Granted Patent B2

US 12,492,074 · App. 18/349,872 · Granted Dec 9, 2025

Inventors: Daniel Jarvis (Orlando, FL); Paolo Gerli Amador (Framingham, MA); Michael Bhaskaran (Seattle, WA); Amit Kalra (Acton, MA); Rodney Gallaway (Little Rock, AR); Vikranth Gopalakrishnan (Hoboken, NJ)

Assignee: Staples, Inc.

B65G1/1373B65G1/137G01C21/206G05D1/0088G05D1/0225G05D1/0285G05D1/0297G06Q10/087B65G1/1378G05D1/0274

Abstract

Claims (89)

1 . A method comprising:

assigning, by one or more processors, a set of shipping cartons to a cart, the cart being adapted to hold the set of shipping cartons and couple with a first automated guided vehicle (AGV) of one or more AGVs;

receiving, by the one or more processors, scan data of the set of shipping cartons indicating that the set of shipping cartons are held by the cart;

signaling, by the one or more processors, the first AGV to couple with the cart;

based on the scan data and the first AGV being coupled with the cart, signaling, by the one or more processors, the first AGV to navigate to a first location of a first item in a storage area of a fulfillment center, the first item being assigned to at least one of the set of shipping cartons;

outputting, by the one or more processors, a first instruction to one or more client devices instructing one or more pickers to remove the first item from storage in the storage area and place the first item into the at least one of the set of shipping cartons; and

based on determining that a plurality of pick tasks for the set of shipping cartons has been completed, signaling the first AGV to transport the cart holding the set of shipping cartons to a point in the fulfillment center outside of the storage area.

2 . The method of claim 1 , further comprising:

determining, by the one or more processors, that the first AGV is at the first location in the storage area;

outputting, by the one or more processors, the first instruction to the one or more client devices instructing the one or more pickers at the storage area to place the first item in a defined shipping carton of the at least one of the set of shipping cartons held by the cart;

receiving, by the one or more processors, second scan data of the defined shipping carton confirming that the first item has been picked into the defined shipping carton; and

instructing, by the one or more processors, the first AGV to navigate to a second location of a second item in the storage area based on the second scan data.

3 . The method of claim 1 , further comprising:

signaling, by the one or more processors, the first AGV to transport the set of shipping cartons from the first location to a picking station;

instructing, by the one or more processors, a second AGV of the one or more AGVs to deliver a second item to the picking station; and

outputting, by the one or more processors, a second instruction to the one or more client devices instructing the one or more pickers to place the second item into the set of shipping cartons on the cart at the picking station.

4 . The method of claim 3 , wherein instructing the second AGV to deliver the second item to the picking station includes:

signaling, by the one or more processors, the second AGV to transport a storage container holding the second item from a second storage area to the picking station and place the storage container on a shelf at the picking station.

5 . The method of claim 4 , wherein:

outputting the second instruction to the one or more client devices includes instructing the one or more pickers to remove the second item from the storage container on the shelf and place the second item in a defined shipping carton of the set of shipping cartons, the defined shipping carton containing the first item; and

the method includes receiving second scan data of the defined shipping carton confirming that the second item has been picked into the defined shipping carton and instructing the first AGV to transport the cart away from the picking station based on the second scan data.

6 . The method of claim 3 , further comprising:

selecting, by the one or more processors, the picking station from a plurality of picking stations in the fulfillment center based on one or more queues of the one or more AGVs at the plurality of picking stations; and

signaling, by the one or more processors, the first AGV to wait in a queue for the selected picking station.

7 . The method of claim 1 , further comprising:

determining, by the one or more processors, that the plurality of pick tasks for the set of shipping cartons have been completed, the plurality of pick tasks including placing a plurality of items into the set of shipping cartons; and

based on determining that the plurality of pick tasks have been completed, signaling, by the one or more processors, the one or more AGVs to transport the cart holding the set of shipping cartons to a finalizing area of the fulfillment center.

8 . The method of claim 7 , further comprising:

determining, by the one or more processors, that the cart is at the finalizing area; and

in response to determining that the cart is at the finalizing area, decoupling the one or more AGVs from the cart.

9 . The method of claim 8 , further comprising:

determining, by the one or more processors, that one or more finalizing tasks have been completed;

signaling, by the one or more processors, the one or more AGVs to couple with the cart at the finalizing area;

signaling, by the one or more processors, the one or more AGVs to transport the cart to an induction area of the fulfillment center; and

assigning, by the one or more processors, a second set of shipping cartons to the cart.

10 . The method of claim 7 , wherein:

the plurality of pick tasks including placing a first plurality of items into the set of shipping cartons at the storage area and placing a second plurality of items into the set of shipping cartons at a picking station; and

signaling, by the one or more processors, the one or more AGVs to transport the cart holding the set of shipping cartons to the finalizing area includes signaling the one or more AGVs to transport the cart from the picking station to the finalizing area.

11 . A system comprising:

one or more processors; and

a non-transitory computer-readable medium storing computer instructions that, when executed by the one or more processors, cause the system to perform operations including:

assigning a set of shipping cartons to a cart, the cart being adapted to hold the set of shipping cartons and couple with a first automated guided vehicle (AGV) of one or more AGVs;

receiving scan data of the set of shipping cartons indicating that the set of shipping cartons are held by the cart;

signaling the first AGV to couple with the cart;

based on the scan data and the first AGV being coupled with the cart, signaling the first AGV to navigate to a first location of a first item in a storage area of a fulfillment center, the first item being assigned to at least one of the set of shipping cartons;

outputting a first instruction to one or more client devices instructing one or more pickers to remove the first item from storage in the storage area and place the first item into the at least one of the set of shipping cartons; and

based on determining that a plurality of pick tasks for the set of shipping cartons has been completed, signaling the first AGV to transport the cart holding the set of shipping cartons to a point in the fulfillment center outside of the storage area.

12 . The system of claim 11 , wherein the operations further comprise:

determining that the first AGV is at the first location in the storage area;

outputting the first instruction to the one or more client devices instructing the one or more pickers at the storage area to place the first item in a defined shipping carton of the at least one of the set of shipping cartons held by the cart;

receiving second scan data of the defined shipping carton confirming that the first item has been picked into the defined shipping carton; and

instructing the first AGV to navigate to a second location of a second item in the storage area based on the second scan data.

13 . The system of claim 11 , wherein the operations further comprise:

signaling the first AGV to transport the set of shipping cartons from the first location to a picking station;

instructing a second AGV of the one or more AGVs to deliver a second item to the picking station; and

outputting a second instruction to the one or more client devices instructing the one or more pickers to place the second item into the set of shipping cartons on the cart at the picking station.

14 . The system of claim 13 , wherein instructing the second AGV to deliver the second item to the picking station includes:

signaling the second AGV to transport a storage container holding the second item from a second storage area to the picking station and place the storage container on a shelf at the picking station.

15 . The system of claim 14 , wherein:

outputting the second instruction to the one or more client devices includes instructing the one or more pickers to remove the second item from the storage container on the shelf and place the second item in a defined shipping carton of the set of shipping cartons, the defined shipping carton containing the first item; and

the operations include receiving second scan data of the defined shipping carton confirming that the second item has been picked into the defined shipping carton and instructing the first AGV to transport the cart away from the picking station based on the second scan data.

16 . The system of claim 13 , further comprising:

selecting the picking station from a plurality of picking stations in the fulfillment center based on one or more queues of the one or more AGVs at the plurality of picking stations; and

signaling the first AGV to wait in a queue for the selected picking station.

17 . The system of claim 11 , wherein the operations further comprise:

determining that the plurality of pick tasks for the set of shipping cartons have been completed, the plurality of pick tasks including placing a plurality of items into the set of shipping cartons; and

based on determining that the plurality of pick tasks have been completed, signaling the one or more AGVs to transport the cart holding the set of shipping cartons to a finalizing area of the fulfillment center.

18 . The system of claim 17 , further comprising:

determining that the cart is at the finalizing area; and

in response to determining that the cart is at the finalizing area, decoupling the one or more AGVs from the cart.

19 . The system of claim 18 , wherein the operations further comprise:

determining that one or more finalizing tasks have been completed;

signaling the one or more AGVs to couple with the cart at the finalizing area;

signaling the one or more AGVs to transport the cart to an induction area of the fulfillment center; and

assigning a second set of shipping cartons to the cart.

20 . A system comprising:

a plurality of automated guided vehicles (AGVs) including a first AGV of a first type and a second AGV of a second type, the first type being adapted to transport a plurality of shipping cartons, the second type adapted to manipulate and transport one or more mobile storage containers;

a picking station having one or more shelves at one or more first sides, the one or more shelves being adapted to hold the one or more mobile storage containers, the picking station including one or more second sides at which a cart transported by the first AGV of the first type is received; and

one or more processors that cause the system to perform operations including:

assigning a set of shipping cartons to the cart, the cart being adapted to hold the set of shipping cartons and couple with the first AGV;

receiving scan data of the set of shipping cartons indicating that the set of shipping cartons are held by the cart;

signaling the first AGV to couple with the cart;

based on the scan data and the first AGV being coupled with the cart, signaling the first AGV to navigate to a first location of a first item in a storage area, the first item being assigned to at least one of the set of shipping cartons;

outputting a first instruction to one or more client devices instructing one or more pickers to remove the first item from storage in the storage area and place the first item into the at least one of the set of shipping cartons;

signaling the first AGV to transport the set of shipping cartons from the first location to the picking station;

instructing the second AGV to deliver a second item to the picking station in the one or more mobile storage containers;

outputting a second instruction to the one or more client devices instructing the one or more pickers to place the second item into the at least one of the set of shipping cartons on the cart at the picking station;

determining, by the one or more processors, that the second item has been placed into the at least one of the set of shipping cartons at the picking station; and

based on determining that the second item has been placed into the at least one of the set of shipping cartons, signaling the first AGV to transport the cart holding the set of shipping cartons to a finalizing area of a fulfillment center.

Assignments (4)

Continuity (6)

References Cited (400)