IP Library Granted Patent US 11,939,162
Granted Patent B2
US 11,939,162 · App. 17/173,115 · Granted Mar 26, 2024

System-directed robotic cart picking

Inventors: Matthew Robert Douglas (Orlando, FL); Stephen Nilsen (Clayton, NC); Paolo Gerli Amador (Framingham, MA); Gregory Patrick Cox (Sleepy Hollow, NY)
Assignee: Staples, Inc.
B65G1/1375
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Quick Facts
Patent No.
US 11,939,162
App. No.
17/173,115
Granted
Mar 26, 2024
Kind
B2
Abstract

A system-directed robotic cart picking system is described. In an example implementation, the system may generate a picking itinerary including pick-to-cart routing based on locations of items in an order fulfillment center and received order data identifying the items, and may transport the carts in the order fulfillment center according to the pick-to-cart routing. The system may determine a zone of the order fulfillment center to which to assign a picker based on the picking itinerary and may determine tasks, such as picking at least one item from the locations to the carts, for the picker located in the zone. In some instances, the system may output pick instructions to a picker client device directing the picker to perform the tasks and may transport the carts to a defined point in the order fulfillment center in response to completion of the tasks.

Claims (52)

1. A method comprising:

generating, by one or more processors, a picking itinerary based on one or more locations of items in an order fulfillment center and received order data identifying the items, the picking itinerary including pick-to-cart routing for one or more carts;

transporting, by the one or more processors, the one or more carts in the order fulfillment center according to the pick-to-cart routing;

determining, by the one or more processors, a zone of the order fulfillment center to which to assign a picker based on the picking itinerary including:

determining, by the one or more processors, a zone score for each of a plurality of zones, the plurality of zones including the zone; and

assigning, by the one or more processors, the picker to the zone based on the zone scores;

determining, by the one or more processors, one or more tasks for the picker located in the zone, the one or more tasks including picking at least one of the items from the one or more locations to the one or more carts in association with the pick-to-cart routing;

outputting, by the one or more processors, pick instructions to a picker client device directing the picker to perform the one or more tasks; and

responsive to the one or more tasks being performed, transporting, by the one or more processors, the one or more carts to a defined point in the order fulfillment center.

2. The method of claim 1 , wherein transporting the one or more carts in the order fulfillment center includes autonomously navigating a cart autonomous guided vehicle (AGV) according to the pick-to-cart routing using a guidance system.

3. The method of claim 1 , wherein determining the zone of the order fulfillment center to which to assign the picker is based on the one or more locations of the items, the one or more tasks including picking a subset of the items, which are located in the zone of the order fulfillment center.

4. The method of claim 1 , wherein determining the zone score for each of the plurality of zones is based on a quantity of the one or more carts and a quantity of the one or more tasks.

5. The method of claim 4 , wherein determining the zone score for each of the plurality of zones is further based on a distance between the one or more locations.

6. The method of claim 4 , wherein determining the zone of the order fulfillment center is further based on locations of a plurality of pickers, the plurality of pickers including the picker.

7. The method of claim 1 , wherein determining the zone of the order fulfillment center includes determining, by the one or more processors, one or more boundaries of the zone using a clustering algorithm.

8. The method of claim 1 , further comprising:

outputting, by the one or more processors, zone instructions to the picker client device, the zone instructions directing the picker to move to the zone.

9. The method of claim 1 , wherein the pick instructions include instructing the picker to retrieve the at least one of the items from the one or more locations and place the at least one of the items on a certain cart of the one or more carts in coordination with transportation of the certain cart to the zone by an AGV.

10. The method of claim 1 , further comprising:

receiving, by the one or more processors, a confirmation message from the picker client device indicating that the one or more tasks have been completed; and

in response to receiving the confirmation message, reassigning, by the one or more processors, the picker to a second zone of the order fulfillment center.

11. The method of claim 1 , further comprising:

inducting, by the one or more processors, an order into a storage fetching system based on the order data identifying the items in orders to be fulfilled at the order fulfillment center.

12. A system comprising:

a processor; and

a memory storing instructions that, when executed by the processor, cause the system to:

generate a picking itinerary based on one or more locations of items in an order fulfillment center and received order data identifying the items, the picking itinerary including pick-to-cart routing for one or more carts;

transport the one or more carts in the order fulfillment center according to the pick-to-cart routing;

determine a zone of the order fulfillment center to which to assign a picker based on the picking itinerary including determining one or more boundaries of the zone using a clustering algorithm;

determine one or more tasks for the picker located in the zone, the one or more tasks including picking at least one of the items from the one or more locations to the one or more carts in association with the pick-to-cart routing;

output pick instructions to a picker client device directing the picker to perform the one or more tasks; and

responsive to the one or more tasks being performed, transport the one or more carts to a defined point in the order fulfillment center.

13. The system of claim 12 , wherein transporting the one or more carts in the order fulfillment center includes autonomously navigating a cart autonomous guided vehicle (AGV) according to the pick-to-cart routing using a guidance system.

14. The system of claim 12 , wherein determining the zone of the order fulfillment center to which to assign the picker is based on the one or more locations of the items, the one or more tasks including picking a subset of the items, which are located in the zone of the order fulfillment center.

15. The system of claim 12 , wherein the instructions further cause the system to:

determine a zone score for each of a plurality of zones, the plurality of zones including the zone; and

assign the picker to the zone based on the zone scores.

16. The system of claim 15 , wherein determining the zone score for each of the plurality of zones is based on a quantity of the one or more carts and a quantity of the one or more tasks.

17. The system of claim 16 , wherein determining the zone score for each of the plurality of zones is further based on a distance between the one or more locations.

18. The system of claim 16 , wherein determining the zone of the order fulfillment center is further based on locations of a plurality of pickers, the plurality of pickers including the picker.

19. A system comprising:

an automated guided vehicle (AGV) adapted to transport a cart in an order fulfillment center according to pick-to-cart routing;

a picker client device adapted to output pick instructions directing a picker to perform a task; and

a processor performing operations including:

generating a picking itinerary based on one or more locations of items in the order fulfillment center and received order data identifying the items, the picking itinerary including the pick-to-cart routing for the AGV;

determining a zone of the order fulfillment center to which to assign the picker based on the picking itinerary including:

determining a zone score for each of a plurality of zones, the plurality of zones including the zone; and

assigning the picker to the zone based on the zone scores;

determining the task located in the zone for the picker, the task including picking at least one of the items from the one or more locations to the cart in coordination with transportation of the cart by the AGV;

transmitting the pick instructions to the picker client device directing the picker to perform the task; and

responsive to the task being performed, transporting the cart to a defined point by the AGV.

20. The system of claim 19 , wherein determining the zone of the order fulfillment center further includes determining one or more boundaries of the zone using a clustering algorithm.

Assignments (4)
SECURITY INTEREST Recorded Jun 12, 2024
From: STAPLES, INC.
To: COMPUTERSHARE TRUST COMPANY, NATIONAL ASSOCIATION, AS NOTES AGENT
Reel/Frame 067711/0239 →
SECURITY INTEREST Recorded Jun 11, 2024
From: STAPLES, INC.
To: UBS AG, STAMFORD BRANCH, AS TERM LOAN AGENT
Reel/Frame 067687/0558 →
SECURITY INTEREST Recorded Jun 11, 2024
From: STAPLES, INC.
To: COMPUTERSHARE TRUST COMPANY, NATIONAL ASSOCIATION, AS NOTES AGENT
Reel/Frame 067697/0639 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Aug 31, 2021
From: DOUGLAS, MATTHEW ROBERT; NILSEN, STEPHEN; AMADOR, PAOLO GERLI; COX, GREGORY PATRICK
To: STAPLES, INC.
Reel/Frame 057340/0223 →
Cited By (2)
US 12,397,320 US 12,404,107