MANUFACTURING SYSTEM WITH AN INTERCONNECTED STORAGE STRUCTURE AND MANUFACTURING CELLS SHARING A COMMON ROBOTIC FLEET

A manufacturing system including an automated storage and retrieval system (ASRS) structure with a three-dimensional array of storage locations distributed throughout a two-dimensional footprint of the ASRS structure at multiple storage levels; workpieces stored within the storage locations of the ASRS structure; robotic storage retrieval vehicles (RSRVs) navigable within the ASRS structure in three dimensions to access the storage locations, and multiple manufacturing cells positioned outside the ASRS structure, is provided. The manufacturing system includes a track structure attached to the ASRS structure and defining one or more travel paths traversable by the RSRVs from the ASRS structure. The same fleet of RSRVs that is navigable within the ASRS structure is operable to deliver the workpieces to the manufacturing cells. One or more of the manufacturing cells are positioned along the track structure, thereby receiving convenient access to the workpieces along with associated tool pieces and workpiece supports for manufacturing goods.

BACKGROUND

Technical Field

The embodiments herein, in general, relate to manufacturing. More particularly, the embodiments herein relate to a manufacturing system with an interconnected automated storage and retrieval system (ASRS) and manufacturing cells sharing a common fleet of robotic storage/retrieval vehicles (RSRVs) that navigate within the ASRS structure and deliver componentry from the ASRS structure to various manufacturing cells of the manufacturing system.

Description of the Related Art

Automation in manufacturing generally refers to implementing systems that perform rote operations such as processing, assembly, material handling, etc., in a completely automated manner. Automated manufacturing comprises automating steps of a manufacturing process in addition to automating steps involved in the delivery of particular componentry such as workpieces, workpiece supports, toolpieces, etc., required at various manufacturing cells of a manufacturing facility according to the particular manufacturing process being carried out at each of the manufacturing cells. With growing advances in automation technology, most operations in manufacturing facilities are typically performed using automated machines and robots with minimal human intervention. In some automated manufacturing facilities, the sequence of processing operations is fixed by the configuration of the manufacturing equipment and cannot be changed from one order to another. In other automated manufacturing facilities that implement programmable automation, reprogramming and changeover of the manufacturing equipment for each order is time consuming and results in significant downtime, thereby reducing the manufacturing rates. To account for the time-intensive reprogramming and changeover of the manufacturing equipment, other automated manufacturing facilities substantially limit the number and variety of goods manufactured, thereby further reducing manufacturing rates.

Conventionally, manufacturing follows a linear workflow, where each manufacturing step occurs in a sequence defined by a typical one-way flow of a conveyor system or a transportation path. Once the workflow is designed and conveyors bolted down to a factory floor, the manufacturing workflow is substantially difficult to modify to changing requirements. As customer expectations are rapidly increasing towards customized products, manufacturers aim to differentiate themselves by focusing on customer experience. As a result, there is a need for automation and manufacturing systems to have the ability to be adapted to changing conditions easily and flexibly.

Conventional manufacturing facilities include manufacturing zones divided into two or more scattered, and mostly detached or separated lines in which manufacturing cells are interlinked by extensive, long-range conveyor systems and transportation paths. The layouts of the conventional manufacturing facilities typically rely on extensive, long-range conveyor systems, numerous aisles between racks, and widely spaced out and discontinuous manufacturing zones, and are, therefore, space, service and equipment intensive. Conventional systems split each manufacturing process into separate functions managed by independent entities connected by fixed conveyor belts or ground based transport. Manufacturing processes typically include receiving, kitting, building sub-assemblies, and final assembly, which are typically separate processes serviced by independent manufacturing equipment connected by linear conveyors or ground based transport. Depending on the assembly process, manufacturing cells are typically configured for a single subassembly with many transportation paths needed to complete the final assembly. There is a need for completing all manufacturing processes by a single automated material handling system that does not require long-range conveyors or ground transport, with manufacturing cells being software configurable and programmable as needed.

Automated storage and retrieval systems (ASRSs) that are used in some manufacturing facilities are typically disconnected from the manufacturing cells, thereby making it difficult to access componentry that is stored in the ASRSs and required for executing manufacturing processes at the manufacturing cells. Moreover, ASRS equipment relies on downstream sortation solutions to deliver goods to service areas at the right time and sequence. There is a need for integrating an ASRS capable of handling substantial volumes of inventory into a manufacturing environment by connecting scalable manufacturing cells to the ASRS to provide convenient access to an abundance of componentry such as workpieces and workpiece kits along with associated toolpieces and workpiece supports for optimizing the manufacture of goods. Moreover, there is a need for configuring manufacturing cells on-the-fly for a wide variety of manufacturing processes on-demand and transporting goods between all manufacturing cells in any sequence, thereby allowing any number of processes to be completed multiple times in any order. Furthermore, there is a need for just-in-time delivery of workpieces, toolpieces, and workpiece supports to the manufacturing cells for just-in-time manufacturing of subassemblies at any stage of the manufacturing process.

Another difficulty of conventional approaches to manufacturing is that due to the reliance of one-way conveyors and flow paths between processes, buffer storage is required if flow rates differ. Without buffer storage, if an upstream process processes goods faster than a downstream process at any given time, material can quickly accumulate and overwhelm the system to a halt. Due to the complexity and expense of buffer storage for each process, conventional automation solutions attempt to solve the problem with careful upfront equipment and workflow design and meticulous management during operation to ensure acceptable flow between processes. As a result, once established, workflows cannot be flexibly changed and manufacturers remain vulnerable to interruptions from unforeseen circumstances.

Moreover, in conventional approaches, componentry such as workpieces have to be physically transferred from one manufacturing cell to another manufacturing cell. Furthermore, each manufacturing cell receives and identifies the componentry, for example, by a barcode scan, a radio frequency identification (RFID) scan, etc., to complete the logical transfer of custody between entities, which is another drawback of conventional logistics. Furthermore, since conventional automated solutions rely on miles of ground-fixed conveyors or travel paths, the footprint of the entire operation is relatively large since most of the vertical space above the conveyor systems and workstations is not used.

Hence, there is a long-felt need for a manufacturing system with an interconnected ASRS and manufacturing cells sharing a common fleet of robotic storage/retrieval vehicles (RSRVs) that navigate within the ASRS structure and deliver componentry from the ASRS structure to various manufacturing cells of the manufacturing system for manufacture of goods with time, space and service efficiency, while addressing the above-recited problems associated with the related art.

SUMMARY

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 manufacturing system with an interconnected automated storage and retrieval system (ASRS) and manufacturing cells sharing a common fleet of robotic storage/retrieval vehicles (RSRVs) that navigate within the ASRS structure and deliver componentry from the ASRS structure to various manufacturing cells of the manufacturing system for manufacture of goods with time, space and service efficiency. The manufacturing system disclosed herein is adaptable to changing conditions easily and flexibly. The embodiments herein allow completion of all manufacturing processes by a single automated manufacturing system that does not require long-range conveyors or ground transport, with manufacturing cells being software configurable as needed. The embodiments herein integrate an ASRS capable of handling substantial volumes of inventory into a manufacturing environment by connecting scalable manufacturing cells to the ASRS to provide convenient access to multiple items of componentry such as workpieces and workpiece kits along with associated toolpieces and workpiece supports for optimizing the manufacture of goods.

In the manufacturing system disclosed herein, the manufacturing cells are configurable on-the-fly for a wide variety of manufacturing processes on-demand. Moreover, the manufacturing system allows transport of componentry and goods between all manufacturing cells in any order and sequence, instead of linearly with conveyors, thereby allowing any number of processes to be completed multiple times in any order. Furthermore, the manufacturing system disclosed herein executes just-in-time delivery of the componentry to the manufacturing cells for just-in-time manufacturing of subassemblies at any stage of the manufacturing process. Furthermore, the manufacturing system disclosed herein allows buffering of the componentry and finished goods in the ASRS structure between the processes performed at the manufacturing cells. Furthermore, the continuity between each of the ASRS structure and the manufacturing cells outside the ASRS structure allows a direct physical transfer of the componentry and the finished goods free of identification or scanning of the componentry and the finished goods.

The manufacturing system disclosed herein comprises a storage arrangement comprising an ASRS structure, a supply of workpieces, and a fleet of RSRVs. The ASRS structure comprises a three-dimensional (3D) array of storage locations distributed throughout a two-dimensional (2D) footprint of the ASRS structure at multiple storage levels within the ASRS structure. The supply of workpieces is stored within the storage locations of the ASRS structure for use in manufacturing goods from the workpieces. Each of the RSRVs in the fleet is navigable within the ASRS structure in three dimensions to access the storage locations in the 3D array. In an embodiment, the ASRS structure comprises at least one track-equipped level comprising a 2D gridded track layout. The fleet of RSRVs is navigable within the ASRS structure in at least two dimensions on the 2D gridded track layout. The manufacturing system disclosed herein further comprises multiple manufacturing cells positioned outside the ASRS structure. In an embodiment, the manufacturing system disclosed herein further comprises a track structure attached to the ASRS structure and extending beyond the 2D footprint of the ASRS structure to define an extension thereof. In an embodiment, the track structure is an extension of the 2D gridded track layout of the track-equipped level of the ASRS structure. The track structure is configured to define one or more travel paths on which the RSRVs are navigable and along which the manufacturing cells are distributed. The same fleet of RSRVs navigable within the ASRS structure in the three dimensions is operable to deliver the workpieces to the manufacturing cells. In an embodiment, the workpieces are transportable between each of the manufacturing cells in any order. In another embodiment, the workpieces are received at a first one of the manufacturing cells for performance of one or more of multiple process steps of a manufacturing process and subsequently stored in the storage locations of the ASRS structure and retrieved from the storage locations of the ASRS structure for the transfer of the workpieces to a second one of the manufacturing cells. In another embodiment, each of the manufacturing cells is configured to receive the workpieces multiple times for performance of one or more of the process steps of the manufacturing process.

In an embodiment, the storage arrangement of the manufacturing system disclosed herein further comprises a supply of toolpieces for use in manufacturing the goods. The toolpieces are stored in the same ASRS structure as the workpieces. The toolpieces are retrievable from the same ASRS structure and deliverable to the manufacturing cells by the same fleet of RSRVs.

In an embodiment, the storage arrangement of the manufacturing system disclosed herein further comprises a supply of storage units of compatible size and shape for storage in the storage locations of the ASRS structure. The storage units are configured to be carried by the RSRVs for transfer of the storage units to and from the storage locations and to and from the manufacturing cells. In an embodiment, the storage units comprise workpiece storage units or toolpiece storage units or any combination thereof. Each of the workpiece storage units is configured to hold one or more of the workpieces. Each of the toolpiece storage units is configured to hold one or more of the toolpieces. In an embodiment, the manufacturing cells are configured in a continuous arrangement outside the ASRS structure. In this embodiment, the storage units are configured to be transferred to and from the storage locations of the ASRS structure and between the manufacturing cells, free of identification of the storage units, due to the continuous arrangement of the manufacturing cells.

In an embodiment, the workpiece storage units comprise inventory storage units and kit storage units. Each of the inventory storage units is configured to contain a collection of inventory workpieces. Each of the kit storage units is configured to contain a kit of mixed workpieces picked from one or more of the inventory storage units according to a manufacturing process to be performed on the mixed workpieces once delivered to one of the manufacturing cells. In another embodiment, the manufacturing system disclosed herein further comprises at least one kitting workstation configured to accept delivery of the inventory storage units from the ASRS structure by the RSRVs for allowing picking of the inventory workpieces from the inventory storage units at the kitting workstation(s). In an embodiment, the kitting workstation(s) is configured to receive a drop-off of the workpiece storage units and/or a travel of the workpiece storage units through the kitting workstation(s) by the same fleet of RSRVs.

In an embodiment, the storage arrangement of the manufacturing system disclosed herein further comprises a supply of workpiece supports. Each of the workpiece supports is configured to hold one or more of the workpieces in predetermined positions during the manufacture of the goods. The workpiece supports are stored in the same ASRS structure as the workpieces. The workpiece supports are retrievable from the same ASRS structure and deliverable to the manufacturing cells by the same fleet of RSRVs. In an embodiment, each of the workpiece supports is of a common footprint of a standardized shape and size as each of a supply of storage units of compatible size and shape configured to fit within the storage locations of the ASRS structure. Each of the workpiece supports comprises a base of a standardized shape and size configured to fit within the storage locations of the ASRS structure. In an embodiment, each of the workpiece supports and each of the storage units are configured to have a matching layout of interface features by which the RSRVs interact with the workpiece supports and the storage units to allow loading and unloading of the workpiece supports and the storage units to and from the RSRVs.

In an embodiment, in addition to the supply of workpieces stored within the storage locations of the ASRS structure, the storage arrangement comprises either a supply of toolpieces or a supply of workpiece supports stored in the ASRS structure. Each of the toolpieces is useful for performance of one or more process steps of a manufacturing process on one or more of the workpieces during the manufacture of the goods. Each of the workpiece supports is configured to hold one or more of the workpieces in predetermined positions during the manufacture of the goods. In this embodiment, the fleet of RSRVs is operable to extract from the storage locations both the workpieces and at least one of the toolpieces and the workpiece supports. The same fleet of RSRVs navigable within the ASRS structure in the three dimensions is operable to deliver supplies or componentry, for example, the workpieces and the toolpieces and/or the workpiece supports among the manufacturing cells. In an embodiment, the componentry is transportable between each of the manufacturing cells in any order. In another embodiment, each of the manufacturing cells is configured to receive the componentry multiple times for performance of one or more of the process steps of the manufacturing process.

In an embodiment, each of the manufacturing cells comprises at least one workpiece holding area configured to hold the workpieces awaiting processing at the corresponding manufacturing cell. The workpiece holding area(s) is configured to accept placement of one of the workpiece storage units thereon. In an embodiment, the workpiece holding area comprises two workpiece holding areas. Each of the two workpiece holding areas is configured to hold a respective set of workpieces required at a corresponding manufacturing cell.

In an embodiment, at least a subset of the manufacturing cells is positioned at the track structure or within an area of the track structure. In an embodiment, the track structure is a gridded track structure comprising sets of intersecting rails on which the RSRVs are navigable in two dimensions. In an embodiment, a width of the workpiece holding area in each of the two dimensions is generally equal to a whole number multiple of a distance measured between two adjacent parallel rails of the gridded track structure. In another embodiment, a width of the workpiece holding area in each of the two dimensions does not exceed a distance measured between two adjacent parallel rails of the gridded track structure.

In an embodiment, the gridded track structure comprises square spots. Each of the square spots is delimited by a first pair of parallel rails lying in a first direction and a second pair of parallel rails lying in a second direction perpendicular to the first direction. Each of the manufacturing cells occupies a cell space of an area equal to a predetermined number of the square spots. In an embodiment, at least one cell space is a square space whose area is divisible into nine square subspaces. Each of the nine square subspaces is equal in area to one of the square spots of the gridded track structure. Four corner subspaces of the nine square subspaces are configured as holding areas for holding supplies needed by the corresponding manufacturing cell. In an embodiment, a first pair of mid-perimeter subspaces positioned between the four corner subspaces at a first pair of opposing perimeter sides of the cell space is occupied by robotic workers. In an embodiment, a central subspace positioned between the robotic workers is configured as a working area to which the workpieces are transferred and at which the workpieces are processed by the robotic workers. In an embodiment, the working area is neighbored by a second pair of mid-perimeter subspaces positioned between the four corner subspaces at a second pair of opposing perimeter sides of the cell space. In an embodiment, at least one of the second pair of mid-perimeter subspaces is an unoccupied open area by which the RSRVs are configured to enter and exit the working area. In another embodiment, both of the second pair of mid-perimeter subspaces are unoccupied open areas, whereby the RSRVs are configured to travel fully through the corresponding manufacturing cell.

In an embodiment, each of the manufacturing cells comprises at least one robotic picker operable to pick the workpieces from the workpiece holding area. In another embodiment, each of the manufacturing cells further comprises a working area to which the picked workpieces are transferred from the workpiece holding area by the robotic picker(s).

In an embodiment, each of the manufacturing cells in the subset comprises at least one tool holding area configured to hold toolpieces required at a corresponding manufacturing cell. In an embodiment, a width of the tool holding area in each of the two dimensions is generally equal to a distance measured between two adjacent parallel rails of the gridded track structure. In another embodiment, a width of the tool holding area in each of the two dimensions does not exceed a distance measured between two adjacent parallel rails of the gridded track structure. In an embodiment, each of the manufacturing cells in the subset comprises at least one robotic worker mounted atop a mounting base that is installed on or within the gridded track structure. In an embodiment, a width of the mounting base in each of the two dimensions is generally equal to a whole number multiple of a distance measured between two adjacent parallel rails of the gridded track structure. In another embodiment, a width of the mounting base in each of the two dimensions does not exceed a distance measured between two adjacent parallel rails of the gridded track structure.

In an embodiment, the manufacturing cells of the manufacturing system disclosed herein is configured in a multi-level structure comprising multiple levels of manufacturing cells. In an embodiment, the multi-level structure comprises a gridded track structure at each of the levels and upright frame members. The gridded track structure comprises sets of intersecting rails on which the RSRVs are navigable in two dimensions. The upright frame members interconnect the intersecting rails of the levels. In an embodiment, one or more of the upright frame members are configured for traversal of the RSRVs thereon in an ascending direction and/or a descending direction to transition between the levels. In an embodiment, the gridded track structure at one of the levels of the multi-level structure is attached to a corresponding one of the storage levels in the ASRS structure at which the RSRVs are configured to transition between the ASRS structure and the multi-level structure.

In an embodiment, the manufacturing cells comprise fully automated manufacturing cells and one or more human-attended manufacturing cells configured with respect to the gridded track structure. The fully automated manufacturing cells are positioned at distributed locations throughout a main internal area of the gridded track structure. The human-attended manufacturing cells are positioned at an outer perimeter area of the gridded track structure.

In an embodiment, the manufacturing system disclosed herein further comprises a computerized control system (CCS) in operable communication with the fleet of 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, for example, a memory unit, is configured to store computer program instructions, which when executed by the processor(s), cause the processor(s) to activate one or more of the RSRVs to perform one or more of: (a) navigating within the ASRS structure and/or through the manufacturing cells; (b) retrieving one or more of the workpieces contained in one or more storage units from the storage locations of the ASRS structure; (c) delivering one or more of the workpieces contained in one or more storage units to at least one kitting workstation for kitting into one or more kit storage units; (d) picking up one or more kit storage units from the kitting workstation(s); returning and storing one or more kit storage units to the storage locations of the ASRS structure; (f) retrieving at least one of one or more kit storage units and one or more of the workpieces contained in another one or more of the storage units, one or more toolpieces contained in another one or more storage units, and one or more workpiece supports from the same ASRS structure; (g) delivering at least one of one or more kit storage units and one or more of the workpieces contained in the other one or more of the storage units, one or more toolpieces contained in the other one or more storage units, and one or more workpiece supports to the manufacturing cells for manufacture of the goods; and (h) inducting the goods into the ASRS structure on a final workpiece support.

Disclosed herein is also a method for executing a workflow in a manufacturing system. In the method disclosed herein, workpieces and workpiece supports are stored in respective storage locations of the ASRS structure. The workpieces are stored in workpiece storage units at the storage locations. In an embodiment, each of the workpiece storage units is filled with a kit of different workpieces according to requirements of the manufacturing process. In an embodiment, each of the workpiece storage units is filled at a kitting workstation that is connected to the ASRS structure. At the kitting workstation, the fleet of RSRVs is configured to deliver inventory storage units containing inventory workpieces retrieved from respective storage locations in the ASRS structure; the different workpieces of the kit are picked from the inventory workpieces in the inventory storage units and compiled into the workpiece storage units; and each of the workpiece storage units is carried away from the kitting workstation by one of the RSRVs and deposited into a respective one of the storage locations in the ASRS structure for subsequent retrieval from the ASRS structure.

In an embodiment, toolpiece storage units configured to hold toolpieces for use in the manufacturing process are stored in the ASRS structure. Using the fleet of RSRVs navigable within the ASRS structure, one or more of the workpiece storage units and a selected workpiece support are extracted from the ASRS structure according to requirements of a manufacturing process to be performed at a manufacturing cell positioned outside the ASRS structure, and separately delivered to the manufacturing cell. In an embodiment, RSRVs of the same type are configured to solely perform the extraction and the delivery of both of the workpiece storage unit(s) and the selected workpiece support from the ASRS structure to the manufacturing cell. At the manufacturing cell, the selected workpiece support is positioned in a working position accessible by one or more workers of the manufacturing cell. At the manufacturing cell, with the selected workpiece support maintained in the working position, (i) one or more of the workpieces are transferred from the workpiece storage unit(s) onto the selected workpiece support; and (ii) a process step of the manufacturing process is performed on the workpiece(s) held on the selected workpiece support. In an embodiment, prior to performing the process step of the manufacturing process, a subset of the toolpiece storage units are extracted from the ASRS structure and delivered to the manufacturing cell using one of the RSRVs. In an embodiment, prior to performing the process step of the manufacturing process a select one of the toolpieces from the subset of the toolpiece storage units is attached to a robotic worker of the manufacturing cell according to the requirements of the manufacturing process to be performed on the workpiece(s) by the robotic worker.

In an embodiment, the workpiece storage unit(s) comprises two workpiece storage units. In this embodiment, the two workpiece storage units are delivered to two respective holding areas of the manufacturing cell. Two workpieces are respectively transferred from the two workpiece storage units parked at the two respective holding areas onto the selected workpiece support.

In an embodiment, after transferring the workpiece(s) from the workpiece storage unit(s) onto the selected workpiece support, an unneeded or empty one of the workpiece storage units from which a selected workpiece is removed and from which no further workpieces are required for the manufacturing process at the manufacturing cell, is removed from the manufacturing cell. In this embodiment, using one of the RSRVs, an additional workpiece storage unit containing one or more additional workpieces needed at the manufacturing cell is delivered to the manufacturing cell. In an embodiment, the additional workpiece(s) is for use in a different manufacturing process to be performed at the same manufacturing cell. In an embodiment, the unneeded or empty one of the workpiece storage units is removed using a different RSRV from that which delivers the additional workpiece storage unit to the manufacturing cell. In an embodiment, the different RSRV is configured to remove the unneeded or empty one of the workpiece storage units after having dropped off a different one of the workpiece storage units at a different manufacturing cell to supply contents of the different one of the workpiece storage units to the different manufacturing cell. After the process step of the manufacturing process is performed on the workpiece(s) held on the selected workpiece support, the selected workpiece support and the workpiece(s) thereon that were processed are removed from the manufacturing cell; another workpiece support is delivered to the manufacturing cell for use in the different manufacturing process using one of the RSRVs; the workpiece support is supported in the working position; the additional workpiece(s) is transferred from the additional workpiece storage unit onto the workpiece support; and one or more process steps of the different manufacturing process are performed on the additional workpiece(s).

In the method disclosed herein, after completion of a finished good by processing of the workpiece(s) at one or more manufacturing cells, the finished good is inducted into the ASRS structure on one of the RSRVs. In an embodiment, the finished good is inducted into the ASRS structure on a final workpiece support on which one or more final processing steps were carried out to complete the finished good. In an embodiment, the final workpiece support is the same selected workpiece support onto which the workpiece(s) was transferred.

The manufacturing system and method disclosed herein integrate the ASRS structure with the plurality of manufacturing cells in a way to perform various manufacturing processes across the multiple manufacturing cells. In the manufacturing system and method disclosed herein, the gridded track structure attached to the lower 2D grid of the ASRS structure allows continuous servicing of all the manufacturing cells by the same fleet of RSRVs navigable to and from the ASRS structure and to and from each of the manufacturing cells.

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.

DETAILED DESCRIPTION

Various aspects of the present disclosure may be embodied as a system of components and/or structures, a method, 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.

FIG. 1illustrates a top plan view of a manufacturing system100comprising an automated storage and retrieval system (ASRS) structure101neighbored by a kitting area102and a manufacturing center105, according to an embodiment herein. The kitting area102is attached to the ASRS structure101in neighboring relation thereto at an outer perimeter101aof the ASRS structure101. The kitting area102comprises one or more kitting workstations, for example, human-operated or human-aided or human-attended kitting workstations103and robotic kitting workstations104as disclosed in the detailed description ofFIG. 7. The manufacturing center105is also attached to the ASRS structure101in neighboring relation thereto at the outer perimeter101aof the ASRS structure101.FIG. 2illustrates a side perspective view of the manufacturing system100shown inFIG. 1, according to an embodiment herein.FIG. 2illustrates a side of the ASRS structure101at which the kitting area102and the manufacturing center105are positioned. For purposes of illustration,FIGS. 1-2show the kitting area102and the manufacturing center105, both neighboring the ASRS structure101at the same perimeter side101athereof; however the scope of the manufacturing system100disclosed herein is not limited to the arrangement of the kitting area102and the manufacturing center105at the same perimeter side101aof the ASRS structure101, but may be extended to any arrangement of either or both the kitting area102and the manufacturing center105on any one or more of the perimeter sides of the ASRS structure101.

The manufacturing system100disclosed herein comprises a storage arrangement comprising the ASRS structure101and a fleet of robotic storage/retrieval vehicles (RSRVs)306as illustrated inFIG. 3andFIGS. 4A-4B. The ASRS structure101comprises a three-dimensional (3D) array of storage locations distributed throughout a two-dimensional (2D) footprint of the ASRS structure101at multiple storage levels within the ASRS structure101. In an embodiment, the ASRS structure101is configured as a 3D gridded storage structure300as illustrated inFIG. 3. Each of the RSRVs306in the fleet is navigable within the ASRS structure101in three dimensions to access the storage locations in the 3D array. The RSRVs306are operable to deposit storage units, for example, bins, trays, boxes, pallets, etc., into the storage locations of the ASRS structure101, and extract the storage units from the storage locations as disclosed below. In an embodiment, the ASRS structure101comprises at least one track-equipped level comprising a 2D gridded track layout302as illustrated inFIG. 3. The fleet of RSRVs306is navigable within the ASRS structure101in at least two dimensions on the 2D gridded track layout302as illustrated inFIG. 3.

The manufacturing system100disclosed herein further comprises multiple manufacturing cells106and107positioned outside the ASRS structure101. The manufacturing cells106and107constitute the manufacturing center105of the manufacturing system100. The manufacturing cells106and107are categorized, standardized, and modularly constructed for different manufacturing processes. In an embodiment, the manufacturing system100disclosed herein further comprises a track structure108attached to the ASRS structure101and extending beyond the 2D footprint of the ASRS structure101to define an extension thereof. In an embodiment, the track structure108is an extension of the 2D gridded track layout302of the track-equipped level of the ASRS structure101. The manufacturing cells106are configured with respect to the track structure108. The track structure108is configured to define one or more travel paths on which the RSRVs306are navigable and along which the manufacturing cells106are distributed. The same fleet of RSRVs306navigable within the ASRS structure101in the three dimensions is operable to deliver componentry, for example, workpieces and/or toolpieces contained in storage units, workpiece supports, etc., to the manufacturing cells106and107. In an embodiment, the componentry is transportable between each of the manufacturing cells106and107in any order. In another embodiment, each of the manufacturing cells106and107is configured to receive the componentry multiple times for performance of one or more of the process steps of the manufacturing process. In an embodiment, each of the manufacturing cells106and107is equipped with product neutral equipment and configured to implement product specific basic functions. In another embodiment, each of the manufacturing cells106can be individually expanded with process specific equipment. The manufacturing cells106are configured to execute a plurality of manufacturing processes, for example, welding, adhesive bonding, punching, brazing, clinching, etc. Components for subsequent process steps of a manufacturing process are routed to each manufacturing cell106on-the-fly during execution of a previous process for uninterrupted manufacturing. In an embodiment, at least a subset of the manufacturing cells106is positioned at the track structure108or within an area of the track structure108. In an embodiment, the track structure108is a gridded track structure comprising sets of intersecting rails on which the RSRVs306are navigable in two dimensions.

The manufacturing center105comprises multiple fully automated or robotic manufacturing cells106distributed in a spaced apart manner over the 2D area of the track structure108that is connected to the 2D gridded lower track layout302of the ASRS structure101. The gridded track structure108of the manufacturing center105forms a coplanar extension of the gridded lower track layout302of the ASRS structure101to allow the same fleet of RSRVs306that navigates the ASRS structure101to deposit and extract the storage units to and from the ASRS structure101to also deliver the extracted storage units to the manufacturing cells106and107, and return the extracted storage units back into the ASRS structure101when no longer required at the manufacturing center105. In the embodiment illustrated inFIGS. 1-2, the manufacturing cells106are arranged, for example, in a rectangular array to align each manufacturing cell106with other manufacturing cells106in a respective row and a respective column of the rectangular array. In other embodiments, the manufacturing cells106are arranged in arrays of different configurations. Similarly, while the embodiment illustrated inFIGS. 1-2shows sixteen manufacturing cells106, the quantity of manufacturing cells106may vary, and need not be a square number, regardless of whether the manufacturing cells106are laid out in a rectangular array, another uniformly distributed pattern or array, or in any other fashion, uniform or otherwise.

As illustrated inFIGS. 1-2, the fully automated manufacturing cells106are spread out over a main internal area of the gridded track structure108. That is, the fully automated manufacturing cells106are positioned at distributed locations throughout the main internal area of the gridded track structure108. In an embodiment, each of the fully automated manufacturing cells106comprises at least one robotic picker109operable to pick componentry, for example, workpieces, toolpieces, etc., from holding areas configured in the respective manufacturing cells106. In an embodiment as illustrated inFIGS. 1-2, the manufacturing center105further comprises one or more human-operated or human-aided or human-attended manufacturing cells107positioned, for example, at an outer perimeter area108aof the gridded track structure108. In an embodiment, the human-attended manufacturing cells107are positioned specifically at a far side of the gridded track structure108furthest from the ASRS structure101; however, in other embodiments, the human-attended manufacturing cells107are additionally or alternatively positioned at either of the two lateral sides108band108cof the gridded track structure108that extend outwardly from the perimeter side101aof the ASRS structure101. Furthermore, for purposes of illustration,FIGS. 1-2show the ASRS structure101being neighbored by a single manufacturing center105, where the entire gridded track structure108and entire population of manufacturing cells106,107are positioned on a single side101aof the ASRS structure101. In another embodiment, the manufacturing system100disclosed herein is configured such that the gridded track structure108of the single manufacturing center105occupies more than one side of the ASRS structure101. In another embodiment, multiple manufacturing centers comprising respective gridded track structures neighbor different respective sides of the ASRS structure101such that navigation of the RSRVs306between the gridded track structures of the separate manufacturing centers is executed via the gridded lower track layout302of the ASRS structure101.

In an embodiment, the manufacturing system100disclosed herein further comprises a computerized control system (CCS)131as illustrated inFIG. 18, in operable communication with the fleet of RSRVs306. At various stages of the workflow executed at the manufacturing system100, the CCS131activates one or more of the RSRVs306to perform one or more of: (a) navigating within the ASRS structure101and/or through the manufacturing cells106,107; (b) retrieving one or more of the workpieces contained in one or more storage units from the storage locations of the ASRS structure101; (c) delivering one or more of the workpieces contained in one or more storage units to at least one kitting workstation103,104for kitting into one or more kit storage units; (d) picking up one or more kit storage units from the kitting workstation(s)103,104; returning and storing one or more kit storage units to the storage locations of the ASRS structure101; (f) retrieving at least one of one or more kit storage units and one or more of the workpieces contained in another one or more of the storage units, one or more toolpieces contained in another one or more storage units, and one or more workpiece supports from the same ASRS structure101; (g) delivering at least one of the one or more kit storage units and one or more of the workpieces contained in the other one or more of the storage units, one or more toolpieces contained in the other one or more storage units, and one or more workpiece supports to the manufacturing cells106,107for manufacture of the goods; and (h) inducting the finished goods into the ASRS structure101on a final workpiece support. When a product is changed, the manufacturing cells106,107are automatically upgraded for a new task. In an embodiment, the CCS131automatically upgrades the manufacturing cells106,107for the new task. While testing and maintenance is being performed by workers on particular manufacturing cells, tasks can be transferred to other manufacturing cells for uninterrupted manufacturing. The manufacturing cells106,107are configured as needed on-the-fly without interrupting manufacturing processes at any manufacturing cell106,107.

Consider an example workflow of the manufacturing system100disclosed herein. Material such as workpieces are inducted into storage units and stored in the ASRS structure101. Similarly, toolpieces are inducted into storage units and stored in the ASRS structure101. Moreover, workpiece supports, for example, jigs are inducted and stored in the ASRS structure101. The CCS131receives digital production plans with defined material or workpiece kits/toolpiece kits and related process instructions. Digital instructions to software configure the manufacturing cells106to manufacture a good or a product. The production plans comprise details of all processes that are required to manufacture the good. The details comprise, for example, a list of all sequential processes involved in manufacturing a good where each process is assigned to one or more manufacturing cells106, a list of materials required to complete each process, a list of toolpieces required to complete each process, a list of steps/specifications required of the robotic workers to complete each process, etc. Kit storage units comprising, for example, workpiece kitted bins and toolpiece kitted bins are built at the kitting workstations103,104and stored in the ASRS structure101. The workpiece kitted bins containing workpieces are cycled through a picking-access port of the kitting workstation103or104to allow a human worker or a robotic worker to pick all workpieces required for each manufacturing process. The toolpiece kitted bins containing toolpieces are cycled through the picking-access port of the kitting workstation103or104to allow a human worker or a robotic worker to pick all workpieces required for each manufacturing process. In an embodiment, the workpiece kitted bins and/or the toolpiece kitted bins comprise cassettes, for example, foam, inserts, etc., to arrange the workpieces and/or the toolpieces depending on whether the robotic workers can handle workpieces or toolpieces. After assembly, the workpiece kitted bins and the toolpiece kitted bins are stored back in the ASRS structure101.

The CCS131receives production or work orders and allocates one or more manufacturing cells106,107to a manufacturing process using order priority. The RSRVs306are routed to retrieve and transport one or more workpiece kitted bins and toolpiece kitted bins to holding stations at the assigned manufacturing cell(s)106. The RSRVs306are routed to retrieve and transport the workpiece supports or jigs to a jig runway of the assigned manufacturing cell(s)106. A first robotic worker, for example, a robotic picker at the assigned manufacturing cell106retrieves a workpiece from the workpiece kitted bin and places the retrieved workpiece in the workpiece support or precisely positions the workpiece for assembly to another workpiece already positioned on the workpiece support. A second robotic worker, for example, a robotic process worker at the assigned manufacturing cell processes the workpiece. The actions of the robotic workers are repeated for all workpieces in the workpiece kitted bins to create assemblies and/or subassemblies. If another sequential process is required, the RSRV306is configured to transport the workpiece support containing the partially finished subassemblies to another preconfigured human or robotic manufacturing cell106,107; and/or if there is no manufacturing capacity, return the workpiece support containing the partially finished subassemblies to the ASRS structure101for future processing. If finished, the RSRV306is configured to return the workpiece support containing the finished assembly/subassembly to the ASRS structure101.

In an embodiment, the RSRVs306traverse the manufacturing system100as follows: An RSRV306retrieves a needed workpiece kitted bin from the ASRS structure101. The RSRV306transports the needed workpiece kitted bin to a designated empty storage location at one of the manufacturing cells106. This RSRV306travels to a designated manufacturing cell106and picks up an unneeded workpiece kitted bin and transports the unneeded workpiece kitted bin to the ASRS structure101for storage. Another RSRV306transports a needed toolpiece kitted bin to a designated empty storage location at the manufacturing cell106. This other RSRV306travels to a designated manufacturing cell106and picks up an unneeded toolpiece kitted bin and transports the unneeded toolpiece kitted bin to the ASRS structure101for storage. In another embodiment, the same RSRV306that delivers the needed workpiece kitted bin to a designated manufacturing cell106, takes away an unneeded workpiece kitted bin from that designated manufacturing cell106. Similarly, the same RSRV306that delivers the needed toolpiece kitted bin to the designated manufacturing cell106, takes away an unneeded toolpiece kitted bin from that designated manufacturing cell106.

FIG. 3illustrates a top isometric view of the three-dimensional (3D) gridded storage structure300defining the automated storage and retrieval system (ASRS) structure101of the manufacturing system100shown inFIGS. 1-2, according to an embodiment herein. In an embodiment, the 3D gridded storage structure300defining the ASRS structure101and the associated robotic storage/retrieval vehicles (RSRVs)306and storage units303of the manufacturing system100are of the type disclosed in Applicant's U.S. patent application Ser. Nos. 15/568,646, 16/374,123, 16/374,143, and 16/354,539, each of which is incorporated herein by reference in its entirety. A small-scale example of the 3D gridded storage structure300is illustrated inFIG. 3. As illustrated inFIG. 3, the gridded storage structure300comprises two-dimensional (2D) gridded track layouts301and302at a track-equipped uppermost or attic level and at a track-equipped lowermost or basement level respectively. That is, the gridded storage structure300comprises a gridded upper track layout301positioned in an elevated horizontal plane above a matching and aligned gridded lower track layout302positioned in a lower horizontal plane closer to a ground level. Between these aligned, gridded upper and lower track layouts301and302is a 3D array of storage locations that occupy multiple intermediate storage levels between the uppermost attic level and the lowermost basement level. Each of the storage locations in the 3D array is capable of holding a respective storage unit303therein. In an embodiment, the storage units303are of the type illustrated inFIG. 3. In other embodiments, the storage units303are configured as holders of different varieties or containers capable of supporting articles thereon or therein, including, bins, trays, totes, pallets, etc. The storage locations are arranged in vertical storage columns304, in which storage locations of equal square footprint are aligned over one another. Each vertical storage column304is neighbored by a vertically upright shaft305through which the storage locations of the vertical storage columns304are accessible. A fleet of RSRVs306is configured to traverse horizontally each gridded track layout301,302in two dimensions, and traverse vertically between the two gridded track layouts301,302in the third dimension via the open upright shafts305.

Each of the gridded track layouts301,302comprises a set of X-direction rails307lying in the X-direction of the respective horizontal plane, and a set of Y-direction rails308perpendicularly crossing the X-direction rails307in the Y-direction of the same horizontal plane. The crossing X-direction rails307and Y-direction rails308define a horizontal reference grid of the 3D gridded storage structure300, of which each horizontal grid row is delimited between an adjacent pair of the X-direction rails307and each horizontal grid column is delimited between an adjacent pair of the Y-direction rails308. Each intersection point between one of the horizontal grid columns and one of the horizontal grid rows denotes a position of a respective vertical storage column304or a respective upright shaft305. That is, each vertical storage column304and each upright shaft305are positioned at a respective Cartesian coordinate point of the horizontal reference grid at a respective area bound between two of the X-direction rails307and two of the Y-direction rails308. Each such area bound between four rails307and308in either gridded track layout301or302is also referred to herein as a respective “spot” of the gridded track layout301or302. The 3D addressing of each storage location in the 3D gridded storage structure300is completed by a given vertical storage column level at which a given storage location resides within the respective vertical storage column304. That is, a 3D address of each storage location is defined by the horizontal grid row, the horizontal grid column, and the vertical storage column level of the storage location in the 3D gridded storage structure300.

A respective upright frame member309spans vertically between the gridded upper track layout301and the gridded lower track layout302at each intersection point between the X-direction rails307and the Y-direction rails308, thereby cooperating with the track rails307and308to define a framework of the 3D gridded storage structure300for containing and organizing the 3D array of storage units303within this framework. As a result, each upright shaft305of the 3D gridded storage structure300comprises four vertical frame members309spanning the full height of the upright shaft305at the four corners thereof Each frame member309comprises respective sets of rack teeth arranged in series in the vertical Z-direction of the 3D gridded storage structure300on two sides of the vertical frame member309. Each upright shaft305, therefore, comprises eight sets of rack teeth in total, with two sets of rack teeth at each corner of the upright shaft305, which cooperate with eight pinion wheels311a,311bon each of the RSRVs306illustrated inFIGS. 4A-4B, to enable traversal of the RSRVs306between the gridded upper and lower track layouts301,302in an ascending direction and a descending direction through the upright shafts305of the 3D gridded storage structure300.

FIG. 4Aillustrates a robotic storage/retrieval vehicle (RSRV)306and a compatible storage unit303employed in the automated storage and retrieval system (ASRS) structure101of the manufacturing system100shown inFIGS. 1-2, according to an embodiment herein. Each RSRV306comprises a wheeled frame or chassis310comprising round conveyance wheels311aand toothed pinion wheels311b.The conveyance wheels311aare configured for conveyance of the RSRV306over the gridded upper and lower track layouts301,302in a track-riding mode. The toothed pinion wheels311bare positioned inwardly of the conveyance wheels311afor traversal of the RSRV306through the rack-equipped upright shafts305of the three-dimensional (3D) gridded storage structure300illustrated inFIG. 3, in a shaft-traversing mode. Each toothed pinion wheel311band a respective conveyance wheel311aare part of a combined singular wheel unit, of which the entirety, or at least the conveyance wheel311a,is horizontally extendable in an outboard direction from the RSRV306for use of the conveyance wheels311ain the track-riding mode on either gridded track layout301or302, and horizontally retractable in an inboard direction of the RSRV306for use of the toothed pinion wheels311bin the shaft-traversing mode, where the toothed pinion wheels311bengage with the rack teeth of the vertical frame members309of an upright shaft305.

A set of four X-direction wheel units is arranged in pairs on two opposing sides of the RSRV306to drive the RSRV306on the X-direction rails307of either gridded track layout301or302of the 3D gridded storage structure300. A set of four Y-direction wheel units is arranged in pairs on the other two opposing sides of the RSRV306to drive the RSRV306on the Y-direction rails308of either gridded track layout301or302. One set of wheel units is raiseable/lowerable relative to the other set of wheel units to switch the RSRV306between an X-direction travel mode and a Y-direction travel mode. Raising one set of wheel units when in the outboard position seated on the gridded upper track layout301is also operable to lower the other set of wheel units into an engagement with the rack teeth of an upright shaft305, after which the raised wheel units are then also shifted inboard to fit within the upright shaft305, thereby completing transition of the RSRV306from the track-riding mode to the shaft-traversing mode to allow descent of the RSRV306through the upright shaft305by a driven operation of the toothed pinion wheels311b.Similarly, lowering one set of wheel units when in the outboard position seated on the gridded lower track layout302is also operable to raise the other set of wheel units into an engagement with the rack teeth of an upright shaft305, after which the lowered wheel units are then also shifted inboard, thereby completing transition of the RSRV306from the track-riding mode to the shaft-traversing mode to allow ascent of the RSRV306through the upright shaft305by the driven operation of the toothed pinion wheels311b.In an embodiment, an external lifting device (not shown) in the gridded lower track layout302is additionally or alternatively used to aid or perform lifting of the RSRV306from the gridded lower track layout302into an overlying upright shaft305.

Each RSRV306comprises an upper support platform312on which any storage unit303is receivable for carrying by the RSRV306. The upper support platform312comprises a rotatable turret313surrounded by a stationary outer deck surface314. The rotatable turret313comprises an extendable/retractable arm315, herein referred to as a “turret arm”, mounted in a diametric slot of the rotatable turret313and movably supported therein for linear movement into and out of a deployed position extending outwardly from the outer circumference of the rotatable turret313.

FIG. 4Billustrates the robotic storage/retrieval vehicle (RSRV)306and the compatible storage unit303ofFIG. 4A, showing an extension of the turret arm315of the RSRV306for engaging with the storage unit303to push or pull the storage unit303off of or onto the RSRV306, according to an embodiment herein. The turret arm315carries a catch member316thereon, for example, on a shuttle movable back and forth along the turret arm315for engaging with mating catch features on an underside of the storage unit303. Together with the rotatable function of the turret313, the turret arm315with the catch member316allows pulling of the storage unit303onto the upper support platform312and pushing of the storage unit303off the upper support platform312at all four sides of the RSRV306, thereby allowing each RSRV306to access a storage unit303on any side of any upright shaft305in the three-dimensional (3D) gridded storage structure300illustrated inFIG. 3, including fully-surrounded upright shafts305that are each surrounded by vertical storage columns304on all four sides of the upright shaft305to maximize storage density in the 3D gridded storage structure300. That is, each RSRV306is operable in four different working positions inside any of the upright shafts305to access to any of the storage locations on any of the four different sides of the upright shaft305to deposit or retrieve a respective storage unit303to or from a selected storage location. In an embodiment, alternative mechanisms capable of four different working positions to enable four-sided loading and unloading of the storage units303are employed in place of the turret and arm combination.

In an embodiment, the framework of the 3D gridded storage structure300comprises a set of shelving brackets at each storage location to cooperatively form a shelf for the storage unit303currently stored at the storage location, whereby any given storage unit303can be removed from its storage location by one of the RSRVs306without disrupting the storage unit303above and below the given storage unit303in the same storage column304. Similarly, the shelf defined by the set of shelving brackets allows a storage unit303to be returned to a prescribed storage location at any storage level in the 3D array of storage locations in the 3D gridded storage structure300. Accordingly, through two-dimensional horizontal navigation of the gridded track layouts301,302, each RSRV306is able to access any of the upright shafts305and is able to travel vertically therethrough in an ascending direction or a descending direction in the third dimension to access any of the storage locations and deposit or retrieve a storage unit303therefrom. In an embodiment, the 3D gridded storage structure300is externally cladded around the outer perimeter thereof as illustrated inFIG. 2, where select portions of the gridded lower track layout302of the 3D gridded storage structure300are visible through uncladded entry/exit ports, for example,127and128illustrated inFIGS. 9A-9F, by which the RSRVs306transition between the gridded track structure108of the manufacturing center105illustrated inFIGS. 1-2and the gridded lower track layout302of the 3D gridded storage structure300.

FIG. 4Cillustrates a bottom plan view of the storage unit303shown in FIG.

4A, according to an embodiment herein. As illustrated inFIG. 4C, a primary catch channel317is positioned in an underside of the bin-type storage unit303. The primary catch channel317is a circular open-bottom channel that follows a 360-degree circular path around a center point318of a floor panel321of the storage unit303illustrated inFIG. 4D, at an intermediate radial distance between the center point318and the outer perimeter of the floor panel321.FIG. 4Dillustrates a partial, cross-sectional view of the storage unit303shown inFIG. 4A, showing interface features on the underside of the storage unit303configured for compatibility with the robotic storage/retrieval vehicles (RSRV)306shown inFIGS. 4A-4B, according to an embodiment herein. As illustrated inFIG. 4D, the primary catch channel317is recessed upwardly from a lowermost plane of the storage unit303to create a continuous circular slot in which the catch member316of the turret arm315of the RSRV306illustrated inFIGS. 4A-4B, can be received to allow loading and unloading of the storage unit303to and from the RSRV306. Just inside the outer perimeter of the floor panel321at each of the four sides thereof, the underside of the storage unit303comprises a respective secondary catch recess319that is recessed upwardly from the lowermost plane of the storage unit303for selective engagement of the secondary catch recess319by the catch member316of the turret arm315of the RSRV306, for example, when the catch member316of the turret arm315fails to catch the primary catch channel317during an attempted engagement of the storage unit303by the extended turret arm315of the RSRV306. Each secondary catch recess319is a relatively small rectangular slot or cavity, located mid-way along the respective perimeter side of the floor panel321of the storage unit303. The four secondary catch recesses319are, therefore, disposed at ninety-degree intervals from one another around the center point318of the floor panel321of the storage unit303just inside the outer perimeter of the storage unit303.

As illustrated inFIGS. 4A-4B, the rotatable turret313and the surrounding outer deck surface314of the upper support platform312of the RSRV306collectively define a square landing area atop which the storage unit303is seated when carried on the upper support platform312of the RSRV306. This landing area is equal or nearly equal in size and shape to the underside of each storage unit303. Accordingly, the storage unit303in a fully and properly seated position on the upper support platform312of the RSRV306occupies a full or near entirety of the landing area without overhanging the outer perimeter of the upper support platform312of the RSRV306. Accordingly, in its properly seated position on the landing area, the entire footprint of the storage unit303is disposed within the outer perimeter of the upper support platform312or the landing area of the RSRV306.

For the purpose of ensuring that the storage unit303is fully received and properly aligned on the landing area of the RSRV306, in an embodiment, the upper support platform312comprises a set of load status sensors401positioned in close proximity to the outer perimeter of the upper support platform312at spaced apart positions along the outer perimeter as illustrated inFIGS. 4A-4B. In the illustrated example, the load status sensors401are optical sensors recessed in the outer deck surface314of the landing area and provided in a quantity of four. Each of the load status sensors401is positioned proximal to a respective one of the four outer corners of the landing area. As part of a loading routine, pulling a storage unit303onto the RSRV306from a storage location in the three-dimensional (3D) gridded storage structure300illustrated inFIG. 3, using retraction of the turret arm315, a computer processor, for example, a local processor on-board the RSRV306, communicably connected to the load status sensors401, checks the status of the four load status sensors401for detected presence of the underside of the storage unit303above the load status sensors401. A positive detection signal from the four load status sensors401, therefore, confirms the presence of the storage unit303at the four corners of the landing area, thereby confirming that the storage unit303is fully received on the landing area and is in properly squared alignment on the landing area. This confirmation confirms that the primary catch channel317in the storage unit303is properly engaged by the catch member316of the RSRV306. Failure to obtain a positive detection signal from all the four load status sensors401indicates a failed engagement of the primary catch channel317, resulting in failure to properly load the storage unit303onto the RSRV306, in response to which the turret arm315of the RSRV306is re-extended to push the failed or improperly loaded storage unit303back into its respective storage location, after which extraction of the storage unit303is reattempted. When the storage unit303is properly loaded onto the RSRV306, the primary catch channel317allows the rotatable turret313to rotate underneath and relative to the storage unit303that sits stationary on the upper support platform312of the RSRV306. In an embodiment, this relative rotation allows later offloading of the storage unit303to a different side of the RSRV306from where the storage unit303was loaded thereonto, according to the targeted destination to which the storage unit303is to be offloaded from the RSRV306.

In an embodiment, reflective optical sensors are employed in the RSRV306for load status detection, where light energy transmitted by an optical beam emitter of the reflective optical sensor is reflected off the underside of the storage unit303back to an optical receiver of the reflective optical sensor when the storage unit303is present over the reflective optical sensor, thereby successfully determining presence of the storage unit303. In an embodiment, time of flight calculation, that is, a difference in time between emission of an optical pulse and detection of the reflected optical pulse, is used to differentiate between reflection off the underside of the storage unit303seated on the landing area of the RSRV306versus reflection off another surface positioned further away from the reflective optical sensor. In other embodiments, sensors of different types other than optical sensors are employed for load status detection. For example, limit switches mechanically actuated by contact with the underside of the storage unit303, or magnetic sensors actuated by presence of cooperating magnetic elements emitting detectable magnetic fields at the underside of the storage unit303are employed for load status detection. Use of optical sensors preclude moving parts or need for magnetic integration or other specialized configuration of the storage units303.

In addition to the primary catch channel317and the secondary catch recesses319, the underside of the storage unit303illustrated inFIG. 4Ccomprises four protruding elements or bosses320disposed just inside the outer perimeter of the floor panel321at the four corners of the floor panel321. The bottom ends of the bosses320form enlarged solid surface areas at the lowermost plane of the storage unit303, which are otherwise largely unoccupied open spaces due to a perforated skeletal or web-like structure of the floor panel321. These enlarged solid surface areas of the bottom ends of the bosses320are positioned for alignment with and detection by the set of load status sensors401at the corners of the upper support platform312of the RSRV306when the storage unit303is properly loaded in an aligned position thereon. In embodiments where the floor panel321is of a solid or less perforated structure, the underside of the floor panel321is, except for the circular primary catch channel317and four secondary catch recesses319, a continuous solid surface spanning uninterruptedly from the primary catch channel317to outer corners of the floor panel321, thereby omitting the need for the bosses320of the skeletal or web-like structure of the floor panel321as illustrated inFIG. 4C.

The storage arrangement of the manufacturing system100illustrated inFIGS. 1-2further comprises a supply of workpieces stored within the storage locations of the 3D gridded storage structure300illustrated inFIG. 3, for use in manufacturing goods from the workpieces. The storage units303are used in the 3D gridded storage structure300for storing the workpieces, for example, raw materials, pre-fabricated components, pre-assembled subassemblies, etc., that are required by various manufacturing processes performed at the manufacturing cells106,107of the manufacturing system100illustrated inFIGS. 1-2. In an embodiment, the storage units303are also used in the 3D gridded storage structure300for storing toolpieces that are required by robotic or human workers at the manufacturing cells106,107to perform the various manufacturing processes. Storage units containing workpieces are herein referred to as “workpiece storage units”, while storage units containing toolpieces are herein referred to as “toolpiece storage units”. In an embodiment, the workpiece storage units and the toolpiece storage units are identical to each other. In another embodiment, the workpiece storage units and the toolpiece storage units are not identical to each other, but share some or all of the same interface features, for example, the primary catch channel317, the secondary catch recesses319, and/or sensor-detectable boss surfaces320illustrated inFIGS. 4C-4D, by which the storage units303are functionality compatible with the RSRVs306for loading and unloading of the storage unit303to and from the RSRVs306. In another embodiment, the 3D gridded storage structure300also stores a supply of workpiece supports, one of which is illustrated inFIGS. 5A-5C.

FIG. 5Aillustrates a top perspective view of a workpiece support501storable in the automated storage and retrieval system (ASRS) structure101comprising the three-dimensional (3D) gridded storage structure300shown inFIGS. 1-3, according to an embodiment herein. The workpiece supports501are configured to provide repeatability, accuracy, and interchangeability in the manufacturing of goods or products. Each workpiece support501is a jig or a fixture configured to hold thereon one or more workpieces that are subject to a manufacturing process at one or more of the manufacturing cells106of the manufacturing center105illustrated inFIGS. 1-2. Each workpiece support501is configured to receive and hold one or more workpieces in a particular predetermined or fixed position for allowing performance of one or more process steps of the manufacturing process on the workpiece(s). Each workpiece support501is configured to guide toolpieces during the manufacturing process.FIG. 5Billustrates atop plan view of the workpiece support501shown inFIG. 5A, according to an embodiment herein.FIG. 5Cillustrates a side elevation view of the workpiece support501shown inFIG. 5A, according to an embodiment herein. Similar to the storage units303, the workpiece supports501are stored on the shelf rails of the ASRS structure101and therefore have the bottom interface as the storage units303.

In an embodiment as illustrated inFIGS. 5A-5C, each workpiece support501comprises a standardized base panel502of a structure identical to all the workpiece supports and of a matching footprint and a matching or comparable underside configuration to the floor panels321of the storage units303illustrated inFIGS. 4C-4D. Each workpiece support501shares a matching footprint with the storage unit303to allow storage of each workpiece support501and the storage units303in any storage location of the ASRS structure101. Accordingly, an underside of the base panel502of each workpiece support501comprises a primary catch channel spanning around a center point of the base panel502similar to the primary catch channel317on the underside of the storage unit303illustrated inFIGS. 4C-4D. In another embodiment, the underside of the base panel502of each workpiece support501further comprises secondary catch recesses positioned closer to the outer perimeter of the base panel502similar to the secondary catch recesses319on the underside of the storage unit303illustrated inFIGS. 4C-4D. In another embodiment, the underside of the base panel502of each workpiece support501further comprises sensor-detectable surfaces near the corners of the base panel502similar to either the bottom ends of the bosses320of a skeletal structure at the underside of the floor panel321illustrated inFIGS. 4C-4Dor areas of a smooth continuous underside surface thereof for reading of these surfaces by load status sensors401of the robotic storage/retrieval vehicle (RSRV)306illustrated inFIGS. 4A-4B. With a footprint of equal or substantially similar area and shape to that of the storage units303, the base panel502of the workpiece support501is configured to fit within each storage location of the ASRS structure101on the shelving thereof, and similarly fit atop the upper support platform312of each RSRV306illustrated inFIGS. 4A-4B, within the prescribed landing area thereof. The interface features on the underside of the workpiece support501are similar to that of the storage units303and allow compatibility of the workpiece support501with the RSRV306. As each workpiece support501shares the same RSRV interface features as the storage units303, each workpiece support501is also configured to be loaded and unloaded to and from each RSRV306in the same manner as the storage units303. It will be appreciated that this shared use of matching RSRV interface features by the base panel502of the workpiece support501and each storage unit303allows use of the same fleet of RSRVs306to deposit and retrieve the workpiece supports501and the storage units303to and from the same 3D gridded storage structure300, regardless of whether the RSRV interface features are those particularly disclosed herein for use with the turret-based RSRV306, or are of some other configuration compatible with a variant of the RSRV306.

FIG. 6Aillustrates a top perspective view of the workpiece support501shown inFIG. 5A, showing workpieces601held within the workpiece support501. The workpieces601comprise, for example, pre-fabricated components, pre-assembled subassemblies, etc., that are required by various manufacturing processes performed at the manufacturing cells106,107of the manufacturing system100illustrated inFIGS. 1-2.FIG. 6Billustrates a top plan view of the workpiece support501with the workpieces601held therein, according to an embodiment herein.

FIG. 7illustrates a top plan view of the kitting area102of the manufacturing system100shown inFIGS. 1-2, according to an embodiment herein. New workpieces arriving at a manufacturing facility in full case quantities may be decanted and inducted into the three-dimensional (3D) gridded storage structure300illustrated inFIG. 3, that defines the automated storage and retrieval system (ASRS) structure101, as general inventory, where multiple workpieces701of an identical type are transferred into a shared workpiece storage unit, herein referred to as an “inventory storage unit”, from which a smaller quantity of workpieces are later pulled to compile either a workpiece storage unit303bcontaining workpieces of a single type or a kit of different workpieces according to the requirements of a manufacturing process to be performed at one of the manufacturing cells106,107of the manufacturing center105illustrated inFIGS. 1-2. The kitted collection of different workpieces compiled from different inventory storage units303ais placed into another storage unit, herein referred to as a “kit storage unit” to distinguish this storage unit303cfrom the inventory storage units303acontaining general inventory workpieces701and the workpiece storage units303bcontaining workpieces of a single type. The kitting process of transferring general inventory workpieces701from multiple inventory storage units303ato a workpiece storage unit303bor a kit storage unit303cis performed at the kitting area102that is equipped with one or more kitting workstations103,104. The number of kitting workstations103,104may vary in various embodiments. In an embodiment, these kitting workstations103,104are identical or similar to the picking workstations of the type disclosed in Applicant's PCT Patent Application Number PCT/IB2020/054380, which is incorporated herein by reference in its entirety.

In an embodiment as illustrated inFIG. 7, each of the kitting workstations103and104is configured with an L-shaped configuration comprising a first leg103a,104aprojecting outwardly from the perimeter side101aof the ASRS structure101and a second leg103b,104bextending parallel to the perimeter side101aof the ASRS structure101. An interior of each kitting workstation103,104is enclosed and accordingly, each kitting workstation103,104comprises upright outer walls that enclose the respective kitting workstation103,104at the sides thereof as illustrated inFIG. 2, other than an inner side that opens into the 3D gridded storage structure300at the gridded lower track layout302thereof. Each kitting workstation103,104further comprises a top cover panel110whose underside defines an interior ceiling of each kitting workstation103,104and whose opposing topside defines an external countertop worksurface.

Inside the first leg103a,104ais a lower track of the respective kitting workstation103,104. The lower track of each kitting workstation103,104is an extension of the gridded lower track layout302of the 3D gridded storage structure300. In an embodiment, the lower track of each kitting workstation103,104is a two-way track that is two spots wide and runs perpendicular to the perimeter side of the 3D gridded storage structure300. Similar to the gridded lower track layout302of the 3D gridded storage structure300, the lower track of each kitting workstation103,104comprises perpendicularly intersecting rails delimiting square spots of the lower track. A first series of spots running along on an outer side of the first leg103a,104a,that is, the side opposite the second leg103b,104bdefines an outbound half of the two-way lower track of the first leg103a,104a,on which a robotic storage/retrieval vehicle (RSRV)306exits the 3D gridded storage structure300at the gridded lower track layout302thereof and travels away from the 3D gridded storage structure300inside the first leg103a,104aof the respective kitting workstation103,104. A second series of spots running along the opposing inner side of the first leg103a,104adefines an inbound half of the two-way lower track of the first leg103a,104a,on which the RSRV306can travel back into the 3D gridded storage structure300on the gridded lower track layout302thereof This circulatory travel of RSRVs306out of the 3D gridded storage structure300, through the first leg103a,104aof the respective kitting workstation103,104and back into the 3D gridded storage structure300is illustrated by arrows702inFIG. 7.

Above an access spot on the inbound half of the lower track, a picking-access port111opens through the top cover panel110from the countertop worksurface thereof into the interior space of the first leg103a,104aof the respective kitting workstation103,104. Accordingly, when an RSRV306traveling through the first leg103a,104aof the respective kitting workstation103,104stops at the access spot on the inbound half of its travel therethrough, a human worker703or a robotic worker704of the respective kitting workstation103,104standing or mounted near the corner of the L-shaped workstation103,104can interact with an inventory storage unit303acarried atop the RSRV306to pick one or more inventory workpieces701therefrom. This inventory storage unit303ais then advanced onward from the access spot of the lower track of the respective kitting workstation103,104back into the 3D gridded storage structure300on the gridded lower track layout302thereof.

The second leg103b,104bof the respective kitting workstation103,104similarly comprises a placement-access port112penetrating through the top cover panel110of the respective kitting workstation103,104from the countertop worksurface thereof at a position overlying another access spot at which an initially empty workpiece storage unit or an initially empty kit storage unit is received. This placement-access port112, therefore, allows access to the empty workpiece storage unit or the empty kit storage unit for placement therein of the inventory workpieces701picked from one or more inventory storage units303acirculated past the picking-access port111. Long term static parking of an RSRV306at the placement-access port112may be considered a wasted resource, preventing assignment of that particular RSRV306to other tasks in the meantime, and therefore, in an embodiment, the second leg103b,104bof the respective kitting workstation103,104does not include a vehicle track for vehicle-carried travel of storage units through this second leg103b,104bof the respective kitting workstation103,104. Instead of the vehicle track, the second leg103b,104bcomprises an internal conveyor114arunning along the second leg103b,104bfrom a distal end thereof furthest from the first leg103a,104a,to the access spot underlying the placement-access port112. An RSRV306unloads an empty workpiece storage unit or an empty kit storage unit onto the internal conveyor114afrom a drop-off/pickup spot113at the perimeter of the gridded lower track layout302of the 3D gridded storage structure300, and the internal conveyor114aof the kitting workstation103,104advances the empty workpiece storage unit or the empty kit storage unit to the placement access port112, where the inventory workpieces701picked from the inventory storage unit303aare placed into the workpiece storage unit303bor the kit storage unit303c.Once the workpiece storage unit303bor the kit storage unit303cis fully compiled, the filled workpiece storage unit303bor the filled kit storage unit303cis displaced out of the kitting workstation103,104onto a return conveyor114bthat runs in a direction opposite to the direction of the internal conveyor114aof the kitting workstation103,104to transfer the filled workpiece storage unit303bor the filled kit storage unit303cback to the drop-off/pickup spot113for pickup thereat by another RSRV306. This RSRV306then carries the filled workpiece storage unit303bor the filled kit storage unit303cinto the 3D gridded storage structure300and deposits the filled kit storage unit303cin an available storage location for later retrieval therefrom when required at a manufacturing cell106or107illustrated inFIGS. 1-2.

Each kitting workstation103,104, therefore, comprises two travel paths on which the inventory storage units303aand the workpiece storage units303bor the kit storage units303care respectively transferable through the kitting workstation103,104past respective access ports111,112at which the storage units303a,303b,303care accessible for picking and placement of workpieces701from and to the respective storage units303a,303b,303ctransitioning through the kitting workstation103,104. One travel path through the kitting workstation103,104involves vehicle-carried travel of the respective storage unit303a,303b,303cover an extension track of the 3D gridded storage structure300, while the other travel path is a short conveyor-based path at which drop-off and pickup of the respective storage unit303a,303b,303cis also performed by the fleet of RSRVs306.

FIGS. 8A-8Dillustrate partial top plan views of the manufacturing center105of the manufacturing system100shown inFIGS. 1-2, showing a fully automated manufacturing cell106and a neighboring human-attended manufacturing cell107, where different storage units303b,303c,and303dare employed in a manufacturing workflow, according to different embodiments herein.FIG. 8AandFIG. 8Cillustrate workpiece storage units303band toolpiece storage units303demployed in the manufacturing workflow.FIG. 8BandFIG. 8Dillustrate kit storage units303cand toolpiece storage units303demployed in the manufacturing workflow.

As illustrated inFIGS. 8A-8D, the gridded track structure108of the manufacturing center105comprises sets of intersecting rails on which the RSRVs306illustrated inFIG. 3andFIGS. 4A-4Bare navigable in two dimensions. Of the two sets of intersecting rails, one set of intersecting rails are extensions of corresponding rails of the gridded lower track layout302of the three-dimensional (3D) gridded storage structure300that defines the ASRS structure101illustrated inFIGS. 1-3. In the embodiment as illustrated inFIGS. 8A-8D, the extension rails115run in the X-direction of a two-dimensional (2D) reference plane shared by the gridded lower track layout302of the 3D gridded storage structure300and the gridded track structure108of the manufacturing center105, and therefore connect in-line with the X-direction rails307of the gridded lower track layout302of the 3D gridded storage structure300. The extension rails115are perpendicularly intersected by cross-rails116of the gridded track structure108, which in the illustrated example, run in the Y-direction of the shared 2D reference plane. The cross-rails116, therefore, lie parallel to the Y-direction rails308of the gridded lower track layout302of the 3D gridded storage structure300at spaced intervals outward from the perimeter of the 3D gridded storage structure300. The gridded track structure108comprises square spots117, each of which is delimited between an adjacent pair of parallel extension rails115and an adjacent pair of cross-rails116.

In an embodiment as illustrated inFIGS. 8A-8B, the spots117in the gridded track structure108are exclusively square. In another embodiment as illustrated inFIGS. 8C-8D, the spots117in the gridded track structure108are not exclusively square, as not every X-direction rail307in the gridded lower track layout302of the 3D gridded storage structure300has a respective extension rail115attached thereto. In this embodiment, while the cross-rails116are positioned at regular, consistent intervals, the extension rails115are omitted at positions that would otherwise pass through the automated manufacturing cells106. As a result, in this embodiment, using the term column to refer to a strip-shaped area spanning the gridded track structure108in the X-direction thereof and having an inner width measured between two adjacent extension rails115, the gridded track structure108comprises wider columns occupied by the automated manufacturing cells106and composed of wider rectangular spots119, and narrower columns arranged in pairs that neighbor each wider column on opposite sides thereof. Using the term row to refer to a strip-shaped area spanning the gridded track structure108in the Y-direction thereof and having an inner width measured across two adjacent cross-rails116, the gridded track structure108comprises uniform rows of equal width as illustrated inFIGS. 8A-8D.

In the embodiment illustrated inFIGS. 8A-8B, the gridded track structure108comprises a full set of extension rails115at regular, consistent intervals across the entire gridded track structure108, in which all spots in the gridded track structure108are in a square configuration, and all columns and rows are of a uniform, equal width. Each square spot117denotes a reference unit of the gridded track structure108by which sizing of the manufacturing cells106and modular components thereof is measured. As exemplarily illustrated inFIGS. 8A-8D, each of the automated manufacturing cells106occupies a square cell space of area equal to nine square spots117of the gridded track structure108. As a result, in an embodiment, the square cell space is divided into a collection of nine square subspaces. Each of the nine square spaces is equivalent in area to a square spot117of the gridded track structure108.

As exemplarily illustrated inFIGS. 8A-8D, each of the automated manufacturing cells106comprises four modular holding stations118a,118b,118c,and118d,a first robotic worker module120a,and a second robotic worker module120b.The four modular holding stations118a,118b,118c,and118doccupy the four corner subspaces of the manufacturing cell106. The first robotic worker module120aoccupies a first mid-perimeter subspace positioned between two of the corner subspaces at a first side of the square perimeter of the manufacturing cell106. The second robotic worker module120boccupies a second mid-perimeter subspace positioned between the other two corner subspaces at an opposing second side of the square perimeter of the manufacturing cell106. In an embodiment, each of the holding station modules118a-118dand the robotic worker modules120a,120bis a square-footprint module having a footprint area that is generally equal to a singular square subspace of the manufacturing cell106. Accordingly, a width of each of the holding station modules118a-118dand the robotic worker modules120a,120bin both the X-direction and the Y-direction does not exceed the width of a square spot117in the same direction, as measured between the two parallel rails at opposing sides of the square spot117. In the embodiment illustrated inFIGS. 8A-8D, each of the holding station modules118a-118dand the robotic worker modules120a,120bis a single-unit 1×1 module occupying only a single reference unit or a square spot117of the gridded track structure108. In other embodiments, multi-unit or multi-spot modules are additionally or alternatively be employed, where each multi-unit or multi-spot module occupies a respective number of whole units or spots in the gridded track structure108. For example, a dual-unit 2×1 module measuring two units wide in one dimension and measuring one unit wide in the other dimension occupies two units of the gridded track structure108. In any case, the width of each of the holding station modules118a-118dand the robotic worker modules120a,120bin either direction is generally equal to a whole number multiple of the width of any square spot117, also referred to herein as a “unit width”. For purposes of illustration,FIGS. 8A-8Dshow 3×3 square spots with two robotic workers123aand123bconstituting a single manufacturing cell106; however, the scope of the manufacturing center105disclosed herein is not limited to each manufacturing cell106comprising 3×3 square spots with two robotic workers123aand123b,but may be extended to include scalable manufacturing cells with additional square spots and robotic workers in the X direction or the Y direction. For example, the manufacturing center105is configured with scalable manufacturing cells106, each comprising3x5square spots with four robotic workers and six storage units.

In an embodiment, each modular holding station118a,118b,118c,118dis a shelving assembly sized to accommodate placement of one of the storage units303b,303c,and303dthereon. As illustrated inFIG. 9A, the shelving assembly comprises a pair of parallel shelf rails129supported by a set of four structural supports or uprights121. Each upright121is installed at the intersection of two perpendicular rails115,116of the gridded track structure108at a respective corner of the square subspace of the manufacturing cell106. Each shelf rail129runs along a respective side of the square subspace, with the distance between the two shelf rails129being less than the width of each square-bottomed storage unit303b,303c,or303d.The open space between the two shelf rails129allows insertion of the turret arm315of an RSRV306illustrated inFIGS. 4A-4B, between the two shelf rails129to push a storage unit303b,303c,or303doff the RSRV306onto the shelf rails129during drop-off of the storage unit303b,303c,or303dat the manufacturing cell106. Similarly, the space between the shelf rails129allows retraction of the turret arm315of the RSRV306once lowered out of engagement with the underside of the storage unit303b,303c,or303dby lowering of the upper support platform312of the RSRV306illustrated inFIGS. 4A-4B, once the storage unit303b,303c,or303dis seated on the shelf rails129, thereby parking the storage unit303b,303c,or303dat the manufacturing cell106and leaving the RSRV306free to perform other retrieval and delivery tasks for other manufacturing cells106. During a later pickup of the storage unit303b,303c,or303d,the reverse process comprising extending the turret arm315of the RSRV306between the shelf rails129, raising the upper support platform312of the RSRV306to raise the extended turret arm315into engagement with the underside of the storage unit303b,303c,or303d,and then retracting the turret arm315to pull the storage unit303b,303c,or303donto the upper support platform312of the RSRV306, is performed. The drop-off and pick-up of the storage units303b,303c,and303dat the holding stations118a-118dis, therefore, the same as the deposit and extraction of the storage units303b,303c,and303dto and from the shelving-equipped storage locations in the 3D gridded storage structure300, as the shelving brackets in the vertical storage columns304of the 3D gridded storage structure300are spaced equivalently to the shelf rails129of the holding stations118a-118d.

In an embodiment as exemplarily illustrated inFIG. 8AandFIG. 8C, the two modular holding stations118a,118bon opposite sides of the first robotic worker module120aare designated as first and second workpiece holding areas to which workpiece storage units303bare delivered by the RSRVs306to supply the manufacturing cell106with workpieces701a,70lb of two types required for a manufacturing process at the manufacturing cell106. In another embodiment as exemplarily illustrated inFIG. 8BandFIG. 8D, the two modular holding stations118a,118bon opposite sides of the first robotic worker module120aare designated as first and second workpiece holding areas to which kit storage units303care delivered by the RSRVs306to supply the manufacturing cell106with particular combinations of workpieces required for a manufacturing process at the manufacturing cell106. The other two modular holding stations118c,118don opposite sides of the second robotic worker module120bare designated as first and second tool holding areas to which toolpiece storage units303dare delivered by the RSRVs306to supply the manufacturing cell106with the particular set of toolpieces801required for the manufacturing process at the manufacturing cell106. The first workpiece holding area and first tool holding area are designated as a first paired set of holding areas for supplying workpieces701a,701band toolpieces801to a first manufacturing process to be performed at the manufacturing cell106, while the second workpiece holding area and second tool holding area are designated as a second paired set of holding areas for supplying workpieces701a,701band toolpieces801to a different second manufacturing process to be performed at the manufacturing cell106.

Each of the robotic worker modules120a,120bcomprises a mounting base122of a square or rectangular shape defining the single-spot or multi-spot footprint of the respective robotic worker module120a,120bthat does not exceed beyond the boundaries of the assigned subspace(s) of the manufacturing cell106at which the respective robotic worker module120a,120bis installed. In an embodiment, the mounting base122is suspended between a set of four uprights121at the four corners of the assigned subspace or subspaces. In an embodiment as illustrated inFIGS. 8A-8D, where each robotic worker module120a,120bis neighbored by two holding stations118a,118bor118c,118dat the immediately adjacent subspaces of the manufacturing cell106, each robotic worker module120a,120bshares two uprights121with each of the two neighboring holding stations118a,118bor118c,118d.A robotic worker123a,123b,for example, in the form of a multi-axis articulated robot arm, is positioned atop the mounting base122. In an embodiment, the robotic worker123aof the first robotic worker module120ais used as a robotic picker for picking workpieces701a,701bfrom the holding stations118a,118bat the two workpiece holding areas that neighbor the robotic worker module120a.The robotic worker123bof the second robotic worker module120bis used as a robotic process worker for performing manufacturing process steps on the workpieces701a,701bpicked by the robotic picker123a.The robotic process worker123bis of a type whose tool support comprises an automatic tool-exchange interface capable of selective coupling of different toolpieces801thereto to allow performance of different manufacturing process steps using the different toolpieces801. The robotic process worker123bcan, therefore, select and attach the necessary toolpiece801for a particular process step to be performed on one or more workpieces701a,701bfrom either one of the two sets of toolpieces801held in the toolpiece storage units303dparked atop the modular holding stations118c,118dat the two tool holding areas that neighbor the robotic worker module120b.

As illustrated inFIGS. 8A-8D, the holding stations118a-118dand the robotic worker modules120aand120boccupy six of the nine subspaces of the manufacturing cell106at opposite sides thereof. A remaining three of the subspaces remain unoccupied between the two sets of occupied subspaces. Of these three unoccupied subspaces, a central subspace between the two robotic worker modules120aand120bdefines a working area of the manufacturing cell106, at which an RSRV306carrying a workpiece support501can be parked to position the workpiece support501in a working position between the two robotic workers123a,123bfor access by the robotic workers123a,123b.This working position of the workpiece support501allows one or more workpieces701a,701bfrom either workpiece holding area to be placed on the workpiece support501by the robotic picker123ain a prescribed position and orientation according to one or more manufacturing process steps that are to be then performed on the supported workpiece(s) by the robotic process worker123busing the appropriate toolpiece(s)801automatically selected and attached by the robotic process worker123bfrom among the sets of toolpieces held at the tool holding stations118c,118d.The other two unoccupied subspaces of the manufacturing cell106are mid-perimeter subspaces124a,124bthat are each left open between one of the workpiece holding areas and one of the tool holding areas at a respective side of the manufacturing cell106. The three unoccupied subspaces form a through-path by which the RSRV306carrying the workpiece support501travels through the manufacturing cell106from one side thereof to the other, pausing partway therethrough at the central subspace to accommodate placement and processing of the workpieces701a,701bon the workpiece support501.FIG. 8AandFIG. 8Cillustrate the manufacturing cell106when two workpiece storage units303bcontaining workpieces701aand701bof two types are used in the manufacturing process, according to an embodiment herein. In this embodiment, multiple workpiece storage units303bare stored, retrieved, and delivered to the manufacturing cell106. Furthermore, there is one toolpiece storage unit303dfor each workpiece storage unit303bin the manufacturing cell106. The workpiece storage units303bare retrieved from the 3D gridded storage structure300and delivered and used in a sequence of assembly steps at the manufacturing cell106.FIG. 8BandFIG. 8Dillustrate the manufacturing cell106when two kit storage units303ccontaining particular combinations of workpieces of different types are used in the manufacturing process, according to an embodiment herein. In an example, the kit storage unit303con the right side illustrated inFIG. 8BandFIG. 8Dis the storage unit currently being assembled, while the kit storage unit303con the left side is the storage unit used in a subsequent manufacturing process.

FIG. 9Aillustrates a perspective view of one of the fully automated manufacturing cells106of the manufacturing center105shown inFIGS. 1-2, showing a robotic picker123aloading a first workpiece701aof a first type from a first workpiece storage unit303bonto an RSRV-carried workpiece support501, according to an embodiment herein. As illustrated inFIG. 9A, an RSRV306carrying a workpiece support501can exit the ASRS structure101comprising the three-dimensional (3D) gridded storage structure300at an uncladded exit port127through which the RSRV306rides from the gridded lower track layout302of the 3D gridded storage structure300onto the gridded track structure108of the manufacturing center105, and can then ride along the gridded track structure108to a manufacturing cell106for which the workpiece support501is destined. The RSRV306enters the through-path of the manufacturing cell106at the mid-perimeter subspace124aat one side of the manufacturing cell106, parks at the central subspace of the manufacturing cell106until the workpieces701a,701bhave been placed and processed on the workpiece support501, and then departs the manufacturing cell106via the mid-perimeter subspace124bat the opposing side of the manufacturing cell106. The RSRV306transports the workpiece support501and the processed workpiece(s) thereon back into the 3D gridded storage structure300for storage in a storage location thereof through an uncladded re-entry port128at which the RSRV306rides from the gridded track structure108of the manufacturing center105onto the gridded lower track layout302of the 3D gridded storage structure300.

In an embodiment as illustrated inFIG. 10, upon exit from the current manufacturing cell106, the RSRV306can travel onward to another manufacturing cell106at which additional workpieces may be added to the workpiece support501and the previously processed workpiece(s) thereon. In an embodiment, this routing of the RSRV306through multiple manufacturing cells106is repeated, until a finished good, for example, a finished product or a finished subassembly is manufactured by the series of manufacturing processes performed at the multiple manufacturing cells106, at which time the finished product or the finished subassembly is returned into the 3D gridded storage structure300and deposited at a respective storage location therein.

The particular size of the manufacturing cell106disclosed herein and the number, type and layout of modular components and unoccupied spaces therein illustrated inFIGS. 9A-9Fare provided as an example and may vary. The modularity of the components of the manufacturing cell106relative to the square-unit gridded track structure108allows a large degree of flexibility to customize and reorganize any of the manufacturing cells106according to new or changing needs of a manufacturing facility. In an embodiment, two workpiece holding areas are provided in each manufacturing cell106to minimize unproductive time at the manufacturing cell106, as disclosed in the exemplary manufacturing scenario below.

As illustrated inFIG. 9A, the first workpiece holding station118aholds multiple workpieces701aof a first type, for example, type A, and the second workpiece holding station118bholds multiple workpieces701bof a different second type, for example, type B. As illustrated inFIG. 9A, the robotic picker123ahas already placed workpieces701aof type A and workpieces701bof type B from the respective workpiece storage units303bonto the RSRV-carried workpiece support501parked at the central subspace of the manufacturing cell106, and is shown placing another workpiece701aof type A from the first set onto the workpiece support501. In the example illustrated inFIG. 9A, the workpiece support501is configured to hold multiple workpieces701aof type A in a prescribed orientation suitable for joining of workpieces701bof type B to respective workpieces701aof type A. Once the required number of workpieces701aof type A has been placed on the workpiece support501, an empty RSRV306can travel from the 3D gridded storage structure300to the manufacturing cell106through the exit port127, pick up the now-unneeded workpiece storage unit303bfrom the first holding station118aas illustrated inFIG. 9B, and return the workpiece storage unit303bto the 3D gridded storage structure300through re-entry port128.

FIG. 9Billustrates a perspective view of the manufacturing cell106, showing the robotic picker123aloading a second workpiece701bof type B from a second workpiece storage unit303bonto the RSRV-carried workpiece support501for attachment to the first workpiece701aof type A on the RSRV-carried workpiece support501by the robotic process worker123b,and an RSRV306removing the first workpiece storage unit303bcontaining leftover workpieces701aof type A to prepare the manufacturing cell106for a different subsequent manufacturing process, according to an embodiment herein. During this pickup of the now-unneeded workpiece storage unit303bfrom the first workpiece holding station118a,the robotic picker123apicks a workpiece701bof type B from the second workpiece holding station118b,transfers the workpiece701bof type B over to the workpiece support501parked at the central subspace of the manufacturing cell106, and places or holds the workpiece701bof type B in a prescribed position and orientation to one of the already-placed workpieces701aof type A for attachment thereto. In the meantime, the robotic process worker123bselects and self-attaches a prescribed toolpiece801from a toolpiece storage unit303dparked on the tool holding station118dat one of the tool holding areas.

FIG. 9Cillustrates a perspective view of the manufacturing cell106, showing an RSRV306delivering a third workpiece storage unit303bcontaining workpieces701cof a third type, for example, type C, to the manufacturing cell106to replace the removed workpiece storage unit303b,while the robotic process worker123bis picking an automatically selected toolpiece801from the toolpiece storage unit303dfor joining the second workpiece701bof type B to the first workpiece701aof type A on the RSRV-carried workpiece support501, according to an embodiment herein. The robotic process worker123buses the attached toolpiece801to join the workpiece701bof type B being held by the robotic picker123ato one of the workpieces701aof type A previously placed on the workpiece support501, while another RSRV306delivers the third workpiece storage unit303bcontaining the workpieces701cof type C to the first workpiece holding station118athat was previously occupied by the now-removed workpiece storage unit303b.In an embodiment, kit storage units that are assembled by kitting operations at the kitting area102of the manufacturing system100illustrated inFIGS. 1-2andFIG. 7, are configured to contain particular combinations of workpieces of various types needed for a particular manufacturing process to preclude retrieval and delivery of multiple workpiece storage units303bto a manufacturing cell106for a single manufacturing process.

FIG. 9Dillustrates a perspective view of the manufacturing cell106, showing completed subassemblies of the joined first and second workpieces701aand701bdeparting the manufacturing cell106on the RSRV-carried workpiece support501, and a new workpiece support501carrying workpieces701dof a fourth type, for example, type D, delivered on another RSRV306for assembly thereof with the workpieces701cof type C during the subsequent manufacturing process, according to an embodiment herein.FIG. 9Dillustrates the workpiece support501as now holding subassemblies, each comprising workpieces701bof type B having been joined to respective workpieces701aof type A by the above disclosed cooperation of the two robotic workers123a,123b.The workpiece support501and the subassemblies thereon are driven out of the manufacturing cell106by the RSRV306on which the workpiece support501is carried, while another RSRV306carrying multiple workpieces701dof type D from the 3D gridded storage structure300arrives at the manufacturing cell106from which the subassemblies are departing. In an embodiment, the departing workpiece support501and the subassemblies thereon are carried by the RSRV306into the 3D gridded storage structure300for storage. In another embodiment, the departing workpiece support501and the subassemblies thereon are carried onward by the RSRV306to another manufacturing cell106for further processing. The workpieces701cof type C from the third workpiece storage unit303bparked on the first workpiece holding station118aare then placed or held in suitable relation to the workpieces701dof type D by the robotic picker123a,while the robotic process worker123bchanges toolpieces, if necessary, at the toolpiece holding station118d,and then performs a joining process to join the workpieces701dof type D to the workpieces701cof type C.

FIG. 9Eillustrates a perspective view of the manufacturing cell106, showing the robotic picker123aloading a third workpiece701cof type C from the third workpiece storage unit303bonto the new RSRV-carried workpiece support501, while the robotic process worker123bis picking an automatically selected toolpiece801from the toolpiece storage unit303dfor joining the third workpiece701cof type C to the fourth workpiece701dof type D on the new RSRV-carried workpiece support501, according to an embodiment herein.

FIG. 9Fillustrates a perspective view of the manufacturing cell106, showing the cooperation between the robotic picker123aand the robotic process worker123bfor joining the third workpiece701cof type C to the fourth workpiece701dof type D on the new RSRV-carried workpiece support501, according to an embodiment herein. The robotic picker123aholds the third workpiece701cand the fourth workpiece701din a prescribed orientation on the workpiece support501, while the robotic process worker123bjoins the third workpiece701cto the fourth workpiece701dusing the selected toolpiece801.

The forgoing example demonstrates how the workpiece storage unit303bat one of two workpiece holding areas can be swapped out while the manufacturing cell106is working on placement and processing of workpieces from the other workpiece holding area, whether this is performed to prepare the manufacturing cell106for a different manufacturing process, as contemplated in the forgoing example, or whether to swap out an empty workpiece storage unit303bwith a full storage unit303bor303chaving the same type or kit of workpieces to replenish the manufacturing cell106for a repeat of the same manufacturing process. Similarly, the foregoing example demonstrates how an RSRV306carrying a second workpiece support501can be queued up at the manufacturing cell106before the completion of the manufacturing process on the workpiece contents of the first workpiece support501. In this manner, as soon as the first workpiece support501departs the manufacturing cell106on its RSRV306, the second workpiece support501advances into the working position between the robotic workers123a,123bat the center of the manufacturing cell106. The foregoing example also demonstrates how the workpiece support501being delivered to the manufacturing cell106can be either an empty workpiece support or an occupied workpiece support on which a processed workpiece or an assembled subassembly was previously processed or assembled, whether such previously processing or assembly was performed earlier at the same manufacturing cell106or at a different manufacturing cell. In the event that the arriving workpiece support501is an occupied workpiece support, the workpiece support501may be arriving directly from another manufacturing cell, or from a storage location in the 3D gridded storage structure300in which the workpiece support501was temporarily stored or buffered between manufacturing processes.

FIG. 10illustrates a top plan view of the manufacturing center105shown inFIGS. 1-2, showing an example of a multi-stop path traversed by one of the RSRVs306to move a workpiece support501illustrated inFIGS. 9A-9F, through multiple manufacturing stages at various manufacturing cells106in the manufacturing center105, according to an embodiment herein. In an embodiment, the manufacturing cells106are daisy chained together to perform several manufacturing processes sequentially using any manufacturing cell order on the gridded track structure108. In another embodiment, individual manufacturing processes are assigned to each manufacturing cell106and completed as availability allows. For example, the steps1,2,3, and4illustrated inFIG. 10can be performed in any combination depending on the priority and availability of the manufacturing cells106. As illustrated inFIG. 10, the RSRV306carrying a workpiece support501with workpieces thereon traverses a path with multiple stops, for example, four stops, at four different manufacturing cells106prior to returning the completed subassembly to the ASRS structure101. The workpieces positioned on the workpiece support501undergo one or more process steps of a manufacturing process at each of the manufacturing cells106for the manufacture of a finished good, for example, a finished product or a finished subassembly. The same RSRV306then delivers the finished good to the ASRS structure101for storage therein.

In an embodiment, the computerized control system (CCS)131randomly assigns the holding stations of each manufacturing cell106for holding the storage units. For example, the CCS131assigns one holding station for a current process workpiece kitted bin, another holding station for a current process toolpiece kitted bin, another holding station for a subsequent process workpiece kitted bin, and another holding station for a subsequent process toolpiece kitted bin. The CCS131further assigns other spots in the manufacturing cell106as follows: spot(s) configured as a runway for an RSRV-carried workpiece support501and spots for housing the robotic workers, for example, the robotic picker for grasping a workpiece to be processed on the workpiece support501and the robotic process worker for using a toolpiece to process the workpiece on the workpiece support501. If a manufacturing process is too complex for robotic processing or if the process deals with workpieces larger than a storage unit, a human-attended manufacturing cell107is used. At the human-attended manufacturing cell107, both workpiece kitted bins and toolpiece kitted bins are delivered to a human worker. The CCS131renders instructions on human-machine interfaces (HMIs) positioned at the human-attended manufacturing cell107. The instructions rendered depending on the type of storage unit is presented at the ports of the human-attended manufacturing cell107.

FIG. 11illustrates a top plan view of the manufacturing center105shown inFIGS. 1-2, illustrating examples of multi-stop paths traversed by a pair of the RSRVs306to transport workpieces and toolpieces between the ASRS structure101and the manufacturing cells106of the manufacturing center105, according to an embodiment herein. Swapping one toolpiece storage unit303dfor another at one of the two tool holding stations118c,118dillustrated inFIGS. 9A-9F, while one or more toolpieces from the other tool holding station is being utilized in the manufacturing cell106is useful for switching the manufacturing cell106from one manufacturing process to another without loss of production time. The use of two workpiece holding areas and two tool holding areas is illustrated inFIG. 11, where an RSRV306sent out from the 3D gridded storage structure300to deliver a workpiece storage unit303bor a kit storage unit303cto a workpiece holding area of one manufacturing cell106can be used to pick up an empty or unneeded workpiece storage unit303bor an empty or unneeded kit storage unit303cfrom another manufacturing cell106, and then return this empty or unneeded workpiece storage unit303bor the empty or unneeded kit storage unit303cto the 3D gridded storage structure300for storage therein. Similarly, an RSRV306sent out from the 3D gridded storage structure300to deliver a toolpiece storage unit303dto a tool holding area of one manufacturing cell106can be used to pick up an unneeded toolpiece storage unit303dfrom another manufacturing cell106, and then return this empty or unneeded toolpiece storage unit303dto the 3D gridded storage structure300for storage therein. In the meantime, with two workpiece holding areas and two tool holding areas at each manufacturing cell106, unproductive time at the manufacturing cell106can be avoided by continuing manufacturing at the still-occupied holding area while the other holding area is being emptied and replenished. In an embodiment, the same RSRV306is configured to pick up an empty or unneeded toolpiece storage unit303dafter drop-off of a needed workpiece storage unit303bor vice versa. That is, the same RSRV306used to drop off a needed workpiece storage unit303bor a kit storage unit303cto the manufacturing cell106can be configured to pick up an empty or unneeded toolpiece storage unit303dfrom the manufacturing cell106. Similarly, the same RSRV306used to drop off a needed toolpiece storage unit303dto the manufacturing cell106can be configured to pick up an empty or unneeded workpiece storage unit303bor kit storage unit303cfrom the manufacturing cell106. While assignment of dual tasks, that is, drop off of a needed storage unit and pickup of an empty or unneeded storage unit to an RSRV's306single trip out from the 3D gridded storage structure300increases efficiency of the manufacturing process, singular-task routing of the RSRV306may also be employed.

The fully-automated manufacturing cells106are distributed throughout the main internal area of the gridded track structure108, with at least one row or column of the gridded track structure108left open between any two adjacent manufacturing cells106to allow the RSRVs306to travel therebetween. In the embodiment exemplarily illustrated inFIGS. 10-11, there are two rows or two columns left open between each pair of adjacent manufacturing cells106to preclude the interaction of an RSRV306with one manufacturing cell106from obstructing another RSRV's306interaction with a neighboring manufacturing cell106.

In an embodiment, each human-attended manufacturing cell107is of the same construction as the workstations disclosed in Applicant's US Patent Application Numbers16/374,123and16/374,143, where each human-attended manufacturing cell107comprises a lower track on which the RSRVs306can ride to deliver storage units to an access spot on the lower track at which the storage units are accessible to a human worker of the human-attended manufacturing cell107through an access opening125in a countertop126that overlies the lower track. In an embodiment as illustrated inFIGS. 1-2andFIGS. 10-12B, multiple human-attended manufacturing cells107are arranged in series with one another such that their lower tracks collectively occupy a singular row or column of the gridded track structure108of the manufacturing center105adjacent to a respective side of the outer perimeter108aof the gridded track structure108. In the illustrated example, four human-attended manufacturing cells107occupy the outermost row of the gridded track structure108at the far side of the manufacturing center105. In an embodiment, the human-attended manufacturing cells107are additionally or alternatively positioned at a respective column of the gridded track structure108at one or both of the lateral sides108band108cof the gridded track structure108. The lower tracks of the human-attended manufacturing cells107that occupy a row or a column of the same gridded track structure108on which the fully automated manufacturing cells106are positioned, are therefore part of the same extension of the gridded lower track layout302of the 3D gridded storage structure300by which the fully automated manufacturing cells106are served by the RSRVs306. The RSRVs306are, therefore, operable to deliver the workpiece storage units303bor the kit storage units303cwhose contents are compiled from the inventory storage units303aat the kitting area102illustrated inFIGS. 1-2andFIG. 7, to the human-attended manufacturing cells107. In an embodiment, the RSRVs306also deliver toolpiece storage units303dcontaining toolpieces required at the human-attended manufacturing cells107to perform process steps of a manufacturing process currently assigned to those human-attended manufacturing cells107, whether those toolpieces are required and used by the human worker of the human-attended manufacturing cell107, or a robotic worker, or another piece of automated manufacturing equipment, for example, a computer numerical control (CNC) machine, or any combination thereof, at that human-attended manufacturing cell107.

Similar to the human-attended manufacturing cells107comprising CNC machines or other automated manufacturing equipment, in an embodiment, one or more of the fully automated manufacturing cells106include such equipment. For example, instead of a robotic picker placing workpieces from one or more workpiece holding areas of an automated manufacturing cell106onto an RSRV-carried workpiece support501, the robotic picker places the workpieces in a CNC machine, for example, a mill, a drill, a lathe, a laser cutter, a plasma cutter, a waterjet cutter, etc., or other piece of automated manufacturing equipment for processing therein, and optionally then transfer the processed workpieces from the CNC machine or other automated manufacturing equipment back onto an RSRV306, for example, either into a workpiece storage unit carried thereon for return into the ASRS structure101, or onto a workpiece support501carried on the RSRV306for travel thereof into the ASRS structure101, or for onward travel to another automated manufacturing cell106. The RSRVs306are used to serve one or more manufacturing cells106and107from the gridded track structure108or other track-defining extension of the ASRS structure101regardless of the particular equipment and layout used in the manufacturing cells106and107. Similarly, though the illustrated embodiment uses fully automated manufacturing cells106in the main internal area of the gridded structure108and positions the human-attended manufacturing cells107at the outer perimeter area108aof the gridded track structure108, in an embodiment, the human-attended manufacturing cells107are alternatively disposed within the internal area of the gridded track structure108, provided that safe human access to and from such human-attended manufacturing cells107is established in a manner to avoid potential collision between human workers and the RSRVs306traversing the gridded track structure108.

FIG. 12Aillustrates a side perspective view of the manufacturing system100, showing the manufacturing center105comprising multiple manufacturing cells106configured in a multi-level structure, according to an embodiment herein. In the multi-level structure, the manufacturing center105comprises multiple levels of manufacturing cells106. That is, the manufacturing center105comprises multiple track-navigated manufacturing levels, for example, two track-navigated manufacturing levels130aand130bas illustrated inFIGS. 12A-12B.FIG. 12Billustrates an enlarged, partial perspective view of the manufacturing center105shown inFIG. 12A, according to an embodiment herein. Each of the track-navigated manufacturing levels130aand130bcomprises a two-dimensional (2D) gridded track structure108of the type disclosed in the detailed description ofFIGS. 8A-8C. The 2D gridded track structure108comprises sets of intersecting rails115,116on which the RSRVs306are navigable in two dimensions as illustrated inFIGS. 8A-8C. The 2D gridded track structure108of each of the track-navigated manufacturing levels130aand130bcomprises a respective set of manufacturing cells106installed on the gridded track structure108at each manufacturing level130aand130b.As illustrated inFIGS. 12A-12B, the lowermost gridded track structure108of the track-navigated manufacturing level130ain the two-level example is a ground level track structure identical to that disclosed in the detailed description ofFIGS. 8A-8Cfor the single-level embodiment, and is therefore connected to the gridded lower track layout302of the three-dimensional (3D) gridded storage structure300illustrated inFIG. 3that defines the ASRS structure101. Each subsequently higher level disposed above the ground level track structure, for example, the second track-navigated manufacturing level130b,lacks a direct connection to a corresponding gridded track layout302of the 3D gridded storage structure300.

In an embodiment, the multi-level structure further comprises upright frame members309. The upright frame members309interconnect the intersecting rails115,116of the levels130a,130b.In an embodiment, one or more of the upright frame members309are configured for traversal of the RSRVs306thereon in an ascending direction and/or a descending direction to transition between the levels130a,130b.In an embodiment, the 2D gridded track structure108at one of the levels of the multi-level structure is attached to a corresponding one of the storage levels in the ASRS structure101at which the RSRVs306are configured to transition between the ASRS structure101and the multi-level structure. To allow RSRV access to each subsequently higher level track structure from the ground level track structure, rack-toothed upright frame members309of the same type used in the 3D gridded storage structure300illustrated inFIG. 3are used to interconnect the track rails115,116at the different levels to allow ascending and descending travel of the RSRVs306between the different levels in the same manner in which the RSRVs306travel upwardly and downwardly through the upright shafts305of the 3D gridded storage structure300. In an embodiment, the rack-toothed frame members309are used for the ascending and descending travel of the RSRVs306at the four corners of any unoccupied square spots in the gridded track structures108that are not occupied by cell components, for example, holding stations, robotic workers, etc., of any manufacturing cell. In an embodiment, the rack-toothed frame members are used throughout the entire multi-level structure so that a vertical space between any unoccupied square spot on one level and a matching unoccupied square spot on the next level can serve as an upright travel shaft through which an RSRV306can ascend and descend between those levels. This maintains flexibility to ensure that even if the manufacturing cell layout or equipment at one or more levels is reconfigured in a manner that obstructs a previously available travel shaft, other travel shafts remain available for inter-level travel of the RSRVs306. In another embodiment, in addition to or alternative to the rack-toothed frame members309, the multi-level structure incorporates lifting mechanisms of the type disclosed in

Applicant's co-pending PCT Application Number PCT/CA2019/050815 filed on Jun. 10, 2019, the entirety of which is incorporated herein by reference. In an embodiment, at each of the gridded track layouts from which the RSRVs306must ascend upward to that of a higher level in the multi-level structure, a lifting mechanism is positioned in a launching spot of the gridded track layout below a respective shaft through which the RSRV306ascends to the higher level above.

In an embodiment as exemplarily illustrated inFIGS. 12A-12B, the multi-level structure of the manufacturing center105is a two-level structure of a lesser height than the ASRS structure101, whereby the uppermost level130bof the multi-level structure is at a lesser elevation than the gridded upper track layout301of the 3D gridded storage structure300illustrated inFIG. 3that defines the ASRS structure101. In other embodiments, the multi-level structure of the manufacturing center105is equal to or of a greater height than the ASRS structure101, in which case an uppermost or intermediate level of the multi-level structure may have its gridded track structure108attached to the gridded upper track layout301of the 3D gridded storage structure300, in which case the RSRVs306may transition between the ASRS structure101and the manufacturing center105at multiple levels of the ASRS structure101and the manufacturing center105. In another embodiment, the 3D gridded storage structure300, at intermediate levels between the gridded upper and lower track layouts301and302thereof, is optionally equipped with exit and return ports opening onto the gridded track structure108at one or more respective levels of the multi-level structure of the manufacturing center105. Such intermediate levels of the 3D gridded storage structure300are equipped with a fully gridded track layout similar to those at the top and bottom of the 3D gridded storage structure300. In another embodiment, to avoid reduction in storage density, the 3D gridded storage structure300, at intermediate levels between the gridded upper and lower track layouts301and302thereof, is optionally equipped with exit ports in outer shafts of the 3D gridded storage structure300so that an RSRV306climbing or descending through the outer shaft can transition into the multi-level structure of the manufacturing center105. To accomplish this, in an embodiment, the outer shaft comprises a pair of transfer rails that are suspended between the frame members309of that outer shaft and that align with a respective pair of rails of the gridded track structure108at the respective level in the multi-level structure of the manufacturing center105. In this embodiment, transition between the 3D gridded storage structure300and the manufacturing center105need not necessarily be to a level of the 3D gridded storage structure300at which a gridded track layout is defined.

Furthermore, in other embodiments, the use of the RSRVs306from the ASRS structure101to directly serve one or more manufacturing cells106to avoid need for intermediary conveyors or other equipment between the ASRS structure101and the manufacturing cells106does not necessarily need to be achieved through a 2D gridded track structure108attached to the ASRS structure101. In an embodiment, a network of tracks extending outward from the gridded track layout of the ASRS structure101and returning thereto is used to allow travel of the RSRVs306out from the ASRS structure101to one or more manufacturing cells106distributed along that network of tracks. In an embodiment, the network of tracks comprises one or more 2D gridded track structures108having an array of manufacturing cells106distributed therein as illustrated inFIGS. 1-2, but with each such 2D gridded track structure108being discretely positioned at a spaced distance from the ASRS structure101and being connected to the ASRS structure101by other tracks of the network. In an embodiment, the other tracks of the network comprise at least one delivery track dedicated to outbound travel of the RSRVs306from the ASRS structure101to the gridded track structure108and at least one return track dedicated to inbound travel of the RSRVs306back to the ASRS structure101from the gridded track structure108.

While in the illustrated embodiments, the RSRVs306depart the 3D gridded storage structure300that defines the ASRS structure101via an extension of the gridded lower track layout302thereof, other embodiments alternatively employ an extension of the upper gridded track layout301of the 3D gridded storage structure300for departure of the RSRVs306therefrom to the external manufacturing cell(s)106. In an embodiment, the network of tracks comprise one or more overhead tracks connected to the gridded upper track layout301of the 3D gridded storage structure300or to an intermediate level of the 3D gridded storage structure300between the gridded upper and lower track layouts301and302, and extending outward therefrom to one or more manufacturing cells106positioned remotely of the 3D gridded storage structure300in other areas of a manufacturing facility. If positioned at a ground level or at any elevation lower than the gridded upper track layout301on the overhead track(s), in an embodiment, the manufacturing cells106are served through drop-down shafts connected to the overhead track(s) and constructed from the same rack-toothed frame members309of the 3D gridded storage structure300and installed at appropriate intervals along the overhead track(s) to allow the RSRVs306to descend down from the overhead track(s) and drop off the RSRV-carried storage units at the manufacturing cells106. In an embodiment, each drop-down shaft serves an individual manufacturing cell, or a plurality of manufacturing cells distributed within a 2D gridded track structure or distributed along a one-dimensional track at the lower elevation. The manufacturing capacity of the manufacturing center105is increased by expanding the 2D gridded track structure or adding more levels to the structure of the manufacturing center105.

FIG. 13illustrates a flowchart of a method for executing a workflow in the manufacturing system, according to an embodiment herein. The manufacturing system disclosed herein comprises a storage arrangement with an automated storage and retrieval system (ASRS) structure and a fleet of robotic storage/retrieval vehicles (RSRVs), and multiple manufacturing cells positioned outside the ASRS structure as disclosed in the detailed descriptions ofFIGS. 1-12B. In an embodiment, the storage arrangement comprises a supply of workpieces. The supply of workpieces is stored within the storage locations of the ASRS structure for use in manufacturing goods from the workpieces. The same fleet of RSRVs navigable within the ASRS structure in three dimensions is operable to deliver the workpieces to the manufacturing cells. In an embodiment, the workpieces are transportable between each of the manufacturing cells in any order. The manufacturing system disclosed herein allows the transport of workpieces between each of the manufacturing cells in any order and sequence instead of linearly with conveyors. In another embodiment, the workpieces are received at a first one of the manufacturing cells for performance of one or more of multiple process steps of a manufacturing process and subsequently stored in the storage locations of the ASRS structure and retrieved from the storage locations of the ASRS structure for the transfer of the workpieces to a second one of the manufacturing cells. In another embodiment, each of the manufacturing cells is configured to receive the workpieces multiple times for performance of one or more of the process steps of the manufacturing process.

In an embodiment, the storage arrangement of the manufacturing system disclosed herein further comprises a supply of toolpieces for use in manufacturing the goods. The toolpieces are stored in the same ASRS structure as the workpieces. The toolpieces are retrievable from the same ASRS structure and deliverable to the manufacturing cells by the same fleet of RSRVs.

In an embodiment, the storage arrangement of the manufacturing system disclosed herein further comprises a supply of storage units of compatible size and shape for storage in the storage locations of the ASRS structure. The storage units are configured to be carried by the RSRVs for transfer of the storage units to and from the storage locations and to and from the manufacturing cells. The manufacturing system disclosed herein allows buffering of storage units in the ASRS structure between each process performed at different manufacturing cells. In an embodiment, the storage units comprise workpiece storage units or toolpiece storage units or any combination thereof. Each of the workpiece storage units is configured to hold one or more of the workpieces. Each of the toolpiece storage units is configured to hold one or more of the toolpieces. In an embodiment, the manufacturing cells are configured in a continuous arrangement outside the ASRS structure. In this embodiment, the storage units are configured to be transferred to and from the storage locations of the ASRS structure and between the manufacturing cells, free of identification of the storage units, due to the continuous arrangement of the manufacturing cells. The continuity between the ASRS structure and each of the different manufacturing cells outside the ASRS structure allows direct physical transfer of the storage units free of identification or scanning of the storage units.

In an embodiment, the workpiece storage units comprise inventory storage units and kit storage units. Each of the inventory storage units is configured to contain a collection of inventory workpieces. Each of the kit storage units is configured to contain a kit of mixed workpieces picked from one or more of the inventory storage units according to a manufacturing process to be performed on the mixed workpieces once delivered to one of the manufacturing cells. In another embodiment, the manufacturing system disclosed herein further comprises at least one kitting workstation configured to accept delivery of the inventory storage units from the ASRS structure by the RSRVs for allowing picking of the inventory workpieces from the inventory storage units at the kitting workstation(s) as disclosed in the detailed description ofFIG. 7. In an embodiment, the kitting workstation(s) is configured to receive a drop-off of the workpiece storage units and/or a travel of the workpiece storage units through the kitting workstation(s) by the same fleet of RSRVs.

In an embodiment, the storage arrangement of the manufacturing system disclosed herein further comprises a supply of workpiece supports as disclosed in the detailed description ofFIGS. 5A-5CandFIGS. 6A-6B. Each of the workpiece supports is configured to hold one or more of the workpieces in predetermined positions during the manufacture of the goods. The workpiece supports are stored in the same ASRS structure as the workpieces. The workpiece supports are retrievable from the same ASRS structure and deliverable to the manufacturing cells by the same fleet of RSRVs. In an embodiment, each of the workpiece supports is of a common footprint of a standardized shape and size as each of a supply of storage units of compatible size and shape configured to fit within the storage locations of the ASRS structure. Each of the workpiece supports comprises a base of a standardized shape and size configured to fit within the storage locations of the ASRS structure. In an embodiment, each of the workpiece supports and each of the storage units are configured to have a matching layout of interface features by which the RSRVs interact with the workpiece supports and the storage units to allow loading and unloading of the workpiece supports and the storage units to and from the RSRVs.

In an embodiment, in addition to the supply of workpieces stored within the storage locations of the ASRS structure, the storage arrangement comprises either a supply of toolpieces or a supply of workpiece supports stored in the ASRS structure. Each of the toolpieces is useful for performance of one or more process steps of a manufacturing process on one or more of the workpieces during the manufacture of the goods. Each of the workpiece supports is configured to hold one or more of the workpieces in predetermined positions during the manufacture of the goods. In this embodiment, the fleet of RSRVs is operable to extract from the storage locations both the workpieces and at least one of the toolpieces and the workpiece supports. The same fleet of RSRVs navigable within the ASRS structure in the three dimensions is operable to deliver supplies or componentry, for example, the workpieces and the toolpieces and/or the workpiece supports among the manufacturing cells. In an embodiment, the componentry is transportable between each of the manufacturing cells in any order. In another embodiment, each of the manufacturing cells is configured to receive the componentry multiple times for performance of one or more of the process steps of the manufacturing process.

In an embodiment, each of the manufacturing cells comprises at least one workpiece holding area configured to hold the workpieces awaiting processing at the corresponding manufacturing cell. The workpiece holding area(s) is configured to accept placement of one of the workpiece storage units thereon. In an embodiment, the workpiece holding area comprises two workpiece holding areas. Each of the two workpiece holding areas is configured to hold a respective set of workpieces required at a corresponding manufacturing cell.

In an embodiment, at least a subset of the manufacturing cells is positioned at the track structure or within an area of the track structure. In an embodiment, the track structure is a gridded track structure comprising sets of intersecting rails on which the RSRVs are navigable in two dimensions as disclosed in the detailed description ofFIGS. 8A-8CandFIGS. 9A-9F. In an embodiment, a width of the workpiece holding area in each of the two dimensions is generally equal to a whole number multiple of a distance measured between two adjacent parallel rails of the gridded track structure. In another embodiment, a width of the workpiece holding area in each of the two dimensions does not exceed a distance measured between two adjacent parallel rails of the gridded track structure.

In an embodiment, the gridded track structure comprises square spots. Each of the square spots is delimited by a first pair of parallel rails lying in a first direction and a second pair of parallel rails lying in a second direction perpendicular to the first direction. Each of the manufacturing cells occupies a cell space of an area equal to a predetermined number of the square spots. In an embodiment, at least one cell space is a square space whose area is divisible into nine square subspaces. Each of the nine square subspaces is equal in area to one of the square spots of the gridded track structure. Four corner subspaces of the nine square subspaces are configured as holding areas for holding supplies needed by the corresponding manufacturing cell. In an embodiment, a first pair of mid-perimeter subspaces positioned between the four corner subspaces at a first pair of opposing perimeter sides of the cell space is occupied by robotic workers. In an embodiment, a central subspace positioned between the robotic workers is configured as a working area to which the workpieces are transferred and at which the workpieces are processed by the robotic workers. In an embodiment, the working area is neighbored by a second pair of mid-perimeter subspaces positioned between the four corner subspaces at a second pair of opposing perimeter sides of the cell space. In an embodiment, at least one of the second pair of mid-perimeter subspaces is an unoccupied open area by which the RSRVs are configured to enter and exit the working area. In another embodiment, both of the second pair of mid-perimeter subspaces are unoccupied open areas, whereby the RSRVs are configured to travel fully through the corresponding manufacturing cell.

In an embodiment, each of the manufacturing cells comprises at least one robotic picker operable to pick the workpieces from the workpiece holding area. In another embodiment, each of the manufacturing cells further comprises a working area to which the picked workpieces are transferred from the workpiece holding area by the robotic picker(s).

In an embodiment, each of the manufacturing cells in the subset comprises at least one tool holding area configured to hold toolpieces required at a corresponding manufacturing cell. In an embodiment, a width of the tool holding area in each of the two dimensions is generally equal to a distance measured between two adjacent parallel rails of the gridded track structure. In another embodiment, a width of the tool holding area in each of the two dimensions does not exceed a distance measured between two adjacent parallel rails of the gridded track structure. In an embodiment, each of the manufacturing cells in the subset comprises at least one robotic worker mounted atop a mounting base that is installed on or within the gridded track structure. In an embodiment, a width of the mounting base in each of the two dimensions is generally equal to a whole number multiple of a distance measured between two adjacent parallel rails of the gridded track structure. In another embodiment, a width of the mounting base in each of the two dimensions does not exceed a distance measured between two adjacent parallel rails of the gridded track structure.

In the method disclosed herein as illustrated inFIG. 13, workpieces and workpiece supports are stored1301in respective storage locations of the ASRS structure. The workpieces are stored in workpiece storage units at the storage locations. In an embodiment, each of the workpiece storage units is filled with a kit of different workpieces according to requirements of the manufacturing process. In an embodiment, each of the workpiece storage units is filled at a kitting workstation that is connected to the ASRS structure. At the kitting workstation, the fleet of RSRVs is configured to deliver inventory storage units containing inventory workpieces retrieved from respective storage locations in the ASRS structure; the different workpieces of the kit are picked from the inventory workpieces in the inventory storage units and compiled into the workpiece storage units; and each of the workpiece storage units is carried away from the kitting workstation by one of the RSRVs and deposited into a respective one of the storage locations in the ASRS structure for subsequent retrieval from the ASRS structure.

In an embodiment, toolpiece storage units configured to hold toolpieces for use in the manufacturing process are stored in the ASRS structure. In the method disclosed herein, using the fleet of RSRVs navigable within the ASRS structure, one or more of the workpiece storage units and a selected workpiece support are extracted1302from the ASRS structure according to requirements of a manufacturing process to be performed at a manufacturing cell positioned outside the ASRS structure, and separately delivered1303to the manufacturing cell. In an embodiment, RSRVs of the same type are configured to solely perform the extraction and the delivery of both of the workpiece storage unit(s) and the selected workpiece support from the ASRS structure to the manufacturing cell. At the manufacturing cell, the selected workpiece support is positioned1304in a working position accessible by one or more workers of the manufacturing cell. At the manufacturing cell, with the selected workpiece support maintained in the working position1305, (i) one or more of the workpieces are transferred1305afrom the workpiece storage unit(s) onto the selected workpiece support; and (ii) a process step of the manufacturing process is performed1305bon the workpiece(s) held on the selected workpiece support. In an embodiment, prior to performing the process step of the manufacturing process, a subset of the toolpiece storage units are extracted from the ASRS structure and delivered to the manufacturing cell using one of the RSRVs. In an embodiment, prior to performing the process step of the manufacturing process a select one of the toolpieces from the subset of the toolpiece storage units is attached to a robotic worker of the manufacturing cell according to the requirements of the manufacturing process to be performed on the workpiece(s) by the robotic worker.

In an embodiment, the workpiece storage unit(s) comprises two workpiece storage units. In this embodiment, the two workpiece storage units are delivered to two respective holding areas of the manufacturing cell. Two workpieces are respectively transferred from the two workpiece storage units parked at the two respective holding areas onto the selected workpiece support.

In an embodiment, after transferring the workpiece(s) from the workpiece storage unit(s) onto the selected workpiece support, an unneeded or empty one of the workpiece storage units from which a selected workpiece is removed and from which no further workpieces are required for the manufacturing process at the manufacturing cell, is removed from the manufacturing cell. In this embodiment, using one of the RSRVs, an additional workpiece storage unit containing one or more additional workpieces needed at the manufacturing cell is delivered to the manufacturing cell. In an embodiment, the additional workpiece(s) is for use in a different manufacturing process to be performed at the same manufacturing cell. In an embodiment, the unneeded or empty one of the workpiece storage units is removed using a different RSRV from that which delivers the additional workpiece storage unit to the manufacturing cell. In an embodiment, the different RSRV is configured to remove the unneeded or empty one of the workpiece storage units after having dropped off a different one of the workpiece storage units at a different manufacturing cell to supply contents of the different one of the workpiece storage units to the different manufacturing cell. After the process step of the manufacturing process is performed on the workpiece(s) held on the selected workpiece support, the selected workpiece support and the workpiece(s) thereon that were processed are removed from the manufacturing cell; another workpiece support is delivered to the manufacturing cell for use in the different manufacturing process using one of the RSRVs; the workpiece support is supported in the working position; the additional workpiece(s) is transferred from the additional workpiece storage unit onto the workpiece support; and one or more process steps of the different manufacturing process are performed on the additional workpiece(s).

In the method disclosed herein, after completion of a finished good by processing of the workpiece(s) at one or more manufacturing cells, the finished good is inducted into the ASRS structure on one of the RSRVs. In an embodiment, the finished good is inducted into the ASRS structure on a final workpiece support on which one or more final process steps were carried out to complete the finished good. In an embodiment, the final workpiece support is the same selected workpiece support onto which the workpiece(s) was transferred.

FIG. 14illustrates a flowchart of a method for executing a kitting operation of a workflow in the manufacturing system, according to an embodiment herein. Consider an example where a work order for a kit storage unit, herein referred to as a “kitted bin”, is received. At step1401, the kitting operation starts on receiving the work order. At step1402, the computerized control system (CCS) of the manufacturing system receives the work order for the required kitted bin. At step1403, the CCS instructs a first robotic storage/retrieval vehicle (RSRV) to retrieve an empty storage unit, herein referred to as an “empty bin”. At step1404, the first RSRV retrieves the empty bin from the automated storage and retrieval system (ASRS) structure and presents the empty bin to a put port or a placement-access port of a kitting workstation in the kitting area of the manufacturing system. At step1405, the CCS instructs a second RSRV to retrieve a required workpiece storage unit, for example, a required single stock keeping unit (SKU) bin. At step1406, the second RSRV retrieves the single SKU bin from the ASRS structure and presents the single SKU bin to a pick port or a picking-access port of the kitting workstation. At step1407, a worker, that is, a human worker or a robotic worker, picks a required number of workpieces from the single SKU bin and places the picked workpieces in the empty bin that is being kitted at the put port of the kitting workstation. At step1408, the CCS instructs the second RSRV to store the single SKU bin. At step1409, the second RSRV stores the single SKU bin in the ASRS structure. At step1410, the CCS determines whether there are more workpieces required in the kitted bin based on the work order. If there are more workpieces required in the kitted bin, the steps1405to1409of the method disclosed herein are repeated until there are no more workpieces required in the kitted bin. If there are no more workpieces required in the kitted bin, at step1411, the CCS instructs the first RSRV to store the kitted SKU bin. At step1412, the first RSRV stores the kitted SKU bin in the ASRS structure. The kitting operation ends1413when the kitted SKU bin is processed and stored. In an embodiment, the above kitting operation is also performed for toolpieces to create kitted toolpiece bins or toolpiece kit storage units.

FIGS. 15A-15Cillustrate a flowchart of a method for executing a manufacturing operation using workpiece storage units for fulfilling a work order in the manufacturing system, according to an embodiment herein. At step1501, the manufacturing operation starts when the manufacturing system receives a work order for assembly. At step1502, the computerized control system (CCS) of the manufacturing system receives the work order for the required assembly with software instructions. At step1503, on executing the software instructions, the CCS instructs a first robotic storage/retrieval vehicle (RSRV) to retrieve a work support associated with the manufacturing operation to be performed. At step1504, the first RSRV retrieves the associated workpiece support from the automated storage and retrieval system (ASRS) structure and presents the workpiece support to an assigned fully automated or robotic manufacturing cell at the manufacturing center of the manufacturing system. At step1505, the CCS instructs a second RSRV to retrieve a required workpiece storage unit. At step1506, the second RSRV retrieves the required workpiece storage unit from the ASRS structure and places the workpiece storage bin on a workpiece holding station at the assigned robotic manufacturing cell. At step1507, the CCS instructs a third RSRV to retrieve a required toolpiece storage unit.

At step1508, the third RSRV retrieves the required toolpiece storage unit from the ASRS structure and places the toolpiece storage unit on a toolpiece holding station at the assigned robotic manufacturing cell.

At step1509, the CCS instructs a robotic worker, that is, a robotic picker operably coupled to another mounting base at the assigned robotic manufacturing cell, to pick an assigned workpiece. At step1510, the robotic picker picks the assigned workpiece from the workpiece storage unit. At step1511, the CCS instructs the robotic picker to place the assigned workpiece in a working position. At step1512, the CCS determines whether the assigned workpiece is to be fastened onto a subassembly positioned on the workpiece support based on the work order. If fastening is not required, the manufacturing operation proceeds to step1516disclosed below. If the assigned workpiece is to be fastened onto the subassembly positioned on the workpiece support, at step1513, the CCS instructs another robotic worker, that is, a robotic process worker operably coupled to a mounting base at the assigned robotic manufacturing cell, to acquire or pick an assigned toolpiece from the toolpiece storage unit. At step1514, the robotic process worker acquires the assigned toolpiece from the toolpiece storage unit. At step1515, the CCS instructs the robotic process worker to fasten the workpiece onto the subassembly using the acquired toolpiece. At step1516, the CCS determines whether more workpieces are required in the subassembly. If more workpieces are required in the subassembly, the steps1509to1515of the method disclosed herein are repeated until no more workpieces are required. If no more workpieces are required in the subassembly, at step1517, the CCS instructs the second RSRV or a fourth RSRV to store the workpiece storage unit. In an embodiment, the CCS instructs the same second RSRV that delivered the workpiece storage unit to the manufacturing cell, to store the workpiece storage unit. In another embodiment, the CCS instructs another RSRV, that is, the fourth RSRV, to store the workpiece storage unit. At step1518, the second RSRV or the fourth RSRV stores the workpiece storage unit in the ASRS structure. At step1519, the CCS instructs the third RSRV or a fifth RSRV to store the toolpiece storage unit. In an embodiment, the CCS instructs the same third RSRV that delivered the toolpiece storage unit to the manufacturing cell, to store the toolpiece storage unit. In another embodiment, the CCS instructs another RSRV, that is, the fifth RSRV, to store the toolpiece storage unit. At step1520, the third RSRV or the fifth RSRV stores the toolpiece storage unit in the ASRS structure. At step1521, the CCS determines whether different workpieces are required in the subassembly. If different workpieces are required in the subassembly, the steps1505to1520of the method disclosed herein are repeated until different workpieces are not required in the subassembly. At step1522, the CCS determines whether the workpiece support is required at another manufacturing cell of the manufacturing center. If the workpiece support is required at another manufacturing cell, at step1523, the CCS instructs the first RSRV to transport the workpiece support with the subassembly to the next manufacturing cell. At step1524, the first RSRV transports the workpiece support with the subassembly to the next manufacturing cell, where steps similar to the steps1505to1522are performed. If the workpiece support is not required at another manufacturing cell, at step1525, the CCS instructs the first RSRV to store the workpiece support with the finished subassembly. At step1526, the first RSRV stores the workpiece support with the finished subassembly for the work order in the ASRS structure. The manufacturing operation ends1527when the work order is complete.

FIGS. 16A-16Cillustrate a flowchart of a method for executing a manufacturing operation using kit storage units for fulfilling a work order in the manufacturing system, according to an embodiment herein. At step1601, the manufacturing operation starts when the manufacturing system receives a work order for assembly. At step1602, the computerized control system (CCS) of the manufacturing system receives the work order for the required assembly with software instructions. At step1603, on executing the software instructions, the CCS instructs a first robotic storage/retrieval vehicle (RSRV) to retrieve a work support associated with the manufacturing operation to be performed. At step1604, the first RSRV retrieves the associated workpiece support from the automated storage and retrieval system (ASRS) structure and presents the workpiece support to an assigned fully automated or robotic manufacturing cell at the manufacturing center of the manufacturing system. At step1605, the CCS instructs a second RSRV to retrieve a required workpiece kit storage unit, also referred to as a “workpiece kitted bin”. At step1606, the second RSRV retrieves the required workpiece kitted bin from the ASRS structure and places the workpiece kitted bin on a workpiece holding station at the assigned robotic manufacturing cell. At step1607, the CCS instructs a third RSRV to retrieve a required toolpiece kit storage unit, also referred to as a “toolpiece kitted bin”. At step1608, the third RSRV retrieves the required toolpiece kitted bin from the ASRS structure and places the toolpiece kitted bin on a toolpiece holding station at the assigned robotic manufacturing cell.

At step1609, the CCS instructs a robotic worker, that is, a robotic picker operably coupled to another mounting base at the assigned robotic manufacturing cell, to pick an assigned workpiece. At step1610, the robotic picker picks the assigned workpiece from the workpiece kitted bin. At step1611, the CCS instructs the robotic picker to place the assigned workpiece in a working position. At step1612, the CCS determines whether the assigned workpiece is to be fastened onto a subassembly positioned on the workpiece support based on the work order. If fastening is not required, the manufacturing operation proceeds to step1616disclosed below. If the assigned workpiece is to be fastened onto the subassembly positioned on the workpiece support, at step1613, the CCS instructs another robotic worker, that is, a robotic process worker operably coupled to a mounting base at the assigned robotic manufacturing cell, to acquire or pick an assigned toolpiece from the toolpiece kitted bin. At step1614, the robotic process worker acquires the assigned toolpiece from the toolpiece kitted bin. At step1615, the CCS instructs the robotic process worker to fasten the workpiece onto the subassembly using the acquired toolpiece. At step1616, the CCS determines whether more workpieces are required in the subassembly. If more workpieces are required in the subassembly, the steps1609to1615of the method disclosed herein are repeated until no more workpieces are required. If no more workpieces are required in the subassembly, at step1617, the CCS instructs the second RSRV or a fourth RSRV to store the workpiece kitted bin. In an embodiment, the CCS instructs the same second RSRV that delivered the workpiece kitted bin to the manufacturing cell, to store the workpiece kitted bin. In another embodiment, the CCS instructs another RSRV, that is, the fourth RSRV, to store the workpiece kitted bin. At step1618, the second RSRV or the fourth RSRV stores the workpiece kitted bin in the ASRS structure. At step1619, the CCS instructs the third RSRV or a fifth RSRV to store the toolpiece kitted bin. In an embodiment, the CCS instructs the same third RSRV that delivered the toolpiece kitted bin to the manufacturing cell, to store the toolpiece kitted bin. In another embodiment, the CCS instructs another RSRV, that is, the fifth RSRV, to store the toolpiece kitted bin. At step1620, the third RSRV or the fifth RSRV stores the toolpiece kitted bin in the ASRS structure. At step1621, the CCS determines whether the workpiece support is required at another manufacturing cell of the manufacturing center. If the workpiece support is required at another manufacturing cell, at step1622, the CCS instructs the first RSRV to transport the workpiece support with the subassembly to the next manufacturing cell. At step1623, the first RSRV transports the workpiece support with the subassembly to the next manufacturing cell, where steps similar to the steps1605to1621are performed. If the workpiece support is not required at another manufacturing cell, at step1624, the CCS instructs the first RSRV to store the workpiece support with the finished subassembly. At step1625, the first RSRV stores the workpiece support with the finished subassembly for the work order in the ASRS structure. The manufacturing operation ends1626when the work order is complete.

FIG. 17illustrates a flowchart of a method for manufacturing a product in the manufacturing system, according to an embodiment herein. Consider an example where the manufacturing system receives1701a purchase order for a predetermined quantity of a product, Product_X, and proceeds to purchase1702raw materials required for manufacturing Product_X in the predetermined quantity. When the raw materials for manufacturing Product_X are received at the manufacturing system, at step1703, the raw materials are inducted into workpiece storage units in the automated storage and retrieval system (ASRS) structure. At step1704, the computerized control system (CCS) of the manufacturing system triggers a kitting operation at the kitting area of the manufacturing system as disclosed in the detailed description ofFIG. 14, for creating kits or kit storage units comprising workpieces of one or more types for manufacturing a quantity of each of a plurality of subassemblies that constitute Product_X. At step1705, the CCS determines whether the manufacturing center has capacity available for manufacturing the quantity of each of the Product_X subassemblies. If there is capacity available, at step1706, the CCS configures one of the fully automated or robotic manufacturing cells of the manufacturing center for manufacturing the quantity of each of the Product_X subassemblies. At step1707, the CCS instructs the robotic manufacturing cell to manufacture the quantity of each of the Product_X subassemblies. The robotic manufacturing cell manufactures the quantity of each of the Product_X subassemblies by executing the manufacturing operation as disclosed in the detailed description ofFIGS. 16A-16C. After the manufacture of each of the Product_X subassemblies, at step1708, the CCS determines whether more Product X subassemblies need to be manufactured to reach the required quantity. If there are more subassemblies that need to be manufactured to reach the required quantity, the steps1705to1707are repeated until the required quantity is reached. If the required quantity is reached, at step1709, the CCS determines whether the manufacturing center has capacity available for manufacturing Product_X in the predetermined quantity. If there is capacity available, at step1710, the CCS configures one of the fully automated or robotic manufacturing cells of the manufacturing center for manufacturing the predetermined quantity of the Product_X final assembly. At step1711, the CCS instructs the robotic manufacturing cell to manufacture the predetermined quantity of the Product_X final assembly using the Product_X subassemblies. The manufacturing operation ends1712when the quantity of Product_X is manufactured. The manufacturing system disclosed herein allows the manufacture of a large number of variants and models of a product in variable quantities.

FIG. 18illustrates an architectural block diagram of the manufacturing system100, showing communication between the computerized control system (CCS)131and components of the manufacturing system100, according to an embodiment herein. The components of the manufacturing system100comprise the automated storage and retrieval system (ASRS) structure101, the fleet of robotic storage/retrieval vehicles (RSRVs)306, kitting workstations103,104, and the manufacturing cells106,107of the manufacturing center105illustrated inFIGS. 1-2. The CCS131is in operable communication with the fleet of RSRVs306, human-machine interfaces (HMIs)138and a light guiding system139of the kitting workstations103,104, the robotic workers123a,123bat the fully automated or robotic manufacturing cells106, and HMIs140at the human-attended manufacturing cells107. The HMIs138of the kitting workstations103,104comprise display screens for displaying instructions to human workers703for performing kitting operations at the kitting area102of the manufacturing system100as illustrated inFIGS. 1-2andFIG. 7. The light guidance system139comprises, for example, a put-to-light guidance system and a pick-to-light guidance system. The CCS131comprises a network interface134coupled to a communication network and at least one processor132coupled to the network interface134. 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 network interface134enables connection of the CCS131to the communication network. In an embodiment, the network interface134is provided as an interface card also referred to as a line card. The network interface134is, 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.

In an embodiment, the CCS131is a computer system that is programmable using high-level computer programming languages. The CCS131is implemented using programmed and purposeful hardware. In the manufacturing system100disclosed herein, the CCS131interfaces with the ASRS structure101, the RSRVs306, the kitting workstations103,104, and the manufacturing cells106,107, and therefore more than one specifically programmed computing system is used for executing a workflow in the manufacturing system100. The CCS131further comprises a non-transitory, computer-readable storage medium, for example, a memory unit137, communicatively coupled to the processor(s)132. As used herein, “non-transitory, computer-readable storage medium” 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 processor132refers to any one or more microprocessors, central processing unit (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, the processor132is implemented as a processor set comprising, for example, a programmed microprocessor and a math or graphics co-processor. The CCS131is not limited to employing the processor132. In an embodiment, the CCS131employs controllers or microcontrollers. The processor132executes the modules, for example,137a-137dof the CCS131.

The memory unit137is used for storing program instructions, applications, and data. The memory unit137stores computer program instructions defined by modules, for example,137a-137dof the CCS131. The memory unit137is operably and communicatively coupled to the processor132for executing the computer program instructions defined by the modules, for example,137a-137dof the CCS131for executing a workflow in the manufacturing system100. The memory unit137is, for example, a random-access memory (RAM) or another type of dynamic storage device that stores information and instructions for execution by the processor132. The memory unit137also stores temporary variables and other intermediate information used during execution of the instructions by the processor132. In an embodiment, the CCS131further comprises read only memories (ROMs) or other types of static storage devices that store static information and instructions for execution by the processor132. In an embodiment, the modules, for example,137a-137eof the CCS131are stored in the memory unit137.

The memory unit137is configured to store computer program instructions, which when executed by the processor(s)132, cause the processor(s)132to activate one or more of the RSRVs306to perform one or more of: (a) navigating within the ASRS structure101and/or through the manufacturing cells106,107; (b) retrieving one or more of the workpieces contained in one or more storage units from the storage locations of the ASRS structure101; (c) delivering one or more of the workpieces contained in one or more storage units to at least one kitting workstation103,104for kitting into one or more kit storage units; (d) picking up one or more kit storage units from the kitting workstation(s)103,104; returning and storing one or more kit storage units to the storage locations of the ASRS structure101; (f) retrieving at least one of one or more kit storage units and one or more of the workpieces contained in another one or more of the storage units, one or more toolpieces contained in another one or more storage units, and one or more workpiece supports from the same ASRS structure101; (g) delivering at least one of one or more kit storage units and one or more of the workpieces contained in the other one or more of the storage units, one or more toolpieces contained in the other one or more storage units, and one or more workpiece supports to the manufacturing cells106,107for the manufacture of the goods; and (h) inducting the goods into the ASRS structure101on a final workpiece support.

As illustrated inFIG. 18, the CCS131further comprises a data bus136, a display unit133, and common modules135. The data bus136permits communications between the modules, for example,132,133,134,135, and137of the CCS131. The display unit133, via a graphical user interface (GUI)133a,displays information, display interfaces, user interface elements such as checkboxes, input text fields, etc., for example, for allowing a user such as a system administrator to trigger an update to digital records for work orders, enter inventory information, update database tables, etc., for executing a workflow in the manufacturing system100. The CCS131renders the GUI133aon the display unit133for receiving inputs from the system administrator. The GUI133acomprises, for example, an online web interface, a web-based downloadable application interface, a mobile-based downloadable application interface, etc. The display unit133displays the GUI133a.The common modules135of the CCS131comprise, for example, input/output (I/O) controllers, input devices, output devices, fixed media drives such as hard drives, removable media drives for receiving removable media, etc. Computer applications and programs are used for operating the CCS131. The programs are loaded onto fixed media drives and into the memory unit137via the removable media drives. In an embodiment, the computer applications and programs are loaded into the memory unit137directly via the communication network.

In an exemplary implementation illustrated inFIG. 18, the CCS131comprises an order management module137a,a kitting management module137b,a storage unit assignment module137c,a robot activation module137d,and a facility database137e.The order management module137adefines computer program instructions for receiving work orders with software instructions for executing a workflow in the manufacturing system100. The order management module137ais configured to update digital records for work orders in the facility database137e.The kitting management module137bdefines computer program instructions for executing kitting operations at the kitting area102of the manufacturing system100based on work order and manufacturing requirements. The kitting management module137btransmits instructions and notifications to HMIs138at the kitting area102for viewing by human workers703who are attending at least one kitting workstation103. In an embodiment, the kitting management module137balso controls the light guidance system139that guides picking and placement operations at the kitting area102. The storage unit assignment module137cdefines computer program instructions for assigning storage units for storing workpieces, particular combinations of workpieces, workpiece supports, toolpieces, particular combinations of toolpieces, etc., at addressed storage locations in the ASRS structure101. The robot activation module137dactivates one or more of the RSRVs306for performing various storage, retrieval, delivery, and return operations during kitting operations at the kitting area102and during manufacturing workflows in the manufacturing cells106,107of the manufacturing center105as disclosed above.

The processor132of the CCS131retrieves instructions defined by the order management module137theting management module137b,the storage unit assignment module137c,and the robot activation module137dfor performing respective functions disclosed above. The processor132retrieves instructions for executing the modules, for example,137a-137d,from the memory unit137. The instructions fetched by the processor132from the memory unit137after being processed are decoded. After processing and decoding, the processor132executes their respective instructions, thereby performing one or more processes defined by those instructions. An operating system of the CCS131performs multiple routines for performing a number of tasks required to assign the input devices, the output devices, and the memory unit137for execution of the modules, for example,137a-137e.The tasks performed by the operating system comprise, for example, assigning memory to the modules, for example,137a-137e,etc., and to data used by the CCS131, moving data between the memory unit137and 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 processor132. The processor132continues the execution to obtain one or more outputs.

For purposes of illustration, the detailed description refers to the modules, for example,137a-137e,being run locally on a single computer system; however the scope of the manufacturing system100and the method disclosed herein is not limited to the modules, for example,137a-137e,being run locally on a single computer system via the operating system and the processor132, 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 manufacturing system100disclosed 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 processor132for executing a workflow in the manufacturing system100. The computer program instructions implement the processes of various embodiments disclosed above and perform additional steps that may be required and contemplated for executing a workflow in the manufacturing system100. When the computer program instructions are executed by the processor132, the computer program instructions cause the processor132to perform the steps of the method for executing a workflow in the manufacturing system100as disclosed above. In an embodiment, a single piece of computer program code comprising computer program instructions performs one or more steps of the method disclosed above. The processor132retrieves these computer program instructions and executes them.

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 the manufacturing system100disclosed herein, connecting scalable manufacturing cells distributed on the gridded track structure to the two-dimensional (2D) gridded lower track layout of the ASRS structure101allows each manufacturing cell to have access to an abundance of workpieces and workpiece kits along with associated toolpieces, toolpiece kits, and workpiece supports. This allows each manufacturing cell to be configurable on-the-fly for a wide variety of manufacturing processes on-demand using the CCS software alone. The just-in-time delivery of the workpieces, the toolpieces, and the workpiece support by the RSRVs306to the manufacturing cells allows just-in-time manufacturing of subassemblies at any stage of the manufacturing process. The ability to store each subassembly in the ASRS structure101between manufacturing processes allows maximum flexibility since any manufacturing step can be completed as capacity becomes available.

Moreover, in the manufacturing system100disclosed herein, all components or componentry delivered to the manufacturing cells use a standardized storage unit footprint. The use of a standardized storage unit footprint in a single automation solution for all manufacturing workflows allows all goods and materials for all manufacturing processes to be densely stored and predictably managed by a single entity as a single collaborative system with any number of manufacturing processes. The manufacturing system100disclosed herein allows all manufacturing processes including receiving, kitting, building sub-assemblies and the final assembly, etc., to be completed by one automated material handling system that does not require conveyors or ground transport, with the manufacturing cells being software configurable as needed. The disclosed invention allows all manufacturing processes to be completed by one automated material handling system that does not require conveyors or ground transport, with manufacturing cells being software configurable as needed.

The manufacturing system100disclosed herein allows configuration of manufacturing operations on-demand and transportation of goods between all manufacturing cells, in any sequence, since the lower 2D grid interconnects all manufacturing cells. This allows any number of processes to be completed in any order and multiple times, if needed, for example, for reworking sub-assemblies to new specifications, etc. This, along with the ability to configure manufacturing cells with software commands, allows new manufacturing processes to be easily and flexibly added as factory manufacturing requirements change. As customer expectations are rapidly increasing towards customized products, manufacturers aim to differentiate themselves by focusing on customer experience. The manufacturing system100disclosed herein adapts to changing conditions and product types easily and flexibly without wait times and without lost production or manufacturing time.

Moreover, in the manufacturing system100disclosed herein, the same storage medium, that is, the ASRS structure101can be used by all interconnected processes at the kitting area102and all the manufacturing cells106to buffer any differences in process flow. This allows maximum flexibility to a manufacturer and minimizes the operational sensitivity to outside circumstances since material can be indefinitely stored. Furthermore, since all manufacturing cells106are interconnected and managed by the same fleet of RSRVs306, and also connected to the ASRS structure101that is navigated by the same fleet of RSRVs306, system logic is simplified with no need to physically transfer componentry from one service area to another service area. Consequently, inventory does not have to be received and identified, for example, using a bar code scan, a radio frequency identification (RFID) scan, etc., by each process to complete the logical transfer of custody between entities, that is, between the ASRS structure101, the kitting area102, and the manufacturing cells106of the manufacturing center105.

Furthermore, the manufacturing system100disclosed herein rectifies the problem of a relatively large footprint provided by conventional automated solutions by integrating vertical storage above the lower 2D grid used for inter-service area conveyance, which maximizes storage density and substantially reduces wasted vertical space. As a result, end-to-end manufacturing solutions are a fraction of the size of conventional solutions and require substantially less real estate to achieve the same deliverables. This allows manufacturers to consolidate storage within their existing facilities to expand their business.

The above disclosed embodiments of the manufacturing system100and method form a large shift in the way manufacturing is achieved and provide “virtual conveyor” and sortation capabilities of an automation system. The 2D gridded track structure of the technology allows the RSRVs306to convey goods between any manufacturing cell attached to the 2D gridded track structure. The movements of the RSRVs306on the 2D gridded track structure are orchestrated by the CCS131, which allows storage units to be presented just-in-time, grouped by work order, and even delivered in specific sequences to the manufacturing cells. Without this capability, solving complex processes with a single integrated automated solution would not be possible, since conventional ASRS equipment relies on downstream sortation solutions to deliver goods to service areas at the right time and sequence. Subsequently, the CCS131configures the manufacturing cells and conducts manufacturing operations with software commands. The manufacturing system100disclosed herein increases scalability of the total capacity, where the size of the manufacturing system100can be expanded modularly. The manufacturing system100disclosed herein provides flexibility in support of standardized manufacturing equipment and componentry delivered in a repeatable manner.

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.