skeletal framework. As a result, each access shaft 124 of the 3D gridded storage structure 100a comprises four vertical frame members 131 spanning the full height of the access shaft 124 at the four corners thereof. Each frame member 131 comprises respective sets of rack teeth arranged in series in the vertical Z-direction of the 3D gridded storage structure 100a on two sides of the frame member 131. Each access shaft 124, therefore, comprises eight sets of rack teeth in total, with two sets at each corner of the access shaft 124. These eight sets of rack teeth cooperate with eight pinion wheels 133b on each of the RSRVs 128 illustrated in
A set of four X-direction wheel units is arranged in pairs on two opposing sides of the RSRV 128 to drive the RSRV 128 on the X-direction rails 129 of the upper track layout 122 or the lower track layout 126 of the 3D gridded storage structure 100a. A set of four Y-direction wheel units is arranged in pairs on the other two opposing sides of the RSRV 128 to drive the RSRV 128 on the Y-direction rails 130 of the upper track layout 122 or the lower track layout 126 of the 3D gridded storage structure 100a. One set of wheel units is an elevationally-adjustable set of wheel units that is raiseable or lowerable relative to the other elevationally-fixed set of wheel units that is positioned at a fixed height on the frame or chassis 132 of the RSRV 128. Such height adjustment of one set of wheel units relative to the other on the upper track layout 122 or the lower track layout 126 of the 3D gridded storage structure 100a is operable to switch the RSRV 128 between an X-direction travel mode and a Y-direction travel mode by controlling which one of the two sets of wheel units currently contact the respective rails 129 and 130 of the upper track layout 122 or the lower track layout 126, and which does not. Raising one set of wheel units when in the outboard positions seated on the upper track layout 122 is also operable to lower the other set of wheel units into engagement with the rack teeth of an access shaft 124, after which the raised wheel units are then also shifted inboard, thereby completing transition of the RSRV 128 from the upper track layout 122 into an access shaft 124 for descending travel therethrough. Similarly, lowering one set of wheel units when in the outboard positions seated on the lower track layout 126 is also operable to raise the other set of wheel units into engagement with the rack teeth of an access shaft 124, after which the lowered wheel units are then also shifted inboard, thereby completing transition of the RSRV 128 from the track-riding mode to the shaft-traversing mode. In an embodiment, a lifting mechanism defined separately of the RSRV 128 and installed in the lower track layout 126 is used to air or perform lifting of the RSRV 128 from the lower track layout 126 into an overlying access shaft 124, as disclosed in Applicant's PCT Application numbers PCT/CA2019/050404 and PCT/CA2019/050815.
Each RSRV 128 further comprises an upper support platform 138 on which the storage unit 127 is receivable for carrying thereon. The upper support platform 138 comprises a rotatable turret 135 surrounded by a stationary outer deck surface 134. The rotatable turret 135 comprises an extendable/retractable arm 136 mounted in a diametric slot of the rotatable turret 135 and movably supported therein for linear movement into and out of a deployed position extending outwardly from the outer circumference of the rotatable turret 135.
The framework of the 3D gridded storage structure 100a comprises a set of shelving brackets at each storage location to cooperatively form a shelf for the storage unit 127 currently stored at the storage location, whereby any storage unit 127 can be removed from its storage location by one of the RSRVs 128 without disrupting the storage units 127 above and below the given storage unit 127 in the same storage column 123. This allows a storage unit 127 to be returned to a prescribed storage location at any level in the 3D gridded storage structure. Accordingly, through two-dimensional horizontal navigation of the track layouts 122 and 126, each RSRV 128 is configured to access any of the access shafts 124, and is able to travel vertically therethrough in ascending or descending directions in the third dimension to access any of the storage locations and deposit or withdraw a storage unit 127 therefrom.
In an embodiment, the centers and transport vehicles used therebetween are part of a larger overall facility and vehicle network in a supply chain or distribution ecosystem, for example, as disclosed in Applicant's PCT international patent application numbers PCT/IB2020/051721 and PCT/IB2020/052287, which are incorporated herein by reference in their entirety. In an embodiment, a four-tiered hierarchy of different facility types is employed. The four-tiered hierarchy comprises mega facilities, macro facilities, micro facilities, and nano facilities. In this order, the quantity of facilities in each category increases from one category to the next, while the individual size of each facility reduces from one category to the next. Typically, the mega facilities form entry points at which products from manufacturers or suppliers first enter the network of facilities, while the nano facilities form exit points from which products depart the network of facilities. The products may enter and depart the network of facilities at various points. Each facility comprises an ASRS of the same three-dimensional (3D) gridded storage structure and RSRV type disclosed in the detailed descriptions of
The central computing system 801 comprises one or more computers comprising one or more processors, for example, central processing units (CPUs) 802 connected to a network interface coupled to a communication network, for example, the Internet or other wide area network, and one or more data storage devices comprising non-transitory, computer-readable storage media or memory among which there is stored executable software for execution by the processors to execute multiple processes disclosed herein. As used herein, “non-transitory, computer-readable storage media” refers to all computer-readable media that contain and store computer programs and data. Examples of the computer-readable media comprise hard drives, solid state drives, optical discs or magnetic disks, memory chips, a read-only memory (ROM), a register memory, a processor cache, a random-access memory (RAM), etc. The data storage devices comprise one or more databases, for example, a central database 803 in which, among other data disclosed below, stores unique bin identifiers (Bin_IDs) of all the storage units illustrated in
As used herein, “communication network” refers, for example, to one of the Internet, a wireless network, a communication network that implements Bluetooth® of Bluetooth Sig, Inc., a network that implements Wi-Fi® of Wi-Fi Alliance Corporation, an ultra-wideband (UWB) communication network, a wireless universal serial bus (USB) communication network, a communication network that implements ZigBee® of ZigBee Alliance Corporation, a general packet radio service (GPRS) network, a mobile telecommunication network such as a global system for mobile (GSM) communications network, a code division multiple access (CDMA) network, a third generation (3G) mobile communication network, a fourth generation (4G) mobile communication network, a fifth generation (5G) mobile communication network, a long-term evolution (LTE) mobile communication network, a public telephone network, etc., a local area network, a wide area network, an internet connection network, an infrared communication network, etc., or a network formed from any combination of these networks. The communication network allows the FMS 805, the VMS 814, and the CCS 817 to communicate with each other and with the central computing system 801.
In an embodiment, the system 800 disclosed herein is implemented in a cloud computing environment. As used herein, “cloud computing environment” refers to a processing environment comprising configurable computing physical and logical resources, for example, networks, servers, storage media, virtual machines, applications, services, etc., and data distributed over a communication network. The cloud computing environment provides an on-demand network access to a shared pool of the configurable computing physical and logical resources. In an embodiment, the system 800 disclosed herein is a cloud computing-based platform implemented as a service for executing an inventory replenishment workflow comprising a 1:1 exchange of transportable storage units. In this embodiment, the central computing system 801 and the central database 803 are herein referred to as a cloud-based computer platform and a cloud database respectively. In an embodiment, the computerized FMS 805 and the CCS 817 are implemented as on-premise software installed and run on computers on the premises of the supply facility 12 and the receiving facility 14 respectively. In an embodiment, the VMS 814 is implemented as an on-premise software installed and run on computers on the premises of each of the transport vehicles, for example, 813.
The computerized FMS 805 is installed at the supply facility 12. The FMS 805 comprises one or more local computers comprising one or more processors, for example, central processing units (CPUs) 806 connected to a network interface coupled to the communication network, for example, the Internet or other wide area network, and one or more data storage devices comprising non-transitory, computer-readable storage media in which there is stored executable software for execution by one more processors to execute multiple processes disclosed herein. The data storage devices comprise one or more databases, for example, a local facility database 808 for storing data pertinent to the supply facility 12. In addition to their connection to the wide area network, the local computers of the FMS 805 are installed in one or more local area networks 807, for example, local wireless networks, of the supply facility 12, by which at least one of the local computers are communicable with automated bin handling equipment of the supply facility 12. The automated bin handling equipment comprises, for example, the robotic handlers or robotic storage/retrieval vehicles (RSRVs) 809 at the supply facility 12, and various conveyors 811 and other handling equipment. Over the local area networks 807, at least one of the local computers of the FMS 805 also communicates with workstations and other equipment and devices comprising, for example, stationary and/or mobile human-machine interfaces (HMIs) 810 for guiding performance of various tasks by human workers, conveyors 811, and the storage units. In an embodiment, the system 800 further comprises an indoor positioning system 812 in operable communication with the FMS 805 of the supply facility 12 for real-time tracking of each of the storage units.
The computerized VMS 814 is installed in each of the inter-nodal transport vehicles, for example, 813, of the system 800. Each VMS 814 comprises one or more local computers comprising one or more processors, for example, central processing units (CPUs) connected to one or more data storage devices comprising non-transitory, computer-readable storage media in which there is stored executable software for execution by the processors to execute multiple processes disclosed herein. The data storage devices comprise a local vehicle database that stores data pertinent to that particular transport vehicle 813 and the transported contents thereof. In an embodiment, a wireless communications unit is operably coupled to the transport vehicle 813. The wireless communications unit, for example, a wide area communication device, is configured to communicate the location of the transport vehicle 813 and the location of any one of the storage units to the central computing system 801, the FMS 805, and the CCS 817 during transport of the storage units between the facilities 12 and 14. For example, the processors of the VMS 814 are connected to a wireless wide area communications device, for example, a cellular communications device, for mobile communication with the central computing system 801 over a wireless wide area network, for example, a cellular network. In an embodiment, a positioning unit, for example, a global positioning system (GPS) device is operably coupled to the transport vehicle 813. The positioning unit is configured to determine a location of the transport vehicle 813 and in turn determine a location of any one of the storage units being transported in the transport vehicle 813. The GPS device is also connected to at least one processor of at least one of the local computers of the transport vehicle 813 for tracking the movement of the transport vehicle 813 via the GPS and sharing the calculated GPS coordinates of the transport vehicle 813 to the respective local computers for communication onward to the central computing system 801. In an embodiment, the GPS device of the transport vehicle 813 communicates directly with the central computing system 801 to report the GPS coordinates thereto, independent of the local computers of the VMS 814. In an embodiment, the local computers of the VMS 814 are installed in a local area network by which at least one of the local computers is communicable with the storage units. In an embodiment, the VMS 814 is operably and communicatively coupled to bin handling equipment, for example, bin carousels 815 installed in the transport vehicle 813.
The CCS 817 configured at the receiving facility 14 controls the RSRVs 128, workstations 114, 115, and 139, and conveyors 120 and 121 for managing orders, executing the 1:1 exchange of transportable storage units between the supply facility 12 and the receiving facility 14, and controlling operations of the RSRVs 128 in the ASRS 816 as disclosed in the detailed description of
The processors disclosed above refer to any one or more microprocessors, CPU devices, finite state machines, computers, microcontrollers, digital signal processors, logic, a logic device, an application specific integrated circuit (ASIC), a field-programmable gate array (FPGA), a chip, etc., or any combination thereof, capable of executing computer programs or a series of commands, instructions, or state transitions. In an embodiment, each of the processors is implemented as a processor set comprising, for example, a programmed microprocessor and a math or graphics co-processor. The system 800 is not limited to employing processors. In an embodiment, the system 800 employs controllers or microcontrollers.
The network interfaces disclosed above are, for example, one or more of infrared interfaces, interfaces implementing Wi-Fi® of Wi-Fi Alliance Corporation, universal serial bus interfaces, FireWire® interfaces of Apple Inc., Ethernet interfaces, frame relay interfaces, cable interfaces, digital subscriber line interfaces, token ring interfaces, peripheral controller interconnect interfaces, local area network interfaces, wide area network interfaces, interfaces using serial protocols, interfaces using parallel protocols, Ethernet communication interfaces, asynchronous transfer mode interfaces, high speed serial interfaces, fiber distributed data interfaces, interfaces based on transmission control protocol/internet protocol, interfaces based on wireless communications technology such as satellite technology, radio frequency technology, near field communication, etc.
The databases of the system 800, for example, the central database 803, the local facility database 808, and the local vehicle databases refer to any storage area or media that can be used for storing data and files. The databases can be, for example, any of a structured query language (SQL) data store or a not only SQL (NoSQL) data store such as the Microsoft® SQL Server®, the Oracle® servers, the MySQL® database of MySQL AB Limited Company, the mongoDB® of MongoDB, Inc., the Neo4j graph database of Neo Technology Corporation, the Cassandra database of the Apache Software Foundation, the HBase® database of the Apache Software Foundation, etc. In an embodiment, the databases can also be locations on a file system. In another embodiment, the databases can be remotely accessed by the computing systems 801, 805, 814, and 817 via the communication network. In another embodiment, the databases are configured as cloud-based databases implemented in a cloud computing environment, where computing resources are delivered as a service over the communication network.
In an embodiment, the storage units containing product inventory are received at the receiving facility 14 on the transport vehicle 813 from the supply facility 12 and automatically inducted into the ASRS 816, for example, the multi-zone ASRS 100 illustrated in
In an embodiment, the CCS 817 is a computer system that is programmable using high-level computer programming languages. The CCS 817 is implemented using programmed and purposeful hardware. In the system disclosed herein, the CCS 817 interfaces with the ASRS, for example, the multi-zone ASRS 100, the RSRVs 128, and the workstations 114, 115, and 139, and in an embodiment, with the central computing system 801, the facility management system 805 at a supply facility 12, and the vehicle management system 814 of the transport vehicle 813 illustrated in
The CCS 817 further comprises a non-transitory, computer-readable storage medium, for example, a memory unit 824, communicatively coupled to the processor(s) 820. The memory unit 824 is used for storing program instructions, applications, and data. The memory unit 824 stores computer program instructions defined by modules, for example, 824a-824d of the CCS 817. The memory unit 824 is operably and communicatively coupled to the processor 820 for executing the computer program instructions defined by the modules, for example, 824a-824d of the CCS 817 for executing workflows in the receiving facility 14. The processor 820 executes the modules, for example, 824a-824d of the CCS 817. The memory unit 824 is, for example, a random-access memory (RAM) or another type of dynamic storage device that stores information and instructions for execution by the processor 820. The memory unit 824 also stores temporary variables and other intermediate information used during execution of the instructions by the processor 820. In an embodiment, the CCS 817 further comprises read only memories (ROMs) or other types of static storage devices that store static information and instructions for execution by the processor 820. In an embodiment, the modules, for example, 824a-824d and 825 of the CCS 817 are stored in the memory unit 824.
The memory unit 824 is configured to store computer program instructions, which when executed by the processor(s) 820, cause the processor(s) 820 to control operation of the RSRVs 128 in the multi-zone ASRS 100 as follows. Through the execution of the computer program instructions by the processor 820, the CCS 817 performs the following method in the multi-zone ASRS 100 comprising a first storage zone 101, a second storage zone 102, and in an embodiment, a third storage zone 103 as illustrated in
In additional steps of the retrieval task associated with the second storage zone 102, the CCS 817 further issues commands to the first RSRV to: upon entry into the second storage zone 102, pick up a buffered storage unit from one of the buffer spots in the second storage zone 102; travel from that buffer spot in the second storage zone 102 toward an access location in the second storage zone 102 from which the targeted storage unit stored in the second storage zone 102 is retrievable; and prior to retrieving the targeted storage unit at the access location, deposit the picked up storage unit into an available one of the storage locations in the second storage zone 102. In an embodiment, the CCS 817 selects the available storage location in the second storage zone 102 from among any of the storage locations available upstream and positioned en route from the buffer spot in the second storage zone 102 to the access location, and/or any of the storage locations available downstream and positioned en route from the access location to an exit portal.
The CCS 817 completes the retrieval task associated with the second storage zone 102 by issuing commands to the first RSRV to retrieve the targeted storage unit stored in the second storage zone 102 and perform delivery of the targeted storage unit to a workstation, for example, 114, 115, or 139, to facilitate picking of product from the targeted storage unit at the workstation. Subsequent to the completion of the retrieval task associated with the second storage zone 102 and picking of the product from the targeted storage unit carried by the first RSRV, the CCS 817 issues commands to the first RSRV or a different RSRV to deposit the targeted storage unit onto one of the buffer spots in the second storage zone 102 and then exit the second storage zone 102. As part of a subsequent retrieval task associated with the second storage zone 102 and assigned to a second RSRV selected from among the first RSRV and a different RSRV, to retrieve another targeted storage unit stored in the second storage zone 102, the CCS 817 issues commands to the second RSRV to: (a) enter the second storage zone 102; (b) pick up the deposited storage unit from the buffer spot in the second storage zone 102; (c) travel from the buffer spot in the second storage zone 102 toward an access location in the second storage zone 102 from which the other targeted storage unit is retrievable; and (d) prior to retrieving the other targeted storage unit at the access location, deposit the picked up storage unit from the buffer spot in the second storage zone 102 into an available one of the storage locations in the second storage zone 102. In an embodiment, the CCS 817 selects the available storage location in the second storage zone 102 from among any of the storage locations available upstream and positioned en route from the buffer spot in the second storage zone 102 to the access location, and/or any of the storage locations available downstream and positioned en route from the access location to an exit portal.
In an embodiment, the CCS 817 assigns a task of depositing an unneeded one of the storage units stored in the second storage zone 102 into one of the storage locations in the second group, to one of the RSRVs 128 that is assigned to retrieve a needed one of the storage units stored in the second storage zone 102 from the second group of the storage locations. In an embodiment, the second storage zone 102 is characterized by a harsher operating environment for the RSRVs 128 than the first storage zone 101. In this embodiment, during the selection of one of the RSRVs 128 to assign to any retrieval task associated with the second storage zone 102, the CCS 817 prioritizes the RSRVs 128 of a longer absence from the second storage zone 102 over the RSRVs 128 of a more recent presence in the second storage zone 102. In an embodiment, the CCS 817 records an exit time at which any of the RSRVs 128 last exited the second storage zone 102. In this embodiment, during the selection of the RSRVs 128 for any retrieval task associated with the second storage zone 102, the CCS 817 compares exit times of the RSRVs 128 for prioritizing the RSRVs 128 of the longer absence from the second storage zone 102 over the RSRVs 128 of the more recent presence in the second storage zone 102. The embodiments herein reduce exposure of the RSRVs 128 to non-ambient, cooled, chilled or freezer environments while the RSRVs 128 operate in the multi-zone ASRS 100, thereby protecting their circuitry and componentry and maintaining their throughput performance.
In an exemplary implementation of the system illustrated in
The processor 820 of the CCS 817 retrieves instructions defined by the order management module 824a, the task assignment module 824b, the robot management module 824c, and the bin consolidation and exchange module 824d for performing respective functions disclosed above. The processor 820 retrieves instructions for executing the modules, for example, 824a-824d, from the memory unit 824. The instructions fetched by the processor 820 from the memory unit 824 after being processed are decoded. After processing and decoding, the processor 820 executes their respective instructions, thereby performing one or more processes defined by those instructions. An operating system of the CCS 817 performs multiple routines for performing a number of tasks required to assign the input devices, the output devices, and the memory unit 824 for execution of the modules, for example, 824a-824d and 825. The tasks performed by the operating system comprise, for example, assigning memory to the modules, for example, 824a-824d, 825, etc., and to data used by the CCS 817, moving data between the memory unit 824 and disk units, and handling input/output operations. The operating system performs the tasks on request by the operations and after performing the tasks, the operating system transfers the execution control back to the processor 820. The processor 820 continues the execution to obtain one or more outputs.
For purposes of illustration, the detailed description refers to the modules, for example, 824a-824d and 825, being run locally on a single computer system, that is, the CCS 817; however the scope of the embodiments herein is not limited to the modules, for example, 824a-824d and 825, being run locally on a single computer system via the operating system and the processor 820, but may be extended to run remotely over the communication network by employing a web browser and a remote server, a mobile phone, or other electronic devices. In an embodiment, one or more computing portions of the system disclosed herein are distributed across one or more computer systems (not shown) coupled to the communication network.
The non-transitory, computer-readable storage medium disclosed herein stores computer program instructions executable by the processor 820 for executing different workflows at the receiving facility 14. The computer program instructions implement the processes of various embodiments disclosed above and perform additional steps that may be required and contemplated for executing the workflows at the receiving facility 14. When the computer program instructions are executed by the processor 820, the computer program instructions cause the processor 820 to perform the steps of the method for executing the workflows at the receiving facility 14 as disclosed above. In an embodiment, a single piece of computer program code comprising computer program instructions performs one or more steps of the methods disclosed above and the methods disclosed in the detailed descriptions of
A module, or an engine, or a unit, as used herein, refers to any combination of hardware, software, and/or firmware. As an example, a module, or an engine, or a unit may include hardware, such as a microcontroller, associated with a non-transitory, computer-readable storage medium to store computer program codes adapted to be executed by the microcontroller. Therefore, references to a module, or an engine, or a unit, in an embodiment, refer to the hardware that is specifically configured to recognize and/or execute the computer program codes to be held on a non-transitory, computer-readable storage medium. The computer program codes comprising computer readable and executable instructions can be implemented in any programming language, for example, C, C++, C#, Java®, JavaScript®, Fortran, Ruby, Perl®, Python®, Visual Basic®, hypertext preprocessor (PHP), Microsoft® .NET, Objective-C®, etc. Other object-oriented, functional, scripting, and/or logical programming languages can also be used. In an embodiment, the computer program codes or software programs are stored on or in one or more mediums as object code. In another embodiment, the term “module” or “engine” or “unit” refers to the combination of the microcontroller and the non-transitory, computer-readable storage medium. Often module or engine or unit boundaries that are illustrated as separate commonly vary and potentially overlap. For example, a module or an engine or a unit may share hardware, software, firmware, or a combination thereof, while potentially retaining some independent hardware, software, or firmware. In various embodiments, a module or an engine or a unit includes any suitable logic.
In an embodiment, each product record in the vendor's product table 1003 comprises one or more product attributes of the product concerned, for example, size, color, etc.; vendor-specific product handling data that defines particular actions or conditions that must be fulfilled for that product type while the product moves within the supply chain ecosystem; vendor-specific customization data that defines performance of one or more modifications to the product by the operating entity based on value-added services (VAS), for example, re-packaging, labeling, price tagging, security tagging, etc., offered thereby; environmental data concerning controlled-environment requirements, or a lack thereof, for the particular product, for example, as may be necessitated by the nature of the product itself to prevent damage, leakage, or spoilage thereof or avoid, prevent, and/or minimize hazards presented thereby, etc. Examples of the environmental data comprise an indication of a freezer-storage requirement for frozen food items, an indication of a chilled-storage requirement for chilled but non-frozen food items, an indication of ambient-storage acceptability for general items requiring no particular controlled-environment conditions, etc. In an embodiment, the central computing system 801 uses the environmental data to determine and control placement of a product in various environmentally distinct or environmentally controlled storage zones or areas in the receiving facility and the transport vehicles, for example, 813, of the supply chain ecosystem.
In
As illustrated in
The storage bins table 1008 of the central database 803 stores the Bin_IDs of all the storage units, also referred to as “storage bins”, of the system 800 illustrated in
The global storage locations table 1010 of the central database 803 lists all the indexed storage locations of the indexed storage arrays of all the facilities and the transport vehicles. Each record in this global storage locations table 1010, therefore, comprises the Location_ID of a respective storage location in the system 800, the Facility_ID of the facility at which the storage location resides, or the Vehicle_ID of the transport vehicle on which the storage location resides, an environmental status indicator reflecting the environmental control category to which that storage location belongs, and the Bin_ID of a storage or order bin currently stored at that storage location, if any. The environmental status indicator denotes residence of the storage location in an ambient storage zone, a chilled storage zone, or a freezer storage zone of a given facility or transport vehicle.
The indexed storage arrays of all facilities and all transport vehicles are, therefore, fully indexed for global mapping of stored bin locations throughout the system 800, as each individual indexed storage location throughout the system 800 has a footprint specifically sized and shaped to accommodate placement and storage of a respective singular storage unit therein, and has a respective location identifier or address (Location_ID) in the records of the central database 803 by which the exact whereabouts of any storage bin stowed in any indexed storage array is identifiable at any time, even during transit between the facilities due to the inclusion of such indexed storage arrays in the transport vehicles. Through the combination of the vendor's stocked inventory table 1004, the facilities table 1006, the transport vehicle table 1007, the storage bins table 1008, the storage bin contents table 1009, and the global storage locations table 1010, the locations of all inventory placed into the storage units and inducted into any of the indexed storage arrays compatible with the storage units are thus recorded and tracked. In an embodiment where the system 800 employs only ambient storage with no environmentally controlled storage environments comprising, for example, chilled storage zones and/or freezer storage zones, then the environmental data is omitted from the vendor's product table 1003 and the facilities table 1006, along with the environmental status being omitted from the global storage locations table 1010.
In addition to the storage units for holding vendor inventory, the system 800 also employs picked-order (PO) storage units, also referred to as “PO bins” of the same standardized size and configuration as the storage units, so that picked orders placed in these PO bins are likewise storable in the indexed storage locations found in the facilities, and on the transport vehicles travelling therebetween, on a 1:1 bin-to-location basis. Accordingly, the PO bins table 1011 of the central database 803 is of a structure similar to the storage bins table 1008. In this embodiment, the separate PO bin contents table 1012 of the central database 803 tracks the contents of each compartment of each PO bin.
The order numbers recorded in the PO bin contents table 1012 are retrieved and assigned from a separate customer orders table 1015, each record of which contains the order number of a respective customer order, a unique identifier (Customer_ID) of a customer for whom that customer order is to be fulfilled, a unique identifier (Vendor_ID) of the vendor who fulfills the customer order, and any shipping preferences applied to that customer order during creation thereof. In a related order line items table 1016, each record contains a line item number, the order number of the customer order to which that line item belongs, the Product_ID(s) of a product type required to fulfill that line item of the customer order, and a quantity of that product type to be fulfilled for that line item. The Customer_ID of each customer is also stored in a separate customer table 1014 along with all other customer account information, including the name, address, and billing information of each customer.
In addition to the multi-compartment PO bins in which picked orders are placed, in an embodiment, the system 800 also employs single-compartment finished-order (FO) storage units, also referred to as “FO bins”, in which individual customer orders are packed once packaged into a finished state ready for pickup by, or delivery to, the customer. In an embodiment, the FO bins are of a different smaller standardized size than the storage and PO bins, and are, for example, about half the size of those other bins. The smaller FO bins are not compatible with the indexed storage arrays of the mega facilities, the macro facilities, and the micro facilities or the transport vehicles travelling therebetween, and are instead sized and configured for a different type of indexed storage array used at the nano facilities. Each record of the FO bins table 1013 of the central database 803 comprises a static field containing the Bin_ID of a respective one of the FO bins, the order number of a particular customer order of which one or more ordered products reside in the FO bin; the Facility_ID of the facility at which the respective FO bin currently resides or the Vehicle_ID of the transport vehicle on which the respective FO bin currently resides; and the Location_ID of a particular storage location at which the FO bin resides in the indexed storage array of the facility or the transport vehicle, if the FO bin is currently stowed in one of the indexed storage arrays, or of a dynamic storage location on a robotic handler or a conveyor on which the storage bin is placed and is being moved within or out of the facility.
The supply shipment table 1017 of the central database 803 is populated with expected inventory supply shipments scheduled to deliver new inventory to the system 800, typically at the mega facilities thereof. The contents of the supply shipments are itemized in a separate shipment details table 1018, each record of which comprises a unique identifier (Case_ID) for each case of product in the expected supply shipment, the Shipment_ID of the shipment to which the case belongs, the Product_ID(s) of a product type contained in the case, and a quantity of the product type found in the case.
The local facility database 825 further comprises an automation equipment information table 825c comprising a static field for a unique identifier (Equipment_ID) of each piece of automation equipment, for example, a robotic storage/retrieval vehicle (RSRV) or a conveyor operable at a particular facility. The RSRV is indexed and defines a dynamic storage location for placing and locating a storage unit while moving the storage unit within or out of the facility. In an embodiment, the conveyor also defines a storage location onto which the storage unit is being transferred within the facility or from the facility to the transport vehicle and vice versa. The Equipment_ID is used as the Location_ID of the storage unit when the storage unit is being navigated by an RSRV or a conveyor within or out of the facility, to allow continuous tracking of the storage unit. The automation equipment information table 825c further comprises a variable field for the Bin_ID of a storage unit that is currently held on and moved by a particular RSRV or conveyor within and out of the facility. The automation equipment information table 825c also stores other information such as equipment type, for example, an RSRV or a conveyor, real-time location of the automation equipment, etc. In another embodiment, manual operations equipment, for example, a forklift, is also mapped to an Equipment_ID and defines a dynamic storage location. In this embodiment, the Equipment_ID of the manual operations equipment is used as the Location_ID of the storage unit when the storage unit is being manually operated on by the manual operations equipment within the facility to allow continuous tracking of the storage unit.
The local facility database 825 further comprises one or more on-site bins tables 825e that list the Bin_IDs of all storage units and/or order bins currently on location at that particular facility. In an embodiment, the on-site bins table 825e of the local facility database 825 comprises fields for storing an empty/occupied status of each storage unit, an environmental flag, a Location_ID of a respective storage location, a destination Facility_ID, and timing data. For facilities having multiple bin types, in an embodiment, each bin type has its own respective on-site bins table 825e in the local facility database 825. The local facility database 825 further comprises a workstation information table 825d containing unique identifiers (Workstation_IDs) of different workstations situated at that particular facility; and for each such workstation, a workstation type denoting the type of work operations performed at that workstation, for example, an induction workstation, a value-added service (VAS) workstation, a kitting workstation, a picking workstation, a packing workstation, an order management workstation, etc.; a location of the workstation in the facility, for example, in an addressed format configured to command travel of RSRVs thereto, and/or carrying or conveyance of storage units thereto by conveyors or other automated bin handling equipment; identification of particular work supplies stocked at that workstation, for example, packaging, labelling, and tagging supplies; and in an embodiment, one or more workstation category fields designating any specialized operating characteristics or capabilities provided at that workstation that distinguish the workstation from other workstations of the same type, for example, category fields denoting compatibility or incompatibility with particular classes of product such as food-grade workstations maintained to greater sanitary standards for exposed food handling; allergen-safe workstations at which allergenic products are prohibited, optionally organized by subcategory, for example, peanut-free, tree nut-free, gluten-free, shellfish-free, dairy-free, etc.; and hazardous goods workstations specifically for hazardous goods forbidden at other workstation categories. In an embodiment, the categorization is on a flagged basis, where only specialized workstations are flagged with a special categorization, and the lack of any such flag denotes a general-goods workstation where anything other than controlled-product classes, for example, hazardous goods, exposed food products, etc., are acceptable, regardless of potential allergen content. The local facility database 825 further comprises a facility information table 825a for storing the same or similar content to the respective record in the facilities table 1006 of the central database 803 illustrated in
The local facility database 825 further comprises a robot information table 825f for storing data associated with the RSRVs within the automated storage and retrieval system (ASRS), for example, the multi-zone ASRS 100 illustrated in
The robot information table 825f allows tracking of the location of the RSRVs within the multi-zone ASRS 100, the storage units held by the RSRVs, and information pertaining to the last journey of the RSRVs into environmentally controlled storage zones or temperature-controlled storage zones, also referred to herein as “temperature zones”, of the multi-zone ASRS 100. In the determination of the temperature factor for each RSRV, the time span between the current system time, that is, the CCS clock time and the Last_TempZone_Exit_Time helps determine when each RSRV last accessed an environmentally controlled storage zone. In an embodiment, the CCS 817 normalizes the time span according to a degree of exposure of the RSRV to a non-ambient temperature. For normalization, in an embodiment, the CCS 817 calculates the duration of time that the RSRV spent in an environmentally controlled storage zone by differencing the Last_TempZone_Exit_Time by the Last_TempZone_Entry_Time. When RSRVs have accessed an environmentally controlled storage zone at a similar time in the past, the calculation of the duration of time spent by each of the RSRVs helps weigh or prioritize the RSRVs that have spent less time in the environmentally controlled storage zone and hence are closer to ambient temperature. For example, if two RSRVs exit the same environmentally controlled storage zone at about the same time, by calculating the duration that each RSRV spent in the environmentally controlled storage zone, the CCS 817 optimally predicts which RSRV is closer to ambient temperature.
In another embodiment, if the receiving facility, for example, a micro-fulfillment center (MFC) has multiple environmentally controlled storage zones, the CCS 817 normalizes the temperature factor of the RSRVs based on the environment or temperature of the storage zone. Frozen environments impact the RSRVs to a much greater degree than chilled environments, and therefore, the CCS 817 adjusts the temperature factor of each RSRV to account for the environmental properties of each storage zone. The Last_TempZone_Type field in the robot information table 825f delineates the type of environmentally controlled storage zone, which can be used to lookup the environmental properties of the environmentally controlled storage zone to normalize the temperature factor based on the environment. The CCS 817 then uses the temperature factor to select the optimal RSRV for a task, for example, a pick task. If the pick task is in an environmentally controlled storage zone, for example, a chilled storage zone or a freezer storage zone, the CCS 817 selects an RSRV with a high temperature factor, that is, the RSRV that has spent the most time in the ambient storage zone since the last zone pick and normalizes the temperature factor based on time spent in the last environmentally controlled storage zone and harshness of the environmentally controlled storage zone. If the pick task is in the ambient storage zone, the CCS 817 selects RSRVs with low temperature factors. That is, the CCS 817 assigns an RSRV that has recently visited an environmentally controlled storage zone, for example, a chilled storage zone or a freezer storage zone, to execute a pick task to allow that RSRV to heat back up to ambient temperatures. The CCS 817 updates the Last_TempZone_Entry_Time and Last_TempZone_Exit_Time fields in the robot information table 825f when a storage unit retrieval task is completed. In an embodiment, the CCS 817 does not update the Last_TempZone_Entry_Time and Last_TempZone_Exit_Time fields in the robot information table 825f when the RSRV performs a switch of the storage units at the buffer spots of the multi-zone ASRS 100.
During the selection of the RSRVs for any retrieval task associated with a temperature zone, the CCS 817 prioritizes the RSRVs of longer absence from the temperature zone over the RSRVs of a more recent presence in the temperature zone. For example, from the data recorded in the robot information table 825f illustrated in
In an embodiment, the CCS assigns a retrieval task associated with the second storage zone to the second RSRV. The retrieval task comprises retrieving a second storage unit from a second storage location in the second storage zone. The second storage location from which to retrieve the second storage unit is selected from among any of the storage locations available upstream and positioned en route from a buffer spot in the second storage zone to the second storage locations in the second storage zone, and/or any of the storage locations available downstream and positioned en route from the second storage location in the second storage zone to an exit portal of the second storage zone.
After performance of product placement to or product extraction 1203 from the first storage unit at the workstation, the CCS commands 1203a the first RSRV or a different RSRV to transport the first storage unit from the workstation back into the second storage zone, and to drop off 1203b the first storage unit at a buffer spot in the second storage zone that is distinct from the storage locations of the second storage zone. The CCS issues commands to the first RSRV or the different RSRV to promptly exit the second storage zone after dropping off the first storage unit at the buffer spot in the second storage zone. The CCS issues commands to another RSRV to enter the second storage zone from the first storage zone, pick up the first storage unit from the buffer spot in the second storage zone, and deposit the first storage unit into one of the storage locations in the second storage zone. The CCS issues commands to the other RSRV to, after depositing the first storage unit into one of the storage locations in the second storage zone, retrieve a second storage unit from a second storage location in the second storage zone different from that in which the first storage unit was deposited. The CCS selects one of the storage locations in the second storage zone into which to deposit the first storage unit from among any of the storage locations in the second storage zone available upstream and positioned en route from the buffer spot to the second storage location in the second storage zone from which the second storage unit is to be retrieved, and any of the storage locations available downstream and positioned en route to an exit of the second storage zone from the second storage location from which the second storage unit is to be retrieved.
In accordance with the instructions received from the CCS, the RSRVs retrieve and present 1307 the designated bins to a workstation. Moreover, the CCS generates and issues instructions regarding the picking process to a worker at the workstation, for example, via a human-machine interface (HMI) provided at the workstation. In accordance with the instructions received from the CCS, the worker, for example, a human worker or a robotic worker, at the workstation picks 1308 the line items of the order from the bins to fulfill the order. The CCS determines 1309 whether the designation bins, that is, the previously retrieved designated bins or order bins containing the fulfilled order, are to be returned to or zoned in the cooled storage zone, Zone 2. If the designation bins are to be returned to or zoned in Zone 2, the CCS instructs 1310 the assigned RSRVs to put away the designated bins using a Zone 2 bin putaway process as disclosed in the detailed description of
In addition to the access shafts 124, around which the storage columns 123 are clustered and are free of the shelving of the storage columns 123 to allow travel of the RSRVs 128 therethrough as illustrated in
In accordance with the vortex travel pattern disclosed above, in an embodiment, the CCS generates and implements the following exemplary navigation scheme for minimizing the time spent by the RSRVs 128 in either the cooled, second storage zone 102 or the cooled, third storage zone 103. The CCS ensures that RSRVs 128 spend minimal time in cooled storage zones, for example, chilled storage zones 102 or freezer storage zones 103. In an embodiment, each RSRV 128 resides on the first track area 122a of the upper track layout 122 by default, thereby residing normally in the ambient, first storage zone 101. The CCS commands the RSRVs 128 to enter the cooled, second storage zone 102 or the cooled, third storage zone 103 when retrieval of a storage unit therefrom is required.
In the method disclosed herein, storage units are referred to as either “ambient bins”, denoting bins containing products storable in an ambient environment in ambient conditions and therefore designated for storage in the ambient, first storage zone 101, or “cool bins”, denoting bins requiring storage in a cooled environment, for example, in the chilled, second storage zone 102 or the freezer, third storage zone 103. The example illustrated in
The CCS selects one of the available RSRVs for a cool bin retrieval task based on an assessment of which of the available RSRVs has been in ambient conditions for the longest period of time, that is, which RSRV has been outside the cooled, second storage zone 102 (Zone 2) and third storage zone 103 (Zone 3) the longest. In an embodiment, the CCS tracks presence and absence of each RSRV in the cooled storage zones 102 and 103 by recording an exit time at which the RSRV exits either cooled storage zone 102 or 103, and storing the exit time in records of the robot information table of the local facility database of the CCS illustrated in
Moreover, at step 1602, having selected an RSRV to assign to the cool bin retrieval task, the CCS commands that RSRV to travel up to the upper track layout 122 from the lower track layout 126 through one of the outer shafts 124a, unless the RSRV is already on the upper track layout 122. The CCS then commands the RSRV to travel to a spot on the upper track layout 122 that neighbors one of the buffer spots 112a of the first storage zone 101 near the entrance portal 108a of the second storage zone 102 illustrated in
Having unloaded this unneeded ambient bin to this buffer spot 112a of the first storage zone 101 positioned near the second storage zone 102, at step 1603, the CCS commands the RSRV to enter the upper attic space of the cooled, second storage zone 102 via the nearby upper entrance portal 108a, and to travel to a pickup spot adjacent to one of the buffer spots 112b of the second storage zone 102, where an unneeded cool bin resides, having been previously deposited at the buffer spot 112b by another RSRV as will similarly be performed later by the currently assigned RSRV at step 1608. At step 1603, the CCS commands the RSRV to load the unneeded cool bin from the buffer spot 112b of the second storage zone 102 onto the upper support platform of the RSRV.
At step 1604, the CCS commands the RSRV now carrying the unneeded cool bin to travel to the spot in the second track area 122b of the upper track layout 122 that overlies the access shaft 124 by which the storage column 123 containing the targeted cool bin is accessible. The CCS identifies an available or unoccupied storage location in one of the storage columns 123 neighboring this access shaft 124, for example, at a level of the 3D gridded storage structure equal to or above the storage location of the targeted cool bin, and at step 1605, commands the RSRV carrying the unneeded cool bin to descend down the access shaft 124 to the level of the available storage location and to deposit the unneeded cool bin into the available storage location. At step 1606, the CCS commands the now bin-less RSRV to travel through the same access shaft 124, for example, in a descending direction, presuming an available storage location for the unneeded cool bin was available at a higher level in the same access shaft 124, to the storage location at which the targeted cool bin resides, and to retrieve the targeted cool bin from this storage location and load the targeted cool bin onto the upper support platform of the RSRV.
As disclosed above, the selected available storage location into which the unneeded cool bin is deposited resides, for example, at an equal level to or higher level than the storage location where the targeted cool bin resides such that the selected available storage location resides upstream of the storage location of the targeted cool bin in the overall travel path of the RSRV from the buffer spot 112b of the second storage zone 102, through the same access shaft 124 from which the targeted cool bin is located, and to a lower exit portal 109a illustrated in
In another example, the selected available storage location is alternatively positioned a lower level than the storage location of the targeted cool bin, for example, in situations where there are no open upstream storage locations unoccupied by stored cool bins. In this example, the selected available storage location resides downstream of the storage location of the targeted cool bin in the overall travel path of the RSRV, and therefore, the RSRV is configured to temporarily reverse direction after depositing the unneeded cool bin to travel in an ascending upstream direction from the deposited storage location of the unneeded cool bin back up to the storage location of the targeted cool bin. Despite necessitating such momentary backtracking of the RSRV in the upstream direction, the available downstream storage location still resides on the same overall travel path of the RSRV from the buffer spot 112b of the second storage zone 102 to the lower exit portal 109a through the same access shaft 124 by which the targeted cool bin is accessible, but is positioned en route from the storage location of the targeted cool bin to the lower exit portal 109a rather than en route from the buffer spot 112b of the second storage zone 102 to the storage location of the targeted cool bin. Regardless of upstream or downstream relation to the storage location of the targeted cool bin, the CCS keeps the overall occupancy time of the RSRV inside the second storage zone 102 low by selecting an available storage location for the unneeded cool bin by avoiding the need for the RSRV to travel between and transition into and out of multiple access shafts 124 in the cooled, second storage zone 102.
At step 1607, after the RSRV deposits the unneeded cool bin and retrieves the targeted cool bin, the CCS commands the bin-carrying RSRV to descend the access shaft 124 down to the lower track layout 126, exit the cooled, second storage zone 102 via the lower exit portal 109a in the full-span barrier wall 104, and travel through the ambient, first storage zone 101 to the targeted workstation 114 or 115 to which the order being fulfilled has been assigned by the CCS. The targeted workstation is the single-point workstation 114 or the multi-point workstation 115 as exemplarily illustrated in
At step 1608, the CCS commands the RSRV to travel upwardly through one of the outer shafts 124a of the 3D gridded storage structure, thereby carrying the retrieved cool bin to the upper track layout 122 of the 3D gridded storage structure. At step 1609, the CCS commands (a) re-entry of the RSRV back into the cooled, second storage zone 102 via the entrance portal 108a thereof, thereby carrying the previously retrieved and now unneeded cool bin back into the cooled, second storage zone 102; (b) movement of the RSRV to a spot adjacent to an available one of the buffers spots 112b of the second storage zone 102; and (c) offloading of the now unneeded cool bin from the RSRV to that available buffer spot 112b for later pickup by another RSRV tasked with subsequent retrieval of another targeted cool bin from the second storage zone 102. At step 1610, the CCS commands the now bin-less RSRV to exit the cooled, second storage zone 102 and return to the ambient, first storage zone 101 through the upper exit portal 109a of the second storage zone 102 at the upper track layout 122 of the 3D gridded storage structure. When the RSRV returns to the ambient, first storage zone 101 at the upper track layout 122, the CCS commands the RSRV to pickup an unneeded ambient bin from one of the buffer spots 112a in the first storage zone 101, thereby freeing up that buffer spot 112a for receipt of another unneeded ambient bin by another RSRV assigned to another cool bin retrieval task. In an embodiment, for the next bin assignment 1611, the CCS assigns the RSRV that picked up the unneeded ambient bin to an ambient bin retrieval task, during which the RSRV is configured to deposit the currently carried unneeded ambient bin in an available storage location accessible off the same access shaft 124 by which the targeted ambient bin is to be retrieved. This available storage location may reside upstream or downstream of the storage location at which the targeted ambient bin of the ambient bin retrieval task resides.
The foregoing method minimizes time spent by any one RSRV in the cooled storage zone 102 or 103 containing the targeted cool bin, in that the CCS assigns a cool bin retrieval task to an RSRV that starts outside the cooled storage zone 102 or 103 in the ambient, first storage zone 101, wherein the assigned RSRV deposits a previously buffered cool bin in an available storage location accessed off the same access shaft 124 as the targeted cool bin the RSRV has been tasked to retrieve, and on the back end, the RSRV returns the retrieved cool bin only to a buffer spot 112b or 112c on the upper track area 122b or 122c of the cooled storage zone 102 or 103 illustrated in
While the illustrated embodiment uses drive-through workstations 114 and 115 in which the retrieved bins from which product is to be picked are carried through the workstations 114 and 115 on the RSRVs, other embodiments alternatively employ drop-off workstations, for example, conveyor-only workstations, in which case the return path of the bin retrieval and return process is performed by a different RSRV that performed the retrieval task. In an embodiment, the same brief drop-off of the returning cool bin at a buffer spot 112b or 112c of the cooled storage zone 102 or 103 and prompt re-exit of the RSRV after such drop-off are used to minimize time spent by the RSRV in the harsher operating conditions of the cooled storage zones 102 and 103, regardless of whether this RSRV returning the unneeded cool bin to the cooled storage zone 102 or 103 is the same RSRV that previously retrieved that same bin. The subsequent reliance on a different RSRV or the same RSRV once ambiently reacclimatized after spending sufficient time outside the cooled storage zones 102 and 103, to deposit the buffered cool bin in an available storage location positioned en route to its retrieval of another targeted cool bin also helps minimize the time spent by the RSRV in the cooled storage zones 102 and 103 by using one trip through an access shaft 124 of the cooled storage zone 102 or 103 to both retrieve a newly targeted cool bin and deposit a previously returned cool bin. These techniques for minimizing the time spent by the RSRVs in the cooled storage zones 102 and 103 allows use of a universal fleet of standardized RSRVs of a same type that would be used in a purely ambient ASRS without having to incur the cost of specialized cold climate RSRVs specifically configured to optimally handle the harsher operating conditions inside the cooled storage zones 102 and 103.
While the detailed embodiments herein relate to multiple zones of the 3D gridded storage structure being characterized by ambient and cooled environmental conditions, in other embodiments, similar division of the 3D gridded storage structure into isolated storage zones and strategic navigation of the RSRVs to minimize time spent by the RSRVs in one or more storage zones are employed regardless of the particular environmental differences that represent a harsher environment in one or more storage zones relative to the remaining other storage zones. For example, in an embodiment, the multi-zone ASRS 100 is configured with an ambient zone accompanied by a warmed zone that is heated to elevated temperatures above the ambient conditions, for example, for fulfilling food or meal orders with warmed food items from the heated storage zone, in which case the elevated temperatures of the warmed zone denote a harsher operating environment for the RSRVs, exposure time to which is therefore limited using some or all of the techniques disclosed herein. In addition or alternative to temperature, an example of another environmental condition that may be varied between storage zones is humidity, where one or more humidity-controlled storage zones are each configured to operate in a respective humidity range, and are accompanied by one ambient humidity storage zone that lacks any dedicated humidity control beyond any humidity control equipment of the facility that controls the surrounding environment outside the 3D gridded storage structure.
In another example, the different storage zones need not necessarily differ from one another in terms of temperature-controlled environments, and in various embodiments, may focus more on physical isolation of the storage zones from one another due to different categories of product stored therein, for example, high-security goods stored in a fully enclosed second storage zone 102 or third storage zone 103 versus low-security goods stored in a more environmentally open first storage zone 101, whether the security is defined, for example, by value, safety in product items such as firearms, ammunition, pharmaceuticals, etc., or combinations thereof. Another example is physical isolation of allergenic and non-allergenic foods and products such as nuts, allergens, etc., to prevent cross-contamination. In another example, different vendors or customers may demand physical separation of their supplied or ordered goods from those of others to ensure accuracy in inventory management and order tracking. In another example, flammable or otherwise hazardous goods are isolated from others in one of the enclosed storage zones, and one or more enclosed storage zones differ from any one or more other storage zones in terms of safety related equipment such as increased ventilation for storage of odorous and/or noxious substances, and/or inclusion of added or specialized fire suppression equipment to augment existing fire suppression means of the facility, for example, for particularly flammable or hazardous goods. Where flammable goods are being stored in the contained storage zones 102 and 103, in an embodiment, the boundary walls thereof employ particularly fire-retardant construction techniques and materials.
While the illustrated embodiment of the multi-zone ASRS 100 uses open-top storage units to hold inventory within the 3D gridded storage structure, in other embodiments, various storage units capable of storing inventory are stored in the 3D gridded storage structure similarly divided into isolated storage zones, regardless of the particular shape and scale of those storage units and the corresponding configuration and scale of the 3D gridded storage structure, and therefore, the term “storage unit” is used herein to refer to any variety of inventory holders, for example, bins, totes, trays, boxes, pallets, gaylords, etc. While the 3D gridded storage structure in the illustrated embodiment employs both upper and lower track layouts 122 and 126 respectively residing above and below the 3D gridded storage structure comprising the 3D array of storage locations, other embodiments comprise grids with a singular track layout either above or below the 3D array. As disclosed above, the workstations need not necessarily be of a travel-through type in which the RSRVs fully enter the workstations, and therefore, the workstations accordingly need not be positioned directly adjacent a track layout, for example, 126, of the 3D gridded storage structure, or connected thereto by an extension track, as alternative conveyance may alternatively be employed to handle the storage units between the RSRV drop-off points and access points of the workstations where workers interact with the storage units.
Also, while the embodiments employ a cooperative 3D gridded storage structure and RSRV configurations by which the RSRVs travel in their entirety up and down through access shafts 124 in which the RSRVs are operable in four different working positions to laterally access storage columns 123 on any side of any access shaft 124, other embodiments employ a stack-and-dig approach of the type in which the storage units are stacked directly atop one another and retrieved in an overhead manner by robotic handlers, each having a wheeled chassis that remains atop an upper track layout and travels in only two horizontal dimensions, and relies on a lowerable crane to interact with only the uppermost storage units of the stacks from a directly overhead relation thereto. While in the illustrated embodiment, an access location from which each storage unit is retrieved or deposited refers to a space in the neighboring access shaft 124 from which the RSRV laterally reaches into the storage location to or from which the storage unit is deposited or retrieved, in another embodiment, the access location from which a storage unit is extracted or deposited is the spot of the upper track layout overlying a storage column 123 in which storage units are stacked or stackable.
After an unneeded bin is retrieved from a buffer spot in the second storage zone, the CCS selects the storage location to put away the unneeded bin based on vacant or unoccupied storage locations contained in the storage column containing a needed bin. After putting away the unneeded bin in a vacant storage location of the storage column, the RSRV travels to the needed bin, picks the needed bin from the storage location, and exits the second storage zone.
As exemplarily illustrated in
As illustrated in
If the order tote is waiting to be stored, in accordance with instructions received from the CCS, the worker places 2108 the order tote into the order bin. The CCS determines 2109 whether the empty or tote-occupied order bin should be zoned or stored in the cooled, second storage zone of the multi-zone ASRS 100. If the order bin should be zoned in the cooled, second storage zone, the CCS instructs 2110 the assigned RSRV to put away the order bin using the Zone 2 bin putaway process as disclosed in the detailed descriptions of
In an embodiment, the receiving facility comprises a bin exchange area 119 comprising an inbound lane and an outbound lane as illustrated in
Each bin has assigned thereto a unique bin identifier (Bin_ID). The CCS controls the exchange of the incoming bins for the outgoing bins as follows. The CCS receives a notification of an arrival or an approach of the transport vehicle at or near the receiving facility. The CCS commands an RSRV to deliver an outgoing bin from the ASRS of the receiving facility to the outbound lane of the bin exchange area 119. The CCS commands the same RSRV that delivered the outgoing bin to the outbound lane to pickup an incoming bin at the inbound lane and carry the incoming bin to a destination through the ASRS. The destination to which the RSRV is commanded to carry the incoming bin is an available storage location within the ASRS. In an embodiment, the outgoing bins comprise one or more occupied bins. In another embodiment, at least one of the occupied bins contains one or more customer returns. In another embodiment, at least one of the occupied bins contains one or more expired inventory items. In another embodiment, at least one of the occupied bins contains one or more recalled inventory items. In another embodiment, at least one of the occupied bins contains one or more inventory transfers.
The flowchart illustrated in
At step 2205, the supply FMS sends some or all of these shipment details, and at least the quantity of supply bins to the CCS of the receiving facility, before or during actual fulfillment of the replenishment order at the supply facility. In an embodiment, the CCS at the receiving facility optionally performs a bin consolidation process at step 2206 to optimize a quantity of outgoing bins to be exchanged for the incoming supply bins, for example, to best accomplish or approximate a 1:1 exchange ratio, and/or make optimal use of a bin capacity of the transport vehicle. In the bin consolidation process, the CCS issues commands for bin consolidation to create empty bins of a specified quantity. In an embodiment, the bin consolidation process is performed to increase the quantity of empty bins on hand at the receiving facility, or to consolidate customer returns, expired inventory, recalled inventory, or inventory transfers from a current number of bins occupied thereby into a smaller number of bins. In parallel with performance of the consolidation process at the receiving facility, the supply facility fulfills the replenishment order at a workstation of the ASRS of the supply facility by picking and compiling the required replenishment inventory from the ASRS into supply bins for shipment to the receiving facility according to the calculated and transmitted bin quantity and configuration. That is, at step 2207, the supply FMS triggers the assembly of the supply bins according to quantity and configuration. At step 2208, the supply FMS issues commands for loading the supply bins onto a transport vehicle at a loading dock of the supply facility. The now-filled supply bins at the supply facility are loaded into a storage array of the transport vehicle, on an automated or manual basis, and at step 2209, the transport vehicle travels from the supply facility to the receiving facility for auto-induction 2210 at the receiving facility.
In an embodiment, prior to identifying at least two non-empty, less-than-full bins currently holding items therein, the CCS at the receiving facility, at which replenishment inventory is required, receives an incoming communication identifying a required quantity of outgoing bins needed from the supply facility for delivery elsewhere; queries a database to identify a currently available quantity of candidate outgoing bins; and compares the currently available quantity of candidate outgoing bins against the required quantity of outgoing bins, thereby determining a need to create one or additional empty bins. The incoming communication is received from the supply facility to which a replenishment order was previously transmitted to request the replenishment inventory therefrom. The incoming communication identifies a quantity of supply bins in which the replenishment inventory will be transported to the receiving facility, and for which the outgoing bins from the receiving facility are to be exchanged.
The flowchart illustrated in
If sufficient resources are determined to be available at step 2303, then at step 2304, the CCS determines whether there is already a sufficient quantity of empty bins available in the ASRS of the receiving facility to fulfill the bin compensation needs. If there is a sufficient quantity of empty bins available in the ASRS of the receiving facility to fulfill the bin compensation needs, then no bin consolidation is required and the process is terminated 2311. If there is an insufficient quantity of empty bins available in the ASRS of the receiving facility to fulfill the bin compensation needs, then the CCS checks for the presence of multiple inventory bins containing the same product, also referred to as “common stock keeping unit (SKU) bins”, and upon confirming such a presence, checks whether among the common SKU bins there are multiple less-than-full bins, of which a remaining quantity in an emptiest of the less-than-full bins is accommodatable by available capacity in one or more of the other less-than-full bins. If there are multiple less-than-full bins, then at steps 2305 and 2306, the CCS commands one RSRV to retrieve the emptiest bin for delivery to the two-point workstation, and commands one or more additional RSRVs to retrieve one or more other less-than-full bins that have the capacity to receive the product quantity from the emptiest bin, and deliver and present the same to the same two-point workstation in sequence. At step 2307, the CCS commands the RSRV carrying the emptiest bin to travel to the picking port of the two-point workstation, and at step 2308, the CCS commands the RSRV(s) carrying one or more other less-than-full bins to sequentially queue up at the placement port of the two-point workstation. At step 2309, the CCS instructs a human or robotic worker to pick the remaining product items in the emptiest bin therefrom and place the remaining product items in one or more other less-than-full bins as the other less-than-full bins are sequentially indexed to the placement port. At step 2310, the CCS updates the local facility database to change a recorded status of the previously emptiest bin to “empty”. The process is then re-iterated from step 2303 onward until enough bins have an empty status to fulfill the bin compensation needs of the replenishment order. The bin consolidation process therefore converts a first set of one or more non-empty, though less-than-full and near-empty, bins into fully-empty bins to be exchanged for incoming supply bins slated to arrive from the supply facility, while a second set of non-empty less-than-full bins are converted into now-fuller bins due to the addition of product items thereto from the now fully-empty bins.
In an embodiment, picking of the replenishment order, or at least shipping thereof from the supply facility, is made conditional on the availability of sufficient outgoing bins at the receiving facility, such that the FMS of the supply facility may await a “sufficient outgoing bin count” confirmation signal from the CCS of the receiving facility before picking or shipping the replenishment order. This represents prioritized fulfillment of in-stock customer orders than can be fulfilled without delay based on already on-hand inventory at the receiving facility during peak order hours, and delaying of inbound transport of the replenishment order until off-peak hours where the lower order frequency frees up more ASRS resources at the receiving facility to enable completion of the bin consolidation process on which the shipment of the replenishment order is conditional. In other embodiments, other prioritization schemes are employed. While the forgoing example of the bin consolidation process is performed on common SKU bins containing the same product, in other embodiments, bin consolidation is also performed in instances of mixed SKU bins containing different products therein. In these embodiments, subdivided multi-SKU bins whose interiors are each divided into multiple compartments are employed, in which case an occupied or empty status of each compartment is used to gauge the overall emptiness and available capacity of a less-than-full bin that qualifies for bin consolidation.
The 1:1 bin swap is implemented for predictable, consistent, balanced bin flow between facilities. In another embodiment, in an example scenario where the supply bin count of a replenishment order is less than a bin capacity of the transport vehicle, and there is a large quantity of occupied outgoing bins awaiting transport to a destination other than the supply facility, but on a route in which the supply facility serves as a cross-dock or through-point, then outgoing empty bins are swapped at a 1:1 ratio to the incoming bins to not shortchange the supply facility for its loss of the incoming bins, while using the extra available vehicle capacity to ship out some of the excess occupied bins, or even to swap the outgoing empty bins at less than 1:1 and increase the quantity of outgoing occupied bins if the need to offload them from the receiving facility exceeds the need to compensate the supply facility with empty bins.
In other embodiments, the same consolidation of useful product inventory in the ASRS of the receiving facility is performed for purposes other than specifically creating empty inventory bins for exchange with incoming supply bins, that is, for purposes other than compensating the bin loss of a supply facility from which those incoming supply bins are arriving. For example, picking an order for a large quantity of a single product from a multitude of inventory bins each containing a less-than-full or near-empty quantity of that product is much less time and resource efficient than fulfilling that order from a lesser quantity of full or near-full inventory bins. Accordingly, the same identification of at least two non-empty, less-than-full common SKU bins for consolidation can be used in combination in subsequent execution of steps 2305-2310 illustrated in
In other embodiments, the same bin consolidation process, instead of generating empty outgoing bins by consolidating useful product inventory of the receiving facility, is used to consolidate customer returns, expired inventory, recalled inventory, and inventory transfers, generally categorized as unwanted goods, from less-than-full bins currently stored in the ASRS of the receiving facility to reduce the quantity of bins occupied by such unwanted goods. For example, this is useful if the quantity of stored bins occupied by such unwanted goods exceeds the quantity of expected incoming supply bins, and/or exceeds the capacity of the transport vehicle on which the incoming supply bins are expected and on which it would be desirable to ship out at least some of the unwanted goods. The consolidation process can therefore be used to reduce the number of bins storing unwanted goods to a quantity equal to the transport vehicle bin capacity or equal to the quantity of incoming supply bins expected on the transport vehicle, if the initial number of bins containing unwanted goods originally exceeded such vehicle capacity or incoming bin quantity. Alternatively, if the initial number of bins containing unwanted goods is already less than the vehicle capacity or incoming supply bin quantity, then the consolidation process can be used to decrease the number of bins storing unwanted goods to free up more room for empty outgoing bins on the transport vehicle, whether the empty bins loaded onto the transport vehicle are already-empty bins stored in the ASRS of the receiving facility, one or more empty bins created by this consolidation of unwanted goods, and/or one or more empty bins created by the consolidation of useful product inventory in the method disclosed in the detailed description of
In consolidation of unwanted goods, the method illustrated in
The bin exchange and induction process illustrated in
Starting with the supply bin management sequence on the left side of
Meanwhile, in the empty bin management sequence on the right side of
Returning to the empty bin management sequence, the RSRV carrying the first extracted empty inventory bin on the lower track layout of the 3D gridded storage structure unloads this empty bin to the outbound port 147 of the induction station at step 2512. Returning to the supply bin management sequence, at step 2506, the same RSRV that just dropped off the first empty inventory bin at the outbound port 147 of the induction station then loads the first supply bin onto itself, and at step 2507 travels to an available storage location in the 3D gridded storage structure and deposits the supply bin therein. In an embodiment, following the vortex travel patterns disclosed above, this depositing of the supply bin comprises first carrying the supply bin up an outer shaft 124a of the 3D gridded storage structure to the upper track layout, then travelling thereon to the spot overlying an access shaft 124 neighboring the available storage location as illustrated in the solid-line travel path of
Meanwhile, at step 2513 in the empty bin management sequence, since having been dropped off at the outbound port 147 of the induction station, the first empty bin is being conveyed toward the loading dock of the receiving facility on the outbound conveyor 121 illustrated in
In addition to the local computerized facility management system (FMS) 805 at each facility and the computerized control system (CCS) 817 at the receiving facility 14, the overall computerized inventory management system further comprises a cloud-based computer platform or the central computing system 801, and the computerized VMS 814 on each transport vehicle 813 as illustrated in
The carousels 815 of the transport vehicle 813 form a dynamic array of storage locations, in that each platform denotes a respective storage location, but each storage location is movable into different positions within the trailer by operation of the carousel 815. This differs from the static array of storage locations at the facilities, where each storage location in the 3D gridded storage structure is at a fixed static position therein and not at a dynamically movable position. The use of a dynamic storage array in the transport vehicle 813 enables convenient loading thereof from the rear loading door of the trailer. However, in other embodiments, a different type of storage array is used in the transport vehicle 813, for example, a miniaturized version of the RSRV-served gridded storage structure used in each facility, or another human or robot-served storage array with storage locations, for example, shelves, cubbies, etc., suitably sized to specifically fit the standardized size and shape of the storage units 127. The transport vehicle 813 is equipped with a global positioning system (GPS) device that tracks the movement and location of the transport vehicle 813, and a mobile cellular communication device that communicates the current location of the transport vehicle 813 to the cloud-based computer platform. Querying of the cloud database for a Bin_ID, for example, based on the cataloged product currently stored in that storage unit 127, therefore, reports on the current location of that storage unit 127 based on the GPS coordinates of the transport vehicle 813 on which the storage unit 127 is travelling.
In various embodiments, supply bins from the supply facility for replenishing stock at the receiving facility 14 are exchanged for outgoing bins from the receiving facility 14, whereby the ASRS of the supply facility is not continually shorted in its on-hand supply of storage bins. In an embodiment, the exchange is typically performed at a one-to-one ratio. In an embodiment, the outgoing bins include at least some empty inventory bins from the ASRS. In another embodiment, the outgoing bins additionally or alternatively include one or more customer return bins, each containing one or more customer-returned products for the purpose of shipping the customer return to the supply facility, where the customer return can be inspected and handled on the larger premises of the supply facility, or can be shipped even further upstream toward another returns-handing facility, whether part of the facility network or external thereto, for example, to an outside supplier or manufacturer. In addition or alternative to empty inventory bins and customer return bins, outgoing bins from the receiving facility 14 comprise inventory transfer bins containing unneeded or slow-moving inventory to be shipped upstream to the supply facility, for example, for redistribution to another facility in the network at a locale with greater market demand for such items.
In another embodiment, the outgoing bins from the receiving facility 14 comprise expired-inventory bins containing expired inventory to be transported upstream to the supply facility for disposal thereat, or redistribution therefrom to a suitable disposal site or other final destination, for example after consolidation with expired inventory from other facilities replenished by that same supply facility. In another embodiment, the outgoing bins from the receiving facility 14 comprise recalled-inventory bins containing inventory that has been recalled by a supplier or a manufacturer and can be routed upstream thereto via the supply facility. The outgoing bins from the receiving facility 14 can therefore be categorized generally into two groups, empty bins free of any content and occupied bins having items therein, for example, customer returns, expired inventory, recalled inventory, and inventory transfers.
The multi-zone ASRS 100 exemplarily illustrated in
Having vertical delineated temperature zones that are in direct communication with the ambient storage zone constrains the number of temperature transitions to one. The method that RSRVs access storage units in each temperature zone minimizes time spent in temperature zones and maximizes throughput performance. Using the access portals on the 2D upper track layout of the 3D gridded storage structure to enter the temperature zones and the access portals on the 2D lower track layout to exit temperature zones minimizes route contention and route length. This reduces the journey time in temperature zones, which minimizes exposure to non-ambient temperatures. As a result, the physical temperature change of the RSRVs is minimized, which lowers the requirements for corrective measures of adverse effect, for example, fogging of a camera, when the RSRVs transition temperature gradients. Spending as little time as possible in non-ambient temperatures allows one RSRV variant to work in all temperature zones, while also lowering RSRV design requirements since operation is not exclusive to harsh environments.
Since all workstations are attached to the 2D lower track layout, which is continuous to all temperature zones, all RSRVs and therefore all storage units from each temperature zone are accessible at all workstations. Order pickers can therefore work in the comfort of ambient temperatures while picking goods that are chilled or frozen. Orders containing items from multiple temperature zones can also be assembled at a single workstation, rather than conducting picking operations from each temperature zone and having to consolidate all lines items to fulfill the order. The insulated workstation variant illustrated in
The storage geometry of the multi-zone ASRS 100 is useful in chilled and frozen environments since the central void of downshafts acts as ducts between a cold air reservoir in the upper track layout and the lower track layout of the 3D gridded storage structure of the multi-zone ASRS 100, thereby allowing the multi-zone ASRS 100 to act as a self-contained, freestanding freezer or cooler. Each storage unit is in communication with the downshaft which optimizes access to cold air to chill its contents. Each storage unit is also shelved which allows for voids between storage units further increasing air flow to the contents of each storage unit.
Moreover, orders, once picked, can be assembled in advance and stored within the multi-zone ASRS 100 until customers arrive for order pickup. The integrated workflow of the order management disclosed herein allows workers to both remove orders for pickup and induct orders for storage with a single presentation of an RSRV at a workstation. This 1:1 exchange of order totes minimizes RSRV touches and therefore lowers the number of RSRVs required in the system to meet throughput requirements.
Furthermore, the embodiments herein also employ a 1:1 exchange technique of forward and reverse storage units during auto-induction at the receiving facility, for example, a micro-fulfillment center, and a supply facility, for example, a servicing distribution center, during the replenishment process. As the forward flow rate is identical to the reverse flow rate and physical and logical custody of each storage unit is directly transferred between entities, shipping and receiving processes and associated staging areas can be eliminated in the micro-fulfillment and distribution center sites, which substantially reduces labor, real estate and resource requirements while streamlining logistics, making operations orderly and easier to monitor in real time over the chaotic approaches used in conventional supply chains. This eliminates the buffer overflow of materials and therefore staging areas, while further increasing the orderliness and predictability of the supply chain network. Storage units flowing in a reverse direction can be loaded with goods to be transported up the hierarchy of facilities to support customer returns, making reverse logistics cost effective over conventional methods. To support this, upon replenishment requests, the forward quantity of storage units is calculated and known to allow the receiving facility to use consolidation and return processes to create the corresponding number of reverse storage units. The consolidation process both streamlines replenishment and frees up space within the storage structure to maximize density.
Where databases are described such as the central database 803, the local facility databases 808 and 825, and the local vehicle database 826 illustrated in
The embodiments disclosed herein are configured to operate in a network environment comprising one or more computers that are in communication with one or more devices via a communication network. In an embodiment, the computers communicate with the devices directly or indirectly, via a wired medium or a wireless medium such as the Internet, a local area network (LAN), a wide area network (WAN) or the Ethernet, a token ring, or via any appropriate communications mediums or combination of communications mediums. Each of the devices comprises processors that are adapted to communicate with the computers. In an embodiment, each of the computers is equipped with a network communication device, for example, a network interface card, a modem, or other network connection device suitable for connecting to a network. Each of the computers and the devices executes an operating system. While the operating system may differ depending on the type of computer, the operating system provides the appropriate communications protocols to establish communication links with the network. Any number and type of machines may be in communication with the computers.
The embodiments disclosed herein are not limited to a particular computer system platform, processor, operating system, or communication network. One or more of the embodiments disclosed herein are distributed among one or more computer systems, for example, servers configured to provide one or more services to one or more client computers, or to perform a complete task in a distributed system. For example, one or more of embodiments disclosed herein are performed on a client-server system that comprises components distributed among one or more server systems that perform multiple functions according to various embodiments. These components comprise, for example, executable, intermediate, or interpreted code, which communicate over a network using a communication protocol. The embodiments disclosed herein are not limited to be executable on any particular system or group of systems, and are not limited to any particular distributed architecture, network, or communication protocol.
The foregoing examples and illustrative implementations of various embodiments have been provided merely for explanation and are in no way to be construed as limiting of the embodiments disclosed herein. While the embodiments have been described with reference to various illustrative implementations, drawings, and techniques, it is understood that the words, which have been used herein, are words of description and illustration, rather than words of limitation. Furthermore, although the embodiments have been described herein with reference to particular means, materials, techniques, and implementations, the embodiments herein are not intended to be limited to the particulars disclosed herein; rather, the embodiments extend to all functionally equivalent structures, methods and uses, such as are within the scope of the appended claims. It will be understood by those skilled in the art, having the benefit of the teachings of this specification, that the embodiments disclosed herein are capable of modifications and other embodiments may be effected and changes may be made thereto, without departing from the scope and spirit of the embodiments disclosed herein.
This application is a national stage application of the Patent Cooperation Treaty (PCT) international application titled “Multi-zone Automated Storage and Retrieval System”, international application number PCT/IB2020/057931, filed in the Receiving Office of the International Bureau of the World Intellectual Property Organization (WIPO) on Aug. 25, 2020, which claims priority to and the benefit of the provisional patent application titled “Multi-Zone ASRA Structure, and Auto-Induction Processes Employing Bin Consolidation and Bin Exchange Techniques”, application No. 62/891,549, filed in the United States Patent and Trademark Office (USPTO) on Aug. 26, 2019. The specifications of the above referenced patent applications are incorporated herein by reference in their entirety.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/IB2020/057931 | 8/25/2020 | WO |
| Number | Date | Country | |
|---|---|---|---|
| 62891549 | Aug 2019 | US |
