Fulfillment system, article and method of operating same
Fulfillment systems may include an item storage and retrieval system which stores and automatically retrieves items, and an order sorting system, downstream from the item storage and retrieval system, which automatically collates retrieved items into orders. A control system controls operation, advantageously allowing operation without any item buffering buffer between the item storage and retrieval system and the order sorting system. Optionally, a destination sortation system may collate orders by intended destinations. The fulfillment system can handle orders for end user consumer as well as for retail locations simultaneously. Robots and/or conveyors may operate to move items between the systems.
1. A fulfillment system, comprising:
an item storage and retrieval system comprising: a three-dimensional array of storage spaces from which items are automatically retrievable at one or more retrieval rates via one or more robots in response to commands;
an order sorting system positioned downstream from the item storage and retrieval system in a fulfillment flow, the order sortation system comprising a plurality of order collation positions to which items are sortable at one or more sortation rates to collate one or more items that belong to respective ones of a plurality of orders in response to commands without any physical item buffering buffer at the order collation stations and without any physical item buffering buffer between the item storage and retrieval system and the order collation stations; and
a control system operable to adjust at least one of: a current one of the retrieval rates of the item storage and retrieval system or a current one of the sortation rates of the order sortation system to eliminate a need for any physical item buffering buffer and communicatively coupled to at least one of the item storage and retrieval system or the order sortation system to at least partially control operation thereof to adjust the current retrieval rate of the item storage and retrieval system and the current sortation rate of the order sortation system, wherein the control system synchronizes the current retrieval rate or a future retrieval rate of the item storage and retrieval system with the current sortation rate or a future sortation rate of the order sortation system, respectively.
2. The fulfillment system of claim 1 wherein the one or more robots comprise a plurality of robotic vehicles independently operable to retrieve items or totes containing items from the storage spaces.
3. The fulfillment system of claim 2 wherein the item storage and retrieval system includes a number of output stations and the robotic vehicles are operable to deposit the retrieved items or totes containing items at specified ones of the output stations of the item storage and retrieval system, the robotic vehicles comprising part of the item storage and retrieval system.
4. The fulfillment system of claim 3 wherein the order sortation system has a number of input stations, and further comprising:
a number of transfer robots positioned and operable to transfer items from the output stations of the item storage and retrieval system to the number of input stations of the order sortation system.
5. The fulfillment system of claim 3 wherein the transfer robots are each a respective robotic vehicle or includes a respective robotic appendage.
6. The fulfillment system of claim 3 wherein to the order sortation system has a number of input stations, and further comprising:
at least one belt conveyor line positioned and operable to transfer items from the output stations of the item storage and retrieval system to the number of input stations of the order sortation system.
7. The fulfillment system of claim 2 wherein the order sortation system includes a number of input stations and the robotic vehicles are operable to deposit the retrieved items or totes containing items at specified ones of the input stations of the order sortation system without any physical item buffering buffer between the item storage and retrieval system and the order sortation system.
8. The fulfillment system of claim 2 wherein the robotic vehicles are operable to deposit the retrieved items or totes containing items at specified ones of the order collation positions of the order sortation system without any physical item buffering buffer between the item storage and retrieval system and the order sortation system.
9. The fulfillment system of claim 1 wherein the control system receives input representative of the current sortation rate or a future sortation rate of the order sortation system, and adjusts the current retrieval rate or a future retrieval rate to not exceed the current or the future sortation rate.
10. The fulfillment system of claim 9 wherein the current or the future sortation rate is based, at least in part, on a total number of order collation positions of the order sortation system currently in operation or to be placed into operation in the future.
11. The fulfillment system of claim 9 , further comprising:
a number of sensors that sense the current sortation rate of the order sortation system, the sensors communicatively coupled to provide an indication of the current sortation rate to the control system.
12. The fulfillment system of claim 1 wherein the control system receives input representative of the current retrieval rate or a future retrieval rate of the item storage and retrieval system, and adjusts the current retrieval rate or a future retrieval rate to not exceed the current or the future sortation rate.
13. The fulfillment system of claim 12 wherein the current retrieval rate or a future retrieval rate is based, at least in part, on a total number of output positions of the item storage and retrieval system currently in operation or to be placed into operation in the future.
14. The fulfillment system of claim 13 , further comprising:
a number of sensors that sense the current retrieval rate of the item storage and retrieval system, the sensors communicatively coupled to provide an indication of the current retrieval rate to the control system.
15. The fulfillment system of claim 1 wherein item storage and retrieval system is a standalone system from a first manufacturer and the order sortation system is a standalone system from a second manufacturer, the second manufacturer different and independent from the first manufacturer.
16. The fulfillment system of claim 1 wherein the item storage and retrieval system comprises a number of output stations.
17. The fulfillment system of claim 16 wherein the number of output stations of the item storage and retrieval system in operation is variable over time, and the control system synchronizes the current retrieval rate of the storage and retrieval system with the current sortation rate of the sortation system based at least in part on a total number of output stations of the item storage and retrieval system currently in operation.
18. The fulfillment system of claim 16 wherein the number of order collation positions of the sortation system in operation is variable over time, and the control system synchronizes the current retrieval rate of the storage and retrieval system with the current sortation rate of the sortation system based at least in part on a total number of order collation of the sortation system currently in operation.
19. The fulfillment system of claim 1 wherein the sortation system comprises one or more paths and the order collation positions are respective positions along and spaced relatively below the one or more paths.
20. The fulfillment system of claim 1 wherein the sortation system sorts orders placed directly by end customers and placed by retailer specific locations.
21. The fulfillment system of claim 1 , further comprising:
a destination sortation system positioned downstream from the an order sorting system in the fulfillment flow, the destination sortation system comprising a plurality of destination collation positions, and which collates orders, which comprise one or more items, based on a commonality in a respective destination to which the orders are to be delivered, without any physical item buffering buffer between the item storage and retrieval system and the destination sortation system.
22. The fulfillment system of claim 1 wherein the item storage and retrieval system further comprises a dedicated processor-based item storage and retrieval control system and the control system of the fulfillment system is communicatively coupled to send commands to the dedicated processor-based item storage and retrieval control system to control operation of one or more robots.
23. The fulfillment system of claim 1 wherein the sortation system further comprises a dedicated processor-based sortation system control system and the control system of the fulfillment system is communicatively coupled to send commands to the dedicated processor-based sortation system control system to control operation of one or more robots.
24. The fulfillment system of claim 1 wherein the control system of the fulfillment system is communicatively coupled to send commands directly to respective dedicated control systems of the robot vehicles without any intervening control systems.
25. The fulfillment system of claim 1 , further comprising:
a processor-based warehouse management system including at least one nontransitory processor-readable medium that implements a warehouse data store that stores information representative of inventory, wherein the control system of the fulfillment system is communicatively coupled to the processor-based warehouse management system to update the information representative of inventory in the warehouse data store.
26. A fulfillment system, comprising:
an item storage and retrieval system comprising: a three-dimensional array of storage spaces from which items are automatically retrievable at one or more retrieval rates via one or more robots in response to commands;
an order sorting system positioned downstream from the item storage and retrieval system in a fulfillment flow, the order sortation system comprising a plurality of order collation positions to which items are sortable at one or more sortation rates to collate one or more items that belong to respective ones of a plurality of orders in response to commands without any physical item buffering buffer at the order collation stations and without any physical item buffering buffer between the item storage and retrieval system and the order collation stations; and
a control system operable to adjust at least one of: a current one of the retrieval rates of the item storage and retrieval system or a current one of the sortation rates of the order sortation system to eliminate a need for any physical item buffering buffer and communicatively coupled to at least one of the item storage and retrieval system or the order sortation system to at least partially control operation thereof to adjust the current retrieval rate of the item storage and retrieval system and the current sortation rate of the order sortation system, wherein the control system is implemented in a cloud-based virtual server, and provides an item storage and retrieval micro-service, an order sortation or collation micro-service, and a warehouse management micro-service each accessible via an application programming interface gateway.
27. The fulfillment system of claim 26 wherein the control system synchronizes the current retrieval rate or a future retrieval rate of the item storage and retrieval system with the current sortation rate or a future sortation rate of the order sortation system, respectively.