Patent ID: 12258223

The drawings are for illustrative purposed only.

DETAILED DESCRIPTION

In accordance with an embodiment, the invention provides a storage, retrieval and processing system for processing objects that includes a storage bin system, a retrieval system, a programmable motion device, and a destination bin system. The storage bin system is for receiving at a first end thereof, a plurality of storage bins providing storage of a plurality of objects. The retrieval conveyance system is at a second end of the storage bin system that is generally opposite the first end of the storage bin system, and the retrieval conveyance system is in communication with the plurality of storage bins. The programmable motion device is in communication with the retrieval conveyance system for receiving the storage bins from the plurality of storage bins, and the programmable motion device includes an end effector for grasping and moving a selected object out of a selected storage bin. The destination bin system is for receiving the selected object from the end effector of the programmable motion device at first end of the destination bin system, and the destination bin system provides access to the plurality of destination bins at a second end thereof that is generally opposite the first end of the destination bin system.

In an embodiment, the invention provides a system by which vehicles such as trucks, may back up to a bin unloading system, unload the bins into a storage section, process the bins using the automated storage, retrieval and processing system of the invention, and load processed bins automatically into vehicles such as trucks for transport. With reference toFIG.1, an automated storage, retrieval and processing system10in accordance with an embodiment of the present invention includes a storage system12at which a plurality of storage bins14are provided from a vehicle (as discussed further below), a processing system16that includes a programmable motion device18, and a destination system20that includes destination bins22that may be loaded onto a vehicle (as discussed further below). Generally, storage bins14are unloaded from vehicles, and are selectively provided to and from the processing system16, where objects are moved from a selected storage bin and placed or dropped by the programmable motion device18into a primary carriage system24(that moves vertically and horizontally as discussed further below). From the primary carriage system24, objects are delivered to one of a plurality of secondary carriage systems (that run horizontally along the length of the destination system20), which bring objects to destination bins22of the destination system20, and from where the destination bins may be loaded onto vehicles.

In particular, and with reference toFIG.2, the storage system12includes a plurality of storage sections24, each of which includes a plurality of storage bins14on a pair of infeed conveyors26. Each infeed conveyor26is biased (e.g., by gravity) to cause each of the storage bins14to be urged away from an input end28and toward a processing end30of the storage section24as shown inFIG.3. Further, each of the storage bins14includes unique identification indicia (e.g., a barcode) that is detected by storage perception devices34as the bins are delivered onto the infeed conveyors26. The storage system12knows the size of each storage bin14, and therefore knows where each bin is located as well as the identity (and therefore the contents) of each storage bin.

Each storage section also includes a pair of retrieval conveyors36that are provided adjacent to the storage bins, and as further shown with reference toFIGS.4A and4B, when a storage bin14is selected for retrieval, a bin removal mechanism39travels along a guide rail38between the bins14, and stops adjacent to the selected storage bin as shown inFIG.4A. With reference toFIG.4B, the system will then move an urging mechanism40of the mechanism39to push the selected bin onto a retrieval conveyor36. The conveyor36(as well as the other conveyors in the processing system) may be motion controlled so that both the speed and the direction of the conveyor (e.g., rollers or belt) may be controlled. In certain embodiments, certain of the conveyors (e.g., conveyors leading from the storage station12to the processing station16) may be gravity biased to cause any storage bin on any conveyor system to be delivered to the processing section16near the programmable motion device18.

The bins14may be provided as boxes, totes, containers or any other type of device that may receive and hold an item. In further embodiments, the bins may be provided in uniform trays (to provide consistency of spacing and processing) and may further include open covers that may maintain the bin in an open position, and may further provide consistency in processing through any of spacing, alignment, or labeling.

For example,FIG.5shows an exploded view of a box tray assembly130. As shown, the box132(e.g., a standard shipping sized cardboard box) may include bottom131and side edges133that are received by a top surface135and inner sides137of a box tray134. The box tray134may include a recessed (protected) area in which a label or other identifying indicia146may be provided, as well as a wide and smooth contact surface151that may be engaged by an urging or removal mechanism as discussed below.

As also shown inFIG.5, the box132may include top flaps138that, when opened as shown, are held open by inner surfaces140of the box cover136. The box cover136may also include a recessed (protected) area in which a label or other identifying indicia145may be provided. The box cover136also provides a defined rim opening142, as well as corner elements144that may assist in providing structural integrity of the assembly, and may assist in stacking un-used covers on one another. Un-used box trays may also be stacked on each other.

The box132is thus maintained securely within the box tray134, and the box cover136provides that the flaps138remain down along the outside of the box permitting the interior of the box to be accessible through the opening142in the box cover136.FIG.6shows a width side view of the box tray assembly130with the box132securely seated within the box tray134, and the box cover holding open the flaps138of the box132. The box tray assemblies may be used as any or both of the storage bins and destination bins in various embodiments of the present invention.

With reference toFIGS.7A-7D, a box kicker184in accordance with an embodiment of the present invention may be suspended by and travel along a track186, and may include a rotatable arm188and a roller wheel190at the end of the arm188. With reference toFIGS.7B-7D, when the roller wheel190contacts the kicker plate151(shown inFIG.5) of a box tray assembly120, the arm188continues to rotate, urging the box tray assembly180from a first conveyor182to a second conveyor180. Again, the roller wheel190is designed to contact the kicker plate151of a box tray assembly181to push the box tray assembly181onto the conveyor180. Such a system may be used to provide that boxes that are empty or finished being unloaded may be removed (e.g., from conveyor182), or that boxes that are full or finished being loaded may be removed (e.g., from conveyor182). The conveyors180,182may also be coplanar, and the system may further include transition roller183to facilitate movement of the box tray assembly181, e.g., by being activated to pull the box tray over to the conveyor180.

The conveyors36may each serve more than one row of storage bins.FIG.8, for example, shows three retrieval conveyors36that serve two sets of two rows of storage bins. As shown at46, each of the storage bins in two of the rows may feed into one retrieval conveyor36. If, for example, the storage system serves four rows of storage bins by five levels of such rows, the system may receive the four rows in an arrangement as shown inFIG.8, and may provide output bin as shown inFIG.9. In particular,FIG.9shows at44a directional mapping of how storage bins may be directed from the retrieval conveyors36to retrieval output conveyors48via conveyors and bin lifters.

With reference again toFIG.1, the retrieval output conveyors42come together into a pair of processing conveyors48that lead to the programmable motion device18, one of which may provide an input to the processing area of the device18, while the other may provide an output to return a storage bin to the storage system. In addition to the programmable motion device18, the processing system includes a processing perception unit50that is directed to look down into a selected storage unit. Due to the presence of a bin perception unit52that detects the identifying indicia of a bin being processed, the system confirms the identity of the bin (and therefore the objects) being processed. Again, the storage system requested that the selected storage bin be retrieved and provided to the processing system, so the perception unit(s)52confirm that the correct bin is ready to be processed. The perception unit50is directed to look down into the bin being processed, and the field of view, for example, may appear generally as shown at54inFIG.11.

An end effector56of the programmable motion device18grasps an object in bin14, and moves to deliver the object to a primary carriage58as shown inFIG.10. The primary carriage58then moves along an X-Y vertical frame provided by a horizontal section57and two vertical sections59, to move the object to one of plurality of shuttle carriages60(as further shown inFIGS.15-21). The shuttle carriages facilitate moving the object to a desired destination bin22by placing or dropping the object into a carriage, that then shuttles the object to the selected destination bin22.

The storage bin may then be returned to the plurality of storage bins at the storage station, and may be returned anywhere among the bins as long as the system knows where the bin has been returned, and knows how each of the bins may have been moved when the selected storage bin was transferred to the conveyor36. Again, the storage bins, for example, may be biased (e.g., by gravity) to stack against one of the ends of each row of bins.

FIG.11shows an image view54of the bin14from the perception unit50. The image view shows the bin14(e.g., on a conveyor), and the bin14contains objects78,80,82,84and86. In the present embodiment, the objects are homogenous, and are intended for distribution to different distribution packages. Superimposed on the objects78,80,82,84,86(for illustrative purposes) are anticipated grasp locations79,81,83and85of the objects. Note that while candidate grasp locations79,83and85appear to be good grasp locations, grasp location81does not because its associated object is at least partially underneath another object. The system may also not even try to yet identify a grasp location for the object84because the object84is too obscured by other objects. Candidate grasp locations may be indicated using a 3D model of the robot end effector placed in the location where the actual end effector would go to use as a grasp location as shown inFIG.11. Grasp locations may be considered good, for example, if they are close to the center of mass of the object to provide greater stability during grasp and transport, and/or if they avoid places on an object such as caps, seams, etc. where a good vacuum seal might not be available.

If an object cannot be fully perceived by the detection system, the perception system considers the object to be two different objects, and may propose more than one candidate grasp of such two different objects. If the system executes a grasp at either of these bad grasp locations, it will either fail to acquire the object due to a bad grasp point where a vacuum seal will not occur, or will acquire the object at a grasp location that is very far from the center of mass of the object and thereby induce a great deal of instability during any attempted transport. Each of these results is undesirable.

If a bad grasp location is experienced, the system may remember that location for the associated object. By identifying good and bad grasp locations, a correlation is established between features in the 2D/3D images and the idea of good or bad grasp locations. Using this data and these correlations as input to machine learning algorithms, the system may eventually learn, for each image presented to it, where to best grasp an object, and where to avoid grasping an object.

As shown inFIGS.12A and12B, the perception system may also identify portions of an object that are the most flat in the generation of good grasp location information. In particular, if an object includes a tubular end and a flat end such as object87, the system would identify the more flat end as shown at88inFIG.12B. Additionally, the system may select the area of an object where a UPC code appears, as such codes are often printed on a relatively flat portion of the object to facilitate scanning of the barcode.

FIGS.13A and13Bshow that for each object90,92, the grasp selection system may determine a direction that is normal to the selected flat portion of the object90,92. As shown inFIGS.14A and14B, the robotic system will then direct the end effector94to approach each object90,92from the direction that is normal to the surface in order to better facilitate the generation of a good grasp on each object. By approaching each object from a direction that is substantially normal to a surface of the object, the robotic system significantly improves the likelihood of obtaining a good grasp of the object, particularly when a vacuum end effector is employed.

The invention provides therefore in certain embodiments that grasp optimization may be based on determination of surface normal, i.e., moving the end effector to be normal to the perceived surface of the object (as opposed to vertical picks), and that such grasp points may be chosen using fiducial features as grasp points, such as picking on a barcode, given that barcodes are almost always applied to a flat spot on the object.

With reference again toFIG.10, the primary carriage58moves (in vertical and horizontal directions such as X, Y) a selected object (received from the end effector56of the programmable motion device18) toward one of the shuttle carriages, where the object is then dropped into the selected shuttle carriage60.FIG.15further shows that each of the plurality of shuttle carriages60is part of shuttle section62that also includes a plurality of destination bins on conveyors64(that may be gravity fed biased toward an output end66of the destination system20). As further shown inFIG.16, each shuttle section62also includes an output conveyor68onto which completed destination bins may be moved for output to a further processing section or transport at the output end66of the destination system20.

Each of the shuttle carriages60moves between two rows of destination bins22along a track72as further shown inFIG.17. Each carriage60may also be actuated to drop an object70into a desired destination bin22(as shown inFIG.18). The destination bins22may be provided in conveyors64(e.g., rollers or belt), and may be biased (for example by gravity) to urge all destination bins toward one end (for example, the end66as shown. When a destination bin22is selected for removal (e.g., because the bin is full or otherwise ready for further processing), the system will urge the completed bin onto an output conveyor68to be brought to a further processing or shipment station. The conveyor68may also be biased (e.g., by gravity) to cause any bin on the conveyor to be brought to the output end66.

FIGS.19A and19Bshow a bin being urged from a row of the plurality of destination bins, onto the output conveyor68by the use of a displacement mechanism74that is able to move along the row of bins such that when a bin is selected, the displacement mechanism74engages and pushes a bin onto the output conveyor68. In certain embodiments, each of the locations at which a destination bin will be positioned may include its own displacement mechanism. Following displacement of the bin22onto the conveyor68, each of the destination bins may be urged together, and the system will record the change in position of any of the bins that moved. This way, a new empty bin may be added to the end, and the system will record the correct location and identified processing particulars of each of the destination bins. This is shown inFIGS.20and18, whereby a bin22is removed and pushed onto the conveyor68, and then the remaining bins are urged together while the removed bin rolls toward an output location (seeFIG.21).

As noted above, each of the storage system12and destination20may interface directly, or via an adapter conveyor system, with vehicles such as tractor trailer vehicles.FIG.22, for example, shows (with the rear doors removed for clarity) a trailer conveyance system100that includes stacked rows of bins102. The bins102are the same as the bins14and22, each may be used for all purposes in the overall system. The bins102are provided on roller bearing conveyors104(as more clearly shown inFIG.23) that are provided on shelves106within the trailer108. The shelves106may either be built into the trailer floor and inside walls, or may be provided as part of a structure that may be slid into a trailer and then fastened to the floor and/or inside walls of the trailer. The trailer may also provide a mechanism for pushing or pulling each of the rows of bins102out of the trailer.

As discussed above, each of the shelves106may include perception units105that perceive identifying indicia on the outside of each of the bins102that uniquely identifies each bin, and by sequence of detections, knows the location of each bin within the trailer108. Each trailer therefore has stored data regarding not only the contents of the trailer, but also the order of the contents in the bins. Not only may this facilitate the efficient processing of objects and bins at automated storage, retrieval and processing systems in accordance with various embodiment of the present invention, but this provides valuable information regarding which tractor trailers should be routed to which processing centers and when they may be most needed. Such a system also provides that objects within a trailer are not randomly placed in a trailer, and do not need to be individually handled by a human worker to be unloaded from the trailer. The unloading, in fact, may be accomplished very quickly while also knowing the identities of all bins and all contents of the bins, saving an enormous amount of resources.

FIG.24diagrammatically shows a trailer108backed up to a storage system12, andFIG.25diagrammatically shows a trailer110backed up to a destination system20. As mentioned above, each of these interfaces may include an adaptor conveyor system120as shown inFIGS.26A and26B. The adaptor conveyor system120may include a plurality of conveyors that change the vertical and horizontal distances between different conveyors. Through use of such an adaptor system120, bins of conveyors may be closely spaced in a tractor trailer, yet provide enough work room around the conveyors in each of the storage system and the destination system. For example,FIG.26Ashows a top view of such an adaptor system120that may be used between a trailer122(e.g., a trailer108or110) and a system124(e.g., a storage system12or a destination system20). The adaptor system120includes conveyors126that adjust the vertical and horizontal spacing between conveyors so that the conveyor positions of the joining systems will readily connect with one another.

FIG.27shows an overall system (without any adaptor conveyor systems for clarity) in which trailers230engage sortation systems232(e.g., plural sortation system12), that are in communication with processing systems234(e.g., plural processing systems16). The processing systems20are in communication with distribution systems236(e.g., plural distribution systems20), that may engage a plurality of trailers238. Systems of the invention are highly scalable in terms of sorts-per-hour as well as the number of storage bins and destination bins that may be available by adding additional systems and tractor trailer dock bays. Systems of the invention also significantly reduce trailer loading and unloading times, as well as reduce human power assistance in such processes. Further, the systems are easily extensible for throughput (destinations) by adding more linear processing components, as well as stock SKUs by adding more tote storage components.

Systems of various embodiments therefore provide that trailers of tractor trailers may become integrated components of automated storage, retrieval and processing systems. Empty bins may initially be provided to the destination system (either in reverse direction from the output end66, or in further embodiments, by providing a mechanism, such as the end effector of the robot18, by which empty bins may be provided from the sortation system to the destination system). As sortation bins at the sortation system are emptied, the bins are provided to the destination system. New bins of objects may be provided to the sortation system by supplier trailers108,130as discussed above, and output destination bins may be queued up and prepared for delivery to a transportation trailer110,138.

Control of each of the overall system (including interfacing with the vehicles and controlling movement of the bins in the vehicles), may be provided by the computer system76that is in communication with each of the conveyors and displacement mechanisms, carriages, and the programmable motion devices. The computer system76also contains 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. In accordance with certain embodiments, each trailer may also include sensors that identify each bin as it is loaded into the trailer (similar to the perception units34in the storage system), so that each vehicle may have recorded information regarding the contents and order of all bins in the vehicle.

When the trailer comes within a local area network of the system10, the stored information regarding the contents and order of the bins102may be immediately provided to the computer system76. The system therefore, directs the movement of the vehicle bins, 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. Once a full shipment of destination bins22are provided on output conveyors68, a trailer with an empty trailer conveyance system may back up to the destination system and (again, optionally via an adaptor conveyor system) be very quickly loaded with the destination bins (that are also provided in a known order). The shipment destination may also take advantage of the fact that the contents and order of the bins are fully known prior to shipment.

Those skilled in the art will appreciate that numerous modifications and variations may be made to the above disclosed embodiments without departing from the spirit and scope of the present invention.