Patent Description:
The invention generally relates to object processing systems, and relates in particular to robotic and other object processing systems for, e.g., sorting objects, for storing and retrieving objects, and for redistributing objects for a variety of purposes where the systems are intended to be used in dynamic environments requiring the systems to accommodate the processing of a variety of objects.

Current distribution center processing systems, for example, generally assume an inflexible sequence of operations whereby a disorganized stream of input objects is first singulated into a single stream of isolated objects presented one at a time to a scanner that identifies the object. An induction element (e.g., a conveyor, a tilt tray, or manually movable bins) transport the objects to the desired destination or further processing station, which may be a bin, a chute, a bag or a conveyor etc..

In certain sortation systems for example, human workers or automated systems typically retrieve parcels in an arrival order, and sort each parcel or object into a collection bin based on a set of given heuristics. For instance, all objects of like type might go to a collection bin, or all objects in a single customer order, or all objects destined for the same shipping destination, etc. The human workers or automated systems might be required to receive objects and to move each to their assigned collection bin. If the number of different types of input (received) objects is large, a large number of collection bins is required.

Such a system has inherent inefficiencies as well as inflexibilities since the desired goal is to match incoming objects to assigned collection bins. Such systems may require a large number of collection bins (and therefore a large amount of physical space, large capital costs, and large operating costs) in part, because sorting all objects to all destinations at once is not clearly straightforward or efficient.

In particular, when automating sortation of objects, there are a few main things to consider: <NUM>) the overall system throughput (parcels sorted per hour), <NUM>) the number of diverts (i.e., number of discrete locations to which an object can be routed), <NUM>) the total area of sortation system (square feet), and <NUM>) the annual costs to run the system (man-hours, electrical costs, cost of disposable components).

Current state-of-the-art sortation systems rely on human labor to some extent. Most solutions rely on a worker that is performing sortation, by scanning an object from an induction area (chute, table, etc.) and placing the object in a staging location, conveyor, or collection bin. When a bin is full or the controlling software system decides that it needs to be emptied, another worker empties the bin into a bag, box, or other container, and sends that container on to the next processing step. Such a system has limits on throughput (i.e., how fast can human workers sort to or empty bins in this fashion) and on number of diverts (i.e., for a given bin size, only so many bins may be arranged to be within efficient reach of human workers).

Other partially automated sortation systems involve the use of recirculating conveyors and tilt trays, where the tilt trays receive objects by human sortation, and each tilt tray moves past a scanner. Each object is then scanned and moved to a pre-defined location assigned to the object. The tray then tilts to drop the object into the location. Further partially automated systems, such as the bomb-bay style recirculating conveyor, involve having trays open doors on the bottom of each tray at the time that the tray is positioned over a predefined chute, and the object is then dropped from the tray into the chute. Again, the objects are scanned while in the tray, which assumes that any identifying code is visible to the scanner.

Such partially automated systems are lacking in key areas. As noted, these conveyors have discrete trays that can be loaded with an object; they then pass through scan tunnels that scan the object and associate it with the tray in which it is riding. When the tray passes the correct bin, a trigger mechanism causes the tray to dump the object into the bin. A drawback with such systems however, is that every divert requires an actuator, which increases the mechanical complexity and the cost per divert can be very high.

An alternative is to use human labor to increase the number of diverts, or collection bins, available in the system. This decreases system installation costs, but increases the operating costs. Multiple cells may then work in parallel, effectively multiplying throughput linearly while keeping the number of expensive automated diverts at a minimum. Such diverts do not identify a bin and cannot divert it to a particular spot, but rather they work with beam breaks or other sensors to seek to ensure that indiscriminate bunches of objects get appropriately diverted. The lower cost of such diverts coupled with the low number of diverts keep the overall system divert cost low.

Unfortunately, these systems don't address the limitations to total number of system bins. The system is simply diverting an equal share of the total objects to each parallel manual cell. Thus each parallel sortation cell must have all the same collection bins designations; otherwise an object might be delivered to a cell that does not have a bin to which that object is mapped.

Automated storage and retrieval systems (AS/RS), for example, generally include computer controlled systems for automatically storing (placing) and retrieving items from defined storage locations. Traditional AS/RS typically employ totes (or bins), which are the smallest unit of load for the system. In these systems, the totes are brought to people who pick individual items out of the totes. When a person has picked the required number of items out of the tote, the tote is then re-inducted back into the AS/RS.

In these systems, the totes are brought to a person, and the person may either remove an item from the tote or add an item to the tote. The tote is then returned to the storage location. Such systems, for example, may be used in libraries and warehouse storage facilities. The AS/RS involves no processing of the items in the tote, as a person processes the objects when the tote is brought to the person. This separation of jobs allows any automated transport system to do what it is good at - moving totes - and the person to do what the person is better at - picking items out of cluttered totes. It also means the person may stand in one place while the transport system brings the person totes, which increases the rate at which the person can pick goods.

There are limits however, on such conventional systems in terms of the time and resources required to move totes toward and then away from each person, as well as how quickly a person can process totes in this fashion in applications where each person may be required to process a large number of totes. There remains a need for a more efficient and more cost effective object sortation system that sorts objects of a variety of sizes and weights into appropriate collection bins or trays of fixed sizes, yet is efficient in handling objects of such varying sizes and weights.

<CIT> describes a system according to the preamble of claim <NUM> for picking items from a containerised storage system. The items are stored in storage bins in stacks within a framework comprising a grid system disposed above the stacks of bins. Robotic devices are disposed on the grid, the devices acting so as to pick containers from the stacks of bins. The storage system is provided with at least one picking device for picking items from bins and depositing them directly in delivery containers.

<CIT> discloses a robotic service device for use on a robotic picking system grid. The robotic service device is capable of driving to any location on the grid in order to perform maintenance operations or cleaning. Additionally, the service device may be used to rescue robotic load handling devices operational in the picking system. The robotic service device may comprise a releasable docking mechanism to enable it to dock and latch on to malfunctioning load handling devices. The service device may also be provided with cleaning means and camera means to enable the condition of the grid and other robotic devices to be monitored.

According to a first aspect, there is provided a maintenance system in accordance with the appended independent claim <NUM>. According to a second aspect, there is provided a method of providing maintenance in accordance with the appended independent claim <NUM>. Further optional features are provided in the appended dependent claims.

Described herein is a maintenance system for assisting in maintaining an automated carrier system for moving objects to be processed. The maintenance system includes a plurality of automated carriers that are adapted to move on an array of discontinuous standard track sections, each said automated carrier including a carrier body that is no larger in either a length or width direction that a standard track section, and an automated maintenance carrier that is adapted to move on the array of discontinuous track sections, said automated maintenance system including a maintenance body that is larger in at least one of a length or width direction than the standard track section.

Also described herein is a maintenance system for assisting in maintaining an automated carrier system for moving objects to be processed. The maintenance system includes an automated maintenance carrier that is adapted to move on an array of discontinuous track sections, said automated maintenance carrier including a maintenance body that is larger in at least one of a length or width direction than the standard track section, and includes maintenance hardware specially adapted to provide maintenance to the array of discontinuous track sections.

Additionally described herein is a method of providing maintenance of an automated carrier system for moving objects to be processed. The method includes the steps of providing a plurality of automated carriers that are adapted to move on an array of discontinuous standard track sections, each said automated carrier including a carrier body that is no larger in either a length or width direction that a standard track section and providing an automated maintenance carrier that is adapted to move on the array of discontinuous track sections, said automated maintenance carrier including a maintenance body that is larger in at least one of a length or width direction than the standard track section.

The disclosure generally relates in certain embodiments to object processing systems in which objects are carried in initial bins (or totes) in a preprocessed state and are carried in processed bins (or boxes) in a post processed state by a variety of carriers that are able to move about a common track system. In certain embodiments, the track system includes discontinuous tiles, and the carriers include two sets of wheels that are able to pivot (together with each wheel's motor) about <NUM> degrees to provide movement in two orthogonal directions and without rotating the carrier. As herein used, the term bin includes initial bins (including pre-processed objects), processed bins (including post-processed objects), empty bins, boxes, totes and/or even objects themselves that are large enough to be carried by one or more carriers.

<FIG> shows a system <NUM> that is formed of multiple track modules (one track module is shown in <FIG>), and each track module includes a plurality of tack sections <NUM>. The system also includes one or more mobile carrier units <NUM> that carry a bin <NUM> as shown in <FIG> and <FIG>, where the carrier unit <NUM> rides on the track sections <NUM>. Each track section <NUM> is generally in the form of a raised square with rounded edges, and the track segments <NUM> are generally closed spaced from each other (e.g., within a length or width of a mobile carrier unit <NUM>). With reference to <FIG>, each mobile carrier unit <NUM> may include support a bin <NUM> that may contain objects <NUM> to be processed or that have been processed. A computer processor <NUM> may control the movement of each carrier unit <NUM> by wireless communication, as well as all system operations as discussed further below. The track sections <NUM> may also include sensors (as discussed further below) for detecting when each carrier unit <NUM> is positioned about each individual track section <NUM>.

<FIG> shows a track module <NUM> that includes multiple track sections <NUM> on a frame <NUM> such that when multiple frames are joined together, the spacing of the adj acent track sections <NUM> is consistent throughout the larger array. Each module <NUM> includes two sides with protruding connection edges <NUM>, <NUM>, and two sides with (only one is shown) connection recesses <NUM> for receiving the connection edges of adjacent modules. One or the other to the protruding edges <NUM>, <NUM> and the recesses <NUM>, <NUM> may be magnetic to secure the connection between adjacent modules.

With reference to <FIG>, each mobile carrier unit <NUM> includes a pair of guide rails <NUM> that contain the bin <NUM>, as well as a raised region <NUM> that raises the bin sufficient for there to be room on either side of the raised region for shelf forks to engage the bin as will be further discussed below. Each carrier unit <NUM> also includes four wheel assemblies <NUM> that each include guides <NUM> for following the track sections. Each of the wheel assemblies is pivotally mounted such that each wheel assembly may pivot <NUM> degrees as generally shown at A in <FIG> and is further discussed below. Each carrier unit <NUM> also includes a pair of paddles <NUM> on either end of the unit <NUM>. Each paddle may be turned either upward to contain a bin on the unit <NUM>, or turned downward to permit a bin to be loaded onto or removed from the unit <NUM> as will also be discussed in more detail below.

In accordance with certain embodiments therefore, the invention provides a plurality of mobile carriers that may include swivel mounted wheels that rotate ninety degrees to cause each mobile carrier to move forward and backward, or to move side to side. When placed on a grid, such mobile carriers may be actuated to move to all points on the grid. <FIG>, for example, show a mobile carrier <NUM> that includes wheels <NUM>, <NUM>, <NUM> and <NUM> (shown in <FIG>). Each of the wheels is mounted on a motor <NUM>, <NUM>, <NUM>, <NUM> (as best shown in <FIG>), and the wheel and motor units are pivotally mounted to the carrier <NUM> as discussed in more detail below. The wheel assemblies (each including a wheel, its motor and guide rollers <NUM>) are shown in one position in <FIG>, and are shown in a second pivoted position in <FIG>. <FIG> shows an end view of the carrier <NUM> taken along lines 6A - 6A of <FIG>, and <FIG> shows an end view of the carrier <NUM> taken along lines 6B - 6B of <FIG>. Similarly, <FIG> shows a side view of the carrier <NUM> taken along lines 7A - 7A of <FIG>, and <FIG> shows a side view of the carrier <NUM> taken along lines 7B - 7B of <FIG>.

Each carrier <NUM> also includes a pair of opposing rails <NUM>, <NUM> for retaining a bin, as well as a raised center portion <NUM> and stands <NUM>, <NUM> on which a bin may rest. A pair of independently actuated paddles <NUM>, <NUM> are also provided. Each paddle <NUM>, <NUM> may be rotated upward (as shown at B in <FIG>) to retain a bin on the carrier, or may be rotated downward to permit a bin to be moved onto or off of a carrier. The paddles <NUM>, <NUM> are shown rotated downward in <FIG>.

Note that the orientation of the carrier <NUM> (also a bin on the carrier) does not change when the carrier changes direction. Again, a bin may be provided on the top side of the carrier, and may be contained by bin rails <NUM>, <NUM> on the sides, as well actuatable paddles <NUM>, <NUM>. As will be discussed in further detail below, each paddle <NUM>, <NUM> may be rotated <NUM> degrees to either urge a bin onto or off of a shelf, or (if both are actuated) to retain a bin on the carrier during transport. Each paddle may therefore be used in concert with movement of the carrier to control movement of the bin with respect to the carrier <NUM>. For example, when on paddle is flipped into an upward position, it may be used to urge the bin onto a shelf or rack while the carrier is moving toward the shelf or rack. Each carrier may also include one or more emergency stop switches <NUM> for a person to use to stop the movement of a carrier in an emergency, as well as handles <NUM> to enable a person to lift the carrier if needed. <FIG> shows a top view of the carrier <NUM>.

<FIG> shows a bottom view of the carrier <NUM> with the wheels in the position as shown in <FIG>, and <FIG> shows a bottom view of the carrier <NUM> with the wheels in the position as shown in <FIG>. <FIG> show all of the wheels <NUM>, <NUM>, <NUM> and <NUM>, and each of the motors <NUM>, <NUM>, <NUM> and <NUM> is also shown in <FIG>. As may be seen in <FIG>, the entire wheel assemblies including the wheel, guide rollers and the wheel motor, each pivot as a unit. With reference to <FIG>, each pair of wheel assemblies may, in an embodiment, be pivoted by a common pivot motor <NUM> that is coupled to the wheel assemblies via linkages <NUM>. In further embodiments, each wheel assembly may be pivoted by individual motors, or the pivoting wheel may be provided in a passive joint and pivoted by the driving actions of the individual wheel motors. <FIG> shows a pair of wheel assemblies in a position as shown in <FIG>, and <FIG> shows the pair of wheel assemblies in a position as shown in <FIG>. The wheel assemblies are designed to be able to pivot the wheels around corners of a track section when the carrier is directly above a track section. <FIG> show views similar to the underside views of <FIG> but with a track section <NUM> superimposed on the Figures to show the relation of the wheel positions to the track section. Note that the wheels pivot around each of the corners of the track section. When the carrier is centered over the track section, therefore, the wheels may be pivoted such that the carrier may move in a direction that is orthogonal to a prior direction without requiring that the carrier itself be turned. The orientation of the carrier is therefore maintained constant while the carrier is moved about an array of tracks sections.

The movement of the carrier <NUM> about an array of track sections is further discussed below with regard to <FIG>. In short as a carrier leaves one track section, it travels toward an adjacent track section, and if at all misaligned, will realign itself. The realignment of the guide rollers and the tracks may function as follows. While the two sets of wheels (<NUM>, <NUM> and <NUM>, <NUM>) may be designed to move the carrier <NUM> in a linear direction only, some variations may occur. The tracks <NUM> are positioned, though intermittently, close enough to each other than when a carrier leaves one track and moves toward another <NUM> (as shown at C), its potential variation off course will be small enough that the rounded corners of the next adjacent track will urge the carrier back on course. Each track section may be rectangular in shape (e.g., may be square). For example, <FIG> shows a carrier <NUM> leaving a track and beginning to approach a next track <NUM> as the carrier moves in a direction as indicated at C. As shown in <FIG>, if the alignment of the carrier <NUM> is off (possibly from variations in the wheels or the mounting of the wheels, the placement of the track sections or any other variable), one of the rounded corners <NUM> of next adjacent track <NUM> will become engaged by an on-coming guide roller <NUM>, and the rounded corner <NUM> will cause the carrier <NUM> to move slightly in a direction (as shown at D) perpendicular to the direction C to correct the direction of movement of the carrier <NUM>. If the misalignment is too far off, the carrier may reverse direction and try to become again aligned, or may stop moving and be rescued as discussed below in connection with <FIG>. If a carrier does stop moving, the directions of movement of the other carriers are programmed to avoid the area of the stopped carrier until it is removed. If an area results in a number of stopped carriers over time, the alignment of the track(s) in the area may be examined and/or replaced.

<FIG> shows the carrier <NUM> moving in a direction C as properly realigned by the track <NUM>. <FIG> shows a close up view of the wheel <NUM> moving in a direction as shown at E to cause the carrier to move in the direction C, and further shows that the guide rollers <NUM> roll against the track <NUM> in directions as shown at F. The guide rollers <NUM> do not touch the ground (as does the wheel <NUM>), but simply guide the direction of the carrier <NUM> by being urged against the track <NUM>. In further embodiments, biasing means such as springs, elastics or pneumatics may be used to urge the guide rollers against the track, and in further embodiments, the tracks may be more triangular shaped at the edges to further facilitate reception of the carriers. If too much correction is required, however, the system may be operating inefficiently.

Systems of the invention therefore provide for traversing the automated carrier in any one of four directions aligned with the track grid, allowing bidirectional column and row travel on the grid. One pivot motor may be used for each pair of wheels, with a linkage to pivot the wheel modules. In other embodiments, one pivot motor and linkage could be used for all four track sections. The system does not require differential drive line/trajectory following, and keeps the orientation of the carrier fixed throughout all operations.

<FIG> shows a top view of the carrier <NUM>, wherein each of the support surfaces <NUM>, <NUM>, <NUM> is shown, and <FIG> shows the carrier <NUM> with a bin <NUM> on the carrier <NUM> with one paddle <NUM> (shown in <FIG>) rotated upward to retain the bin <NUM> on the carrier <NUM> as the bin is removed from a shelf.

The tote shelf and retrieval mechanism provides that totes or boxes are carried by a carrier, which has a tote storage area which consists of a center rail, two side rails, and a motorized paddle on the front and back of the tote. Totes or boxes are carried by a robot, which has a tote storage area that consists of a center rail, two side rails, and a motorized paddle on the front and back of the tote. In accordance with further embodiments, other guide and retention mechanisms may be employed that accommodate variable sized totes or bins. When the tote is being driven around, both paddles are up and the tote is fully contained. To store a tote, the robot drives into a tote rack, which consists of two fork tine with an incline on the front, and the incline urges the tote above the rail height on the robot. The paddles are put down, and the robot can drive away with the tote left behind on the rack. To retrieve a tote, the robot drives under the shelf, puts its paddles up, and drives away.

<FIG> shows the carrier <NUM> with the paddle <NUM> up such that the bin <NUM> on the carrier <NUM> may be moved (as shown at G) onto a fixed rack <NUM> that includes two forks <NUM>, <NUM>. In particular, the forks <NUM>, <NUM> have ramped ends that engage the carrier <NUM> between the underside of the bin <NUM> and on either side of the raised center portion <NUM> as shown in <FIG>. To remove the bin <NUM> from the rack <NUM>, the carrier <NUM> is driven under the rack, and the opposite paddle <NUM> is actuated as shown in <FIG>. When the carrier is moved away from the rack (as shown at H), the paddle <NUM> urges the bin <NUM> onto the carrier <NUM> as the carrier is driven away from the rack.

<FIG>, for example, shows the carrier <NUM> with the paddle <NUM> activated such that as the carrier <NUM> is moved away from the rack <NUM>, the paddle <NUM> urges the bin <NUM> onto the carrier <NUM>. Again, <FIG> shows a side view of the carrier <NUM> with the paddle <NUM> engaged to urge the bin <NUM> onto the rack <NUM>, and <FIG> shows a side view of the carrier <NUM> with the paddle <NUM> engaged to urge the bin <NUM> off of the rack <NUM>.

As mentioned above, the track system may be formed of disconnected track sections <NUM>. In particular, <FIG> shows a portion of a track system <NUM> that includes a plurality of track sections <NUM>, as well as racks <NUM>, <NUM>, <NUM>. The guide rollers discussed above are positioned to roll against the outside of the tracks <NUM>, and since the carriers generally travel in straight lines (either forward - backward or side - to side), the guide rollers are designed to engage the intermittent tracks and realign themselves due to each track having slightly rounded corners. Each intermittent track also includes a location code <NUM> (e.g., a QR code) that permits the carrier to register its location with the central controller <NUM>. The carrier may include a detector <NUM> (such as a camera or a scanner) on the underside thereof as shown in <FIG> that reads or detects each location code <NUM>. Again, the orientation of each carrier does not change.

In the system <NUM> of <FIG>, numerous intermittent tracks <NUM> are shown, together with carriers <NUM>, <NUM>, <NUM>. In particular, carrier has left a bin <NUM> on rack <NUM> and has been given an instruction to move one track section to the North, carrier <NUM> carrying bin <NUM> has been given an instruction to move one track section to the West, and carrier <NUM> carrying bin <NUM> has been given an instruction to move one track section to the South. The system <NUM> moves each of the carriers in the tracks to avoid each other and to provide desired bins at appropriate shelves or racks. As noted, each carrier is provided an instruction to move only one or two track sections at a time. The system <NUM> is in constant communication with all of the carriers. In certain embodiments, the system provides a wireless heartbeat chain that provides bidirectional heartbeat between mobile carriers and fixed computing infrastructure. If a heartbeat isn't received by a mobile carrier, it triggers an emergency stop, and if a heartbeat isn't received by the processing system <NUM>, it triggers an appropriate response.

<FIG> shows a further embodiment of a rack unit <NUM> that includes a track section <NUM> as its base. The rack unit <NUM> also includes a pair of forks <NUM>, <NUM> for engaging and retaining bins. <FIG> shows a further embodiment <NUM> of a rack unit that includes four forks <NUM> that engage a different carrier <NUM> that includes three raised sections <NUM>, <NUM>, <NUM> in addition to the rail support surfaces <NUM>, <NUM>. Each of the wheel assemblies <NUM> may also be independently pivotable (not using pivot linkages) although the wheel assemblies are pivoted at effectively the same time (prior to movement) as discussed above. With reference to <FIG>, one or more of the track sections <NUM> may include a charging base <NUM>, having, for example, contact positive <NUM> and negative <NUM> charge plates that may mate with charging hardware on the underside of a carrier.

<FIG> show further embodiments of invention that are based on the above carriers and are provided for movement about a track system as discussed above. For example, <FIG> shows a carrier <NUM> in accordance with another embodiment of the present invention that includes swivel mounted wheel assemblies and is operable on a track system as discussed above, but also includes a conveyor <NUM> that is mounted on the carrier <NUM>, and is actuatable to move a bin or box on the carrier in either of opposing directions as indicated at I. When the carrier <NUM> is moved to be positioned adjacent a diverting device (such as a diverting chute or conveyor as shown at <NUM>), the carrier may actuate the conveyor <NUM> to move the bin onto the diverting conveyor <NUM>. The diverting conveyor <NUM> may for example, but not limiting, be a belt conveyor, a roller conveyor, a chain conveyor, a chute, another bin or a hopper. In certain embodiments, the load on the carrier <NUM> may be a bin that contains objects, or may be objects themselves.

<FIG> shows a carrier <NUM> in accordance with further embodiment of the present invention that includes swivel mounted wheel assemblies that run along track sections as discussed above, but also includes a tilt tray <NUM> that is mounted on the carrier base <NUM>, and is actuatable to move a bin in a direction as indicated at G. Similarly, when the carrier <NUM> is moved to be positioned adjacent a diverting device (such as a diverting conveyor as shown at <NUM>), the carrier may actuate the tilt tray <NUM> to move the bin onto the diverting conveyor <NUM>. The diverting conveyor <NUM> may for example, but not limiting, be a belt conveyor, a roller conveyor, a chain conveyor, a chute, another bin or a hopper. In certain embodiments, the load on the carrier <NUM> may be a bin that contains objects, or may be objects themselves.

<FIG> show a carrier <NUM> in accordance with further embodiment of the present invention that includes swivel mounted wheel assemblies that run along track sections as discussed above, and also includes a bomb bay drop mechanism <NUM> that is part of the carrier base <NUM>, and is actuatable to drop an object in a direction as indicated at H into a diverting device. When the carrier <NUM> is moved therefore, to be positioned over a diverting device <NUM>, again, such as a chute, bin, hopper, or conveyor (e.g., belt, roller chain etc.), the carrier may actuate the drop mechanism <NUM> to drop the object into the diverting device <NUM>.

During use, debris (e.g., dust, particulates from paper or cardboard or plastic packages) may fall onto the base floor on which the tracks (or tracks sections) <NUM> are laid. In accordance with a further embodiment, the system provides a vacuum carrier <NUM> that includes the swivel mounted wheel assemblies that run along track sections as discussed above, and also includes a vacuum assembly <NUM> as shown in <FIG>. The vacuum assembly is mounted on the carrier chassis, and is coupled to a grid of vacuum openings <NUM> on the underside <NUM> of the carrier <NUM> as shown in <FIG>. At appropriate times, such as at the end of processing session (e.g., at night), the vacuum carrier <NUM> may be engaged to run through the entire grid of tracks while vacuuming to collect any debris. Since the space between each of the tracks <NUM> is consistent (e.g., consistent in an X direction and consistent in a Y direction), the carrier may be formed not only as a single track section carrier, but may span multiple track sections. For example, the double carrier <NUM> shown in <FIG> and <FIG> includes two carrier bases <NUM>, <NUM>, each of which includes a set of four wheels that may be swiveled and run along track sections as described above. The distance between the carrier bases <NUM>, <NUM> is fixed as a bridge section <NUM> of the double carrier maintains a fixed distance between the carrier bases, and the size of the bridge is designed match the spacing distance between track sections. With further reference to <FIG>, when all of the wheels of the carrier <NUM> are pivoted together, the double carrier may be permitted to be moved along the track in both X or Y dimensions.

The use of such a larger (double) carrier permits further functionalities as follows. With reference to <FIG>, a retrieval system <NUM> may be provided on a double carrier <NUM> that includes an articulated arm <NUM> as well as a receiving bin <NUM>. Any dropped objects or debris may be picked up off of the track system and placed in the bin <NUM>. Additionally, cameras (e.g., <NUM> degree cameras) <NUM>, <NUM> may be provided that monitor the area around the double carrier <NUM> to identify objects that require moving to the receiving bin <NUM>. Again, each of the two carrier bases of the double carrier <NUM> includes a set of actuatable and pivotable wheels, permitting the double carrier to be moved along the track in both X and Y dimensions as discussed above.

A double carrier (or larger) may also be used to pick up a disabled (single) carrier as shown in <FIG>. As shown in <FIG>, such a system <NUM> may include a double carrier <NUM> that supports an articulated tow arm <NUM> having an end effector <NUM>, as well as a camera (e.g., a <NUM> degree camera) <NUM>. The system <NUM> also includes actuatable and pivotable wheels as discussed above, as well as a facilitation member <NUM>. In this way, the carrier <NUM> may move to all possible locations on the track grid as discussed above. As shown in <FIG>, the facilitation member <NUM> may be rotated down to provide a ramp onto the double carrier <NUM>, such that a disabled carrier <NUM> may be grasped by the end effector <NUM> (which may include an extendable section <NUM>), and drawn up the ramp formed by the facilitation member <NUM>. The extendable section <NUM> may be provided, for example, as a cross-sectionally arcuate member (such as in a metal tape measure) that is stiff when (naturally) curved in the cross direction, but may be wound upon itself when caused to be flat in the cross direction. The extendable section <NUM> may further include a central cable. As shown in <FIG>, once the disabled carrier <NUM> is successfully drawn onto the carrier <NUM>, the facilitation member <NUM> may be partially closed (to vertical) to keep the carrier <NUM> on the carrier <NUM>. In this way, the double carrier <NUM> may be used to retrieve disabled carriers.

As shown in <FIG>, a triple carrier <NUM> may be provided that includes three functional carrier bases <NUM>, <NUM>, <NUM>, that are joined by sections <NUM>, <NUM>. Each of the carrier bases includes a set of four wheels that may be pivoted and actuated to run along track sections as described above. All of the wheels of the carrier <NUM> are swiveled together, permitting the carrier <NUM> to be moved along the track in both X and Y directions. With reference to <FIG>, such a triple (or other multiple) carrier <NUM> may be provided with a bed <NUM>, head rest <NUM>, and rails <NUM> for transporting human repair personnel to any point in the track system that is known to be in need of assistance.

Further, and as shown in <FIG>, a quad carrier <NUM> may be provided that includes a general platform as well as four functional carrier bases <NUM>, <NUM>, <NUM> and <NUM> that are joined by sections of the large common platform. Each of the four functional carrier bases includes a set of four wheels that may be pivoted and actuated to run along track sections as described above. All of the wheels of the quad carrier <NUM> are pivoted together, permitting the carrier <NUM> to be moved along the track in both X and Y directions. Any of a wide variety of maintenance of repair systems or personnel may be provided on such a quad ( or greater number) carrier.

Systems and methods of various embodiments of the invention may be used in a wide variety of object processing systems such as sortation systems, automated storage and retrieval systems, and distribution and redistribution systems. For example, in accordance with further embodiments, the invention provides systems that are capable of automating the outbound process of a processing system. The system may include one or more automated picking stations <NUM> (as shown in <FIG>) and manual picking stations <NUM> (as shown in <FIG>) that are supplied with containers by a fleet of mobile carriers that traverse a smart flooring structure formed of track segments as discussed above. The carriers may carry bins that can store objects. The system may provide a novel goods-to-picker system that uses a fleet of small mobile carriers to carry individual inventory totes and outbound containers to and from picking stations.

In accordance with an embodiment of the system includes an automated picking station that picks eaches from inventory totes and loads them into outbound containers. The system involves together machine vision, task and motion planning, control, error detection and recovery, and artificial intelligence grounded in a sensor-enabled, hardware platform to enable a real-time and robust solution for singulating items out of cluttered containers.

With reference to <FIG>, the automated picking system <NUM> perceives the contents of the containers using a multi-modal perception unit and uses a robotic arm equipped with an automated programmable motion gripper and integrated software in processing system <NUM> to pick eaches from homogeneous inventory totes and place them into heterogeneous outbound containers. These elements are co-located in a work cell that meets industry standard safety requirements and interfaces with track system to keep the automated picking system fed with a continual supply of inventory totes and outbound containers.

In particular, the system <NUM> includes an array <NUM> of track elements <NUM> as discussed above, as well as automated carriers <NUM> that ride on the track elements <NUM> as discussed above. One or more overhead perception units <NUM> (e.g., cameras or scanners) acquire perception data regarding objects in bins or totes <NUM>, as well as perception data regarding locations of destination boxes <NUM>. A programmable motion device such as a robotic system <NUM> picks an object from the bin or tote <NUM>, and places it in the adjacent box <NUM>. One or both of the units <NUM>, <NUM> are then moved automatically back into the grid, and one or two new such units are moved into position adjacent the robotic system. Meanwhile, the robotic system is employed to process another pair of adjacent units (again, a bin or tote <NUM> and a box <NUM>) on the other side of the robotic system <NUM>. The robotic system therefore processes a pair of processing units on one side, then switches sides while the first side is being replenished. This way, the system <NUM> need not wait for a new pair of object processing units to be presented to the robotic system. The array <NUM> of track elements <NUM> may also include shelf stations <NUM> at which mobile units <NUM> may park or pick up either bins / totes <NUM> and boxes <NUM>. The system operates under the control, for example, of a computer processor <NUM>.

The manual pick station system is a goods-to-person pick station supplied by mobile automated movement carriers on track systems as discussed above. The system has the same form and function as the automated picking station in that both are supplied by the same carriers, both are connected to the same track system grid, and both transfer eaches from an inventory tote to an outbound container. The manual system <NUM> (as shown in <FIG>) relies on a manual team member to perform the picking operation.

Also, the manual system raises carriers to an ergonomic height (e.g. via ramps), ensures safe access to containers on the carriers, and includes an monitor interface (HMI) to direct the team member's activities. The identity of the SKU and the quantity of items to pick are displayed on an HMI. The team member must scan each unit's UPC to verify the pick is complete using a presentation scanner or handheld barcode scanner. Once all picks between a pair of containers are complete, the team member presses a button to mark completion.

In accordance with this embodiment (and/or in conjunction with a system that includes an AutoPick system as discussed above), a system <NUM> of <FIG> may include an array <NUM> of track elements <NUM> that are provided on planer surfaces <NUM> as well as inclined surfaces <NUM> leading to further planar surfaces. The system <NUM> may also include visual data screens that provide visual data to a human sorter, informing the human sorter of what goods are to be moved from totes or bins <NUM> to destination boxes <NUM>. The system operates under the control, for example, of a computer processor <NUM>.

While the bulk of the overall system's picking throughput is expected to be handled by automated picking systems, manual picking systems provide the carrier and track system the ability to (a) rapidly scale to meet an unplanned increase in demand; (b) handle goods that are not yet amenable to automation; and (c) serve as a QA, problem solving, or inventory consolidation station within the overall distribution system. The system therefore, provides significant scaling and trouble-shooting capabilities in that a human sorted may be easily added to an otherwise fully automated system. As soon as a manual picking system is enabled (occupied by a sorter), the system will begin to send totes or bins <NUM> and boxes <NUM> to the manual picking station. Automated picking stations and manual picking stations are designed to occupy the same footprint, so a manual picking station may later be replaced with an automated picking station with minimal modifications to the rest of the system.

Again, a carrier is a small mobile robot that can interchangeably carry an inventory tote, outbound container, or a vendor case pack. These carriers can remove or replace a container from or onto a storage fixture using a simple linkage mechanism. Since a carrier only carries one container at a time, it can be smaller, lighter, and draw less power than a larger robot, while being much faster. Since the carriers drive on a smart tile flooring, they have lessened sensing, computation, and precision requirements than mobile robots operating on bare floor. These features improve cost to performance metrics.

Unlike shuttle- or crane-based goods-to-picker systems where the mobile component of the system is constrained to a single aisle, all carriers run on the same shared roadway of track sections as independent container-delivery agents. The carriers can move forward, backward, left or right to drive around each other and reach any location in the system. This flexibility allows the carriers to serve multiple roles in the system by transporting (a) inventory totes to picking stations, (b) outbound containers to picking stations, (c) inventory totes to and from bulk storage, (d) full outbound containers to discharge lanes, and (e) empty outbound containers into the system. Additionally, the carriers may be added incrementally as needed to scale with facility growth.

The track floor modules are standard-sized, modular, and connectable floor sections. These tiles provide navigation and a standard driving surface for the carriers and may act as a storage area for containers. The modules are connected to robotic pick cells, induction stations from bulk storage, and discharge stations near loading docks. The modules eliminate the need of other forms of automation, e.g. conveyors, for the transportation of containers within the system.

<FIG> shows a carrier <NUM> in accordance with any of the above disclosed embodiments, wherein the bin is a cardboard box <NUM> for use in any shipping processes (e.g., shipping by truck), and may be particularly designed for use by a particular site (e.g., customer) to whom the processed objects are to be sent. For example, and with reference to <FIG>, such a box <NUM> may include features (such as a window or opening <NUM>) through which goods may be viewed. Further, and with reference to <FIG>, in further embodiments, where boxes <NUM> to be used are non-standard, an adapter tray <NUM> may be used to accommodate fitting the non-standard box <NUM> to a carrier <NUM>.

With reference to <FIG>, an in-feed system allows containers to be inducted into and discharged from the track system. On the inbound side of the system, the in-feed system inducts inventory totes (IVCs) and processing containers (VCPs) from bulk storage and discharges depleted inventory totes back into bulk storage when they are no longer needed. On the outbound side of the system, system inducts empty containers (OBCs) and discharge sequenced containers (OBCs and VCPs) to be built into carts. The in-feed system may also serve as a problem solving station, or inventory consolidation station for containers that must be processed outside the overall system.

Conceptually, an in-feed station is a special module that transfers containers between the track system and a buffer conveyor via a transfer mechanism. A team member inducts a container into the system by placing the container on the buffer conveyor located at an ergonomic height. The buffer conveyor conveys the container to a transfer mechanism, which transfers it onto a carrier. This assumes that the buffer conveyor is a <NUM>' zero pressure accumulation MDR conveyor. This conveyor may be extended.

<FIG> shows an in-feed system <NUM> that includes a gravity conveyor <NUM> that feeds totes <NUM> to a shelf <NUM>, from which a mobile robot <NUM> as discussed above, may acquire each tote in serial fashion for movement about a track module <NUM> having track sections <NUM> as also discussed above. The totes may be loaded by a human that places totes of objects onto the conveyor as shown at <NUM>. The system operates under the control, for example, of a computer processor <NUM>.

Discharging a container proceeds in reverse: the transfer mechanism transfers the container from the carrier to the buffer conveyor, where a team member may remove it from the system. If a height change is needed, an inclined belt conveyor can be used to bridge the height difference.

In accordance with an embodiment the in-feed station's transfer mechanisms may be provided by a serial transfer mechanism that uses a linear actuator to place containers onto and remove containers from an actuated shelf that can be accessed by carriers. The linear actuator can run in parallel with the carrier's motion under the shelf in order to reduce cycle time. In further embodiments, the in-feed may be partially or fully automated using gravity fed conveyors and/or further programmable motion control systems.

The system may provide a serial transfer system in which mobile carriers on a track grid carry totes onto extendable shelves similar to those discussed above, except that the latch mechanism on the shelf may extend out toward a tote to retrieve a tote. The extendable shelves are in communication with ramps, which lead to raised conveyor stations. The system operates under the control, for example, of a computer processor.

To accept an inducted container, a carrier drives into a designated module. While the carrier is entering the module, the actuator extends a loaded container on top of the carrier. The carrier engages its storage latch, the transfer mechanism disengages its latch, and the actuator retracts. Once retracted, the carrier perpendicularly exits the module and the next queued carrier repeats this process.

To discharge a carried container, a carrier drives into the mechanism's module while the actuator extends an empty shelf. The transfer mechanism engages a storage latch, the carrier disengages its storage latch, and the transfer mechanism retracts. Once retracted, the carrier perpendicularly exits the module as described above while the container is removed from the system by the buffer conveyor.

In accordance with further embodiments the system may include a continuous transfer mechanism, which is a design concept that uses a series of conveyors to match the speed of a container to a carrier, in order to induct and discharge the container while both are in motion.

To induct a container, the carrier engages its storage latch and drives under the transfer mechanism at constant speed. The belted conveyor accelerates the container and hands it off to a set of strip belt conveyors that match the speed of the carrier. The carrier receives the container and secures it using its own storage latches.

To discharge a container, the carrier disengages its storage latch and drives under the transfer mechanism at a constant speed. The container is handed off to a set of strip belt conveyors that match the speed of the carrier and carry the container up a short incline to a belted conveyor. The belted conveyor reduces the speed of the container, if necessary, and transfers it to the buffer conveyor.

Such a transfer system may include mobile carriers on track sections that run underneath an elevated conveyor. The transfer system may include a belted conveyor (for speed matching), that passes totes to a pair of strip belt conveyors that urge a tote onto a carrier. The system operates under the control, for example, of a computer processor.

The system, therefore, accepts inventory from a bulk storage solution as input and produces sequenced containers, amenable to being constructed into carts, as output. The desired output of the system is specified as a collection of picking and sequencing orders that are grouped into waves.

A picking order is a request to transfer a specified quantity of a SKU from an inventory tote into an outbound container. An outbound container may contain SKUs from many different picking orders that are destined for similar locations in a store and have mutually compatible transportation requirements. For example, a picking order may request two packs of Body Washes, one pack of Dove Soap, and <NUM> other items to be placed into an outbound container intended to replenish the soap aisle in a particular store.

A sequencing order is a request to sequentially deliver a group of containers to an in-feed station to be assembled into a cart. A cart is assembled from a mixture of VCPs (for SKUs that are replenished in full-case quantity) and outbound containers (filled by picking orders) that are used to replenish nearby sort points within a store. For example, a sequencing order may request two other outbound containers, and five VCPs to be loaded onto a cart destined for the health & beauty department of a particular store.

All orders that are required to fill a trailer form a wave that must be completed by that trailer's cut time. Each wave begins inducting the necessary inventory containers and VCPs from bulk storage into modules. Those containers remain on modules until the wave is complete, at which point they are either (i) sequenced into carts, (ii) returned to bulk storage, or (iii) retained for use in a future wave. Multiple waves are processed concurrently and seamlessly: one wave may be inducting inventory while two waves are processing picking orders and a forth wave is being sequenced.

The operation for inducting inventory into the system, fulfilling picking orders, and sequencing output, may further include the following. Inventory is inducted into the system at in-feed stations bordering the external bulk storage solution. Items intended to go through the each-based process must be decanted and de-trashed into inventory containers that contain homogeneous eaches before being loaded into the system. VCPs intended to pass through the system must be either compatible with carrier transport or placed in a compatible container, e.g. a tray.

Each in-feed station is manned by a team member who accepts containers from the bulk storage solution and transfers them onto a short length of conveyor external to the system. Carriers dock with the station, accept one container each, and depart to store their container in the track grid. The container is scanned during induction to determine its identity, which is used to identify its contents and track its location within the module system.

Once all picking orders that require an inventory container are complete---and no upcoming waves are projected to require it---the container is discharged from the system by completing the induction process in reverse. A carrier docks with the station, deposits its container, and a team member returns the containers to bulk storage.

This same induction process is used to induct empty outbound containers into the system using the in-feed station located near the trailer docks. Just as with inventory containers, empty outbound containers are inducted into the system throughout the day only as they are needed to process active waves. Inventory containers, VCPs, and outbound containers are largely interchangeable: the same carriers, in-feed stations, and track modules are used to handle all three types of containers.

Picking orders are processed by automated picking stations and manual picking stations. Each picking order is completed by requesting two carries to meet at a pick station: one carrying an inventory container of the requested SKU and the second carrying the desired outbound container. Once both carriers arrive the picking station transfers the requested quantity of eaches from the inventory container to the outbound container. At this point, the carriers may carry the containers back into storage or to their next destination.

The system scheduling software optimizes the assignment of storage locations sequence of orders, scheduling of arrival times, and queuing of carriers to keep pick stations fully utilized, and to optimize scheduling and usage of the grid to as to avoid traffic jams and collisions. Orders that are not amenable to automated handling are assigned to manual picking station. Inventory and outbound containers are stored near the picking stations that are assigned process those orders. When possible, multiple orders that require the same container are collated to minimize the storage and retrieval operations.

Once all containers required to build a cart are available, i.e. the requisite VCPs have been inducted and picking orders are completed, those containers are eligible to be sequenced. Containers are sequenced by requesting carriers to transport containers from their current location to an in-feed station that borders the trailer docks. All containers for the cart are delivered to the same in-feed as a group, i.e. all containers assigned to one cart are discharged before any containers for a different cart.

Team members at the in-feed station accept the containers delivered by carriers, assemble carts, and load completed carts onto the appropriate trailers. The carriers and personnel may interact with an in-feed station as discussed above.

In accordance with a further embodiment, the invention provides a feed station <NUM> as shown in <FIG> that may feed containers to and from a track system. The feed station <NUM> includes a support frame <NUM> that supports at least one conveyors for ferrying containers to and from a track. In particular, the embodiment of <FIG> includes two pairs of conveyors <NUM>, <NUM> that are bi-directionally driven by a motor <NUM>. The frame <NUM> provides enough clearance on the underside thereof from front to back, that a mobile carrier <NUM> may travel underneath the frame <NUM> as shown in <FIG>.

For example, <FIG> show a tote <NUM> traveling along a conveyor <NUM> above a track system that includes track sections <NUM> as discussed above. As the tote <NUM> is moving, a mobile carrier <NUM> moves underneath the conveyor <NUM> and matches the speed of movement of the tote <NUM> on the conveyor <NUM> in an inbound direction. As the tote (and the mobile carrier <NUM>) approach the feed station <NUM>, the motor <NUM> causes the strip belts <NUM>, <NUM> to move in the direction of movement of the conveyor <NUM> and to match the speed of the conveyor <NUM> (<FIG>). Paddles <NUM> on the mobile carrier <NUM> are flipped up and the mobile carrier <NUM> moves under the tote <NUM> as it descends along the driven belts <NUM>, <NUM> at the same speed as the mobile carrier <NUM> (<FIG>). The tote <NUM> engages the mobile carrier <NUM> (<FIG>), and is then fully transferred to the mobile carrier <NUM> (<FIG>). As shown in <FIG>, another tote <NUM> may then be provided on the conveyor <NUM>, and another mobile carrier <NUM> may be driven to similarly engage the tote <NUM> as discussed above. The track section <NUM> underneath the feed station <NUM> may be provided as an extended (e.g., double) track section to assist in maintaining alignment of the mobile carrier <NUM> on the track system during transfer of a tote.

With reference to <FIG>, a tote <NUM> may be transferred from a mobile carrier <NUM> at the feed station <NUM> by providing that the motor <NUM> drives the strip belts <NUM>, <NUM> at the same speed as that of the mobile carrier <NUM>. With its rear paddle <NUM> engaged, the tote <NUM> on the mobile carrier <NUM> engages the belts <NUM> (<FIG>). The tote <NUM> is carried upward by the belts <NUM>, <NUM> (<FIG>), and is provided to the conveyor <NUM> which carries the tote in an outbound direction (<FIG>).

<FIG> shows a carrier <NUM> in accordance with a further embodiment of the present invention. The carrier <NUM> includes support surfaces <NUM> on which a bin may be supported, as well as actuatable centering plates <NUM>, <NUM> that may be actuated to move toward (and away from) a center of the carrier <NUM> to secure a tote on the support surfaces <NUM>. The carrier <NUM> may also include bar paddles <NUM>, <NUM> on either end of the carrier <NUM> that may be used similar to paddles <NUM>, <NUM> as discussed above to urge a tote onto or off of the carrier <NUM>. The carrier <NUM> may further include emergency stop buttons <NUM> that may be actuated by human personnel during use. Once a carrier has been stopped, the computer system will know to route other carriers around the stopped carrier.

<FIG> show the carrier <NUM> without wheel coverings <NUM>. As shown, the carrier <NUM> includes guide rollers <NUM> similar to the guide rollers <NUM> of the carrier <NUM> discussed above that are able to ride along a discontinuous track system. The carrier <NUM> further includes a set of wheels <NUM>, <NUM>, <NUM> and <NUM> (each of which is shown in Figures 51A and 51B). The wheels may each be actuated by motors (e.g., wheel <NUM> is actuated by motor <NUM>, and wheel <NUM> is actuated by motor <NUM>) via gear systems <NUM> (as shown further in <FIG>).

As further shown in <FIG>, the bar paddles <NUM>, <NUM> may be independently actuatable to be raised, and subsequently moved toward or away from each other. In particular, <FIG> shows bar paddle <NUM> raised, and <FIG> shows bar paddle 44C also raised. The bar paddles may be actuated by a linear actuator ( e.g., a threaded actuator, a pneumatic actuator or an electromagnetic actuator) with a linear cam to raise the bar paddles, and the centering plates may also be actuated by a linear actuator (e.g., a threaded actuator, a pneumatic actuator or an electromagnetic actuator). <FIG> shows the centering plates <NUM>, <NUM> being actuated to embrace a bin (or tote), and <FIG> shows the raised bar paddles <NUM>, <NUM> being brought toward each other to also embrace a bin (or tote).

<FIG> show the carrier <NUM> with a bin <NUM> on the carrier. <FIG> shows the wheels <NUM>, <NUM>, <NUM>, <NUM> in a first position, aligned in a direction of the bar paddles <NUM>, <NUM>, and <FIG> shows the wheels <NUM>, <NUM>, <NUM>, <NUM> pivoted to a second position, aligned in a direction of the centering plates <NUM>, <NUM>. <FIG> shows a lower side view of the carrier as shown in <FIG>, and <FIG> shows a lower side view of the carrier as shown in <FIG>.

As may be seen in <FIG> (and with further reference to <FIG>), each wheel (e.g., <NUM>) may be part of a wheel assembly <NUM> that includes a wheel motor (e.g., <NUM>), a limited rotation gear <NUM>, and a pivot motor <NUM> that reciprocally drives the limited rotation gear <NUM> via one or more drive gears <NUM>. <FIG> shows the wheel <NUM> in a first position, and <FIG> shows the wheel <NUM> in a second pivoted position. Although each pivot assembly may be individually actuated, in this embodiment, the wheels are pivoted at the same time. <FIG> show the underside of the carrier <NUM> (with the wheel cover <NUM> on the carrier). <FIG> shows the wheels <NUM>, <NUM>, <NUM>, <NUM> in a first position, and <FIG> shows the wheels <NUM>, <NUM>, <NUM>, <NUM> in a second pivoted position.

<FIG> show a bin <NUM> traveling along a conveyor <NUM> above a track system that includes track sections <NUM> as discussed above. As the bin <NUM> is moving, a mobile carrier <NUM> moves underneath the conveyor <NUM> and matches the speed of movement of the bin <NUM> on the conveyor <NUM> in an inbound direction. As the bin (and the mobile carrier <NUM>) approach the feed station <NUM>, the motor <NUM> causes the strip belts <NUM>, <NUM> to move in the direction of movement of the conveyor <NUM> and to match the speed of the conveyor <NUM> (<FIG>). Paddle <NUM> on the mobile carrier <NUM> is flipped up and the mobile carrier <NUM> moves under the bin <NUM> as it descends along the driven belts <NUM>, <NUM> at the same speed as the mobile carrier <NUM> (<FIG>). The bin <NUM> engages the mobile carrier <NUM> (<FIG>), and is then fully transferred to the mobile carrier <NUM>. The track section <NUM> underneath the feed station <NUM> may be provided as an extended (e.g., double) track section to assist in maintaining alignment of the mobile carrier <NUM> on the track system during transfer of a bin.

With reference to <FIG>, a bin <NUM> may be transferred from a mobile carrier <NUM> at the feed station <NUM> by providing that the motor <NUM> drives the strip belts <NUM>, <NUM> at the same speed as that of the mobile carrier <NUM>. With its rear paddle <NUM> engaged, the bin <NUM> on the mobile carrier <NUM> engages the belts <NUM> (<FIG>). The bin <NUM> is carried upward by the belts <NUM>, <NUM> (<FIG>), and is provided to the conveyor <NUM> which carries the bin in an outbound direction (<FIG>). As shown in <FIG> and <FIG>, when the bin is received on the carrier <NUM>, the centering plates <NUM>, <NUM> engage the carrier <NUM>, and as shown in <FIG> and <FIG>, when the bin is to be released to the conveyor <NUM>, the centering plates are withdrawn, permitting the bin to be lifted off of the carrier by the belts <NUM>, <NUM>. Control of the system may be provided (e.g., wirelessly) by one or more computer processing systems <NUM>.

Each of the carriers, tracks, racks, infeed and outfeed system of the above disclosed embodiments may be used with each of the disclosed embodiments and further system in accordance with the invention.

<FIG> shows a system <NUM> in accordance with an embodiment of the present invention that includes a large connected array <NUM> of track members as well as automated mobile carriers for transporting totes about the array. The system also includes both automated processing stations <NUM> and manual processing stations, as well as at least one in-feed station <NUM>, at least one empty outbound vessel in-feed station <NUM> and outbound stations <NUM>. In general, the processing begins with having a team member retrieve inventory totes and VCPs from bulk storage. The inventory totes and VCPs are then loaded onto an in-feed station, and team members build empty outbound vessels and load then onto the in-feed as well. The automated mobile carriers move requested outbound vessels to and from storage, and objects are processed from inventory totes at both automated stations <NUM> and manual stations <NUM>. The carriers then take the VCPs straight to staging for trailer loading, and team members load completed carts onto trailers. The system operates under the control, for example, of a computer processor <NUM>.

As shown at <NUM> in <FIG>, the system may be scaled up to include a much larger array of track modules <NUM>, and many processing stations <NUM> that may, for example, be any of inventory in-feed stations, empty outbound vessel in-feed stations, automated and manual processing stations, and outbound stations as discussed above. The system operates under the control, for example, of a computer processor <NUM>.

In addition to the nominal modes of operation, the systems of the invention are designed with consideration for the following exceptions. Picking orders that contain SKUs that are not amenable to automated handling, e.g. violate the weight and dimension criteria, are routed to manual picks for manual processing. Inside the manual picks station, a team member transfers the desired number of eaches from an inventory container to an outbound container. Any VCPs that are incompatible with carrier transport, e.g. violate the weight and dimension criteria, bypass the track system. Team members are responsible for routing these containers to the appropriate trailers. The track system internally verifies the identity of containers at several points during induction, transportation, and discharge. A container that is detected to be out of place, unexpectedly empty, or prematurely full is automatically flagged as an exception. When such an exception occurs, the work management system is notified of the fault and the container can be routed to an in-feed station for special processing.

Maintenance of static system components can occur while the system is online-without impeding operation-by assigning orders to other stations. This is true for both the manual and the automated processing stations. A carrier can be serviced without impacting system operation by commanding it to move to a track module at the periphery of the system, where it is accessible to maintenance personnel. If a carrier encounters a fault that renders it inoperable, the system maintains degraded operation by routing other carriers around the disabled carrier until maintenance personnel extract the carrier for service.

The interactions between team members and the track module system includes four primary tasks: (<NUM>) picking an each in a manual picking station, (<NUM>) inducting an IVC or VCP from bulk storage through an in-feed station, (<NUM>) inducting an empty OBC through an in-feed station, (<NUM>) discharging a depleted IVC through an in-feed station, and (<NUM>) discharging sequenced OBCs and VCPs to be built into a cart.

Again, manual picking is done by a team member inside a manual picking station, through the following steps. Carriers arrives at the manual picking station: one carrying and IVC and one carrying an OBC. The containers' identities are scanned and verified. A display informs the team member the identity and quantity of eaches they should transfer. The team member picks one each out of the IVC. The team member scans the each using a presentation scanner located between the IVC and OBC. If the each fails to scan, the team member scans the each using a backup handheld scanner. The team member places the each into the OBC. The team member repeats steps the last two steps until the desired number of eaches have been transferred. The team member presses a button to indicate that the picks from the IVC are complete. The carriers depart and the process repeats. In nominal operation, multiple carriers queue at each manual picking station to minimize the team member's downtime. Multiple pairs of carriers may be accessible to the team member at once to further reduce downtime while interchanging containers.

Containers that are amenable to automated scanning, e.g., IVCs and OBCs, are inducted by a team member at an in-feed station through the following steps. A container arrives at an in-feed station. A team member places the container on the in-feed's conveyor. The container is conveyed past an automated scanner which identifies the container's identity. The container is advanced onto the transfer mechanism. An empty carrier arrives at the in-feed station. The carrier accepts the container from the transfer mechanism. The carrier departs and the process repeats. In nominal operation, multiple carriers queue at each in-feed station to maximize container throughput. Multiple team members may simultaneously service the same conveyor if necessary to match the in-feed's throughput.

Automated scanning is expected to be used for IVC and OBC induction. VCP induction is expected to require a manual scanning step by the team member, since vendor labels are may not consistently located on VCPs.

Containers that require manual scanning, e.g., VCPs with vendor labels, are inducted by a team member at an in-feed station through the following steps. A container arrives at an in-feed station. A team member scans the container with a presentation scanner. If the container fails to scan, the team member scans the container using a backup handheld scanner. The team member places the container on the in-feed conveyor. The container is advanced onto the transfer mechanism. An empty carrier arrives at the in-feed station. The carrier accepts the container from the transfer mechanism. The carrier departs and the process repeats. If all containers are labeled in a way that is amenable to automated scanning, e.g. if additional labels are applied to VCPs, then all containers can be inducted through the automated procedure described above. Presentation and handheld scanners are only necessary at in-feeds that are expected to be used for VCP induction.

Containers that are discharged from the system and accepted by a team member through the following steps. A carrier carrying a container arrives at an in-feed station. The transfer mechanism extracts the container from the carrier. The transfer mechanism transfers the container to a conveyor. The container is conveyed to a team member at the end of the conveyor. The team member removes the container from the conveyor. The team member scans the container using a facility-provided HMI as part of their normal workflow (e.g., assembling a cart or returning an IVC to circulation). The track module system is notified of the scan by the work management system to confirm the successful discharge.

If the team member is building a cart out of VCPs and OBCs, the facility-provided HMI will direct the team member to place the container in the correct location on the appropriate cart. The order in which containers must be discharged is encoded in the sequencing orders submitted by the work management system.

Problem solving, resolutions of issues, and inventory consolidation occur at designated manual picking stations and in-feed stations by specially-trained team members. Manual picking stations are used for operations that require access to the contents of containers inside the system, e.g., verifying the content of a container in the system. In-feed stations are used for operations that require access to containers outside the system, removing a container from the system, or inducting a new container into the system; e.g. replacing a damaged container barcode.

The concept of operations for manual picking stations and In-feed stations dedicated to these roles is identical to their nominal operation, except that more options may be available on the station's HMI. The facility may choose to provide additional hardware (e.g. label printers) for the operators of these stations as needed for their processes.

Control of each of the systems discussed above may be provided by the computer system <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> and <NUM> that is in communication with the programmable motion devices, the carriers, and the track modules. The computer systems also contain the knowledge (continuously updated) of the location and identity of each of the storage bins, and contains the knowledge (also continuously updated) of the location and identity of each of the destination bins. The system therefore, directs the movement of the storage bins and the destination bins, and retrieves objects from the storage bins, and distributes the objects to the destination bins in accordance with an overall manifest that dictates which objects must be provided in which destination boxes for shipment, for example, to distribution or retail locations.

In the systems of the present invention, throughput and storage may scale independently, and all inventory SKUs may reach all outbound containers. The systems are robust to failures due to redundancy, and inventory totes (storage bins) and outbound boxes (destination bins) may be handled interchangeably.

Claim 1:
A maintenance system for assisting in maintaining an automated carrier system for moving objects to be processed, said maintenance system comprising:
a plurality of automated carriers (<NUM>) that are adapted to move on an array of discontinuous standard track sections (<NUM>), each said automated carrier (<NUM>) including a carrier body that is no larger in either a length or width direction that a standard track section; and
an automated maintenance carrier (<NUM>) that is adapted to move on the array of discontinuous standard track sections, said automated maintenance carrier (<NUM>) including a maintenance body that is larger in at least one of a length or width direction than the standard track section,
wherein each said automated carrier includes four wheels (<NUM>, <NUM>, <NUM>, <NUM>),
characterized in that each of the wheels (<NUM>, <NUM>, <NUM>, <NUM>) of each said automated carrier (<NUM>) is pivotable between a first position and a second position by a linkage mechanism (<NUM>) that is rotated to move the wheels at the same time, and
wherein said automated maintenance carrier (<NUM>) includes at least two sets of four pivotable wheels.