Claims:1. An apparatus for simultaneous storage and retrieval of multiple packages 200, comprising:
a support frame 201, said support frame 201 being: mechanically associated with a chassis of an at least one cart 300, open to the left and right sides of the at least one cart 300 to enable a plurality of manipulators 202, 203, and 204 to store a plurality of items or packages 207 on an at least a shelf or rack 206, retrieve the plurality of items or packages 207 from the at least one shelf or rack 206, or store and retrieve the plurality of items or packages 207, on either side of the Y-axis without any hindrance;

the plurality of manipulators 202, 203, and 204, with each manipulator being capable of storing, retrieving, or storing and retrieving the plurality of items or packages 207, said manipulator being configured to move up and down along the Z-axis on a first plurality of linear guides 403 and comprising:
linear bearings that support the up and down movement of each manipulator;
a plurality of lead screw mechanisms 405 that actuates the up and down movement of each manipulator, with each lead screw mechanism being driven by an electric motor 409 that is controlled by an at least one controller;
a platform 406 that holds the plurality of items or packages 207, said platform 406 being configured to move horizontally along the Y-axis on a second plurality of linear guides 401, upon actuation;
an at least a sensor that is communicatively associated with: the at least one controller, the at least one autonomous control unit, or both the at least one controller and the at least one autonomous control unit, said at least one sensor including an at least a vision sensor 408 that is associated with: an end-effector, the support frame 201, or both the end-effector and the support frame 201;
a plurality of grippers 407 that is mounted on the end-effector and is configured to move on a horizontal plane along the X-axis and the Y-axis; and
an electric linear actuator 404 that actuates the end-effector, said electric linear actuator 404 being configured to move along the Y-axis on a third plurality of linear guides 402, said third plurality of linear guides 402 being actuated by an electric actuator 410, with the electric linear actuator 404 and the electric actuator 410 being connected to the at least one controller; and
the at least a controller that is associated with an at least an autonomous control unit,
said apparatus 200 being: mechanically associated with the at least a cart 300 to form the system 100, with the at least one vision sensor 408 enabling the system 100 and the apparatus 200 to gain a clear view of the at least one shelf or rack 206 and the plurality of items or packages 207; and electronically associated with the at least one autonomous control unit, which, in turn, communicates with a central server over a network, said central server comprising a task management module that is configured to allocate tasks to carts and the apparatus 200 to ensure that the number of carts and time required to complete the tasks are minimized, while productivity and throughput are maximized, by considering the current location of tasks and available carts, the number of manipulators, their configuration, and their current state.
2. The apparatus for simultaneous storage and retrieval of multiple packages 200 as claimed in claim 1, wherein the plurality of manipulators 202, 203, and 204 is vertically on top of each other facing one side.
3. The apparatus for simultaneous storage and retrieval of multiple packages 200 as claimed in claim 1, wherein the plurality of manipulators 202, 203, and 204 is vertically on top of each other distributed on both sides.
4. The apparatus for simultaneous storage and retrieval of multiple packages 200 as claimed in claim 1, wherein the at least one autonomous control unit comprises modules for:
autonomous navigation, said module for autonomous navigation module processing data from the sensors that are associated with the apparatus 200 and the at least one cart 300 for mapping, localization, path planning, and obstacle avoidance, and sending appropriate velocity commands to a motion control unit;
shelf recognition, said module for shelf recognition identifying the location of the at least one shelf, rack, and/or storage 206, through the sensors that are associated with the apparatus 200 and the at least one cart 300;
inventory recognition, said module for inventory recognition identifying the plurality of items or packages 207, or a plurality of stock keeping units, through the sensors that are associated with the apparatus 200 and the at least one cart 300;
task and event management, said module for task and event management processing data from one or more modules to manage various tasks assigned to the apparatus 200 and the at least one cart 300; and
simultaneous storage and retrieval, said module for simultaneous storage and retrieval planning and executing storage and retrieval of the plurality of packages or items 207 simultaneously through the plurality of manipulators 202, 203, and 204, and the sensors that are associated with apparatus 200 and the at least one cart 300.
5. The apparatus for simultaneous storage and retrieval of multiple packages 200 as claimed in claim 1, wherein the central server comprises: a fleet management module, said fleet management module being configured to perform functions related to setup, configuration, operation, tracking, and remote management of a fleet of carts; a facility management module, said facility management module being configured to maintain all details related to the facility in which the carts and the apparatus 200 are operating; a system administration module; an at least a second processor; a second input/output interface; an at least a second memory; a communication module; a location identification module; an inventory management module; and an at least a second database.

6. The apparatus for simultaneous storage and retrieval of multiple packages 200 as claimed in claim 1, wherein tasks include storing; retrieving; stock replenishment; inventory counting; person following; and transporting inventory.

7. A system for simultaneous storage and retrieval of multiple items or packages autonomously that comprises the apparatus for simultaneous storage and retrieval of multiple packages 200 as claimed in claim 1, said system comprising: a host ERP or store or warehouse management system, which sends tasks to the central server that processes these tasks and executes them through a plurality of carts, carts with the apparatus 200, and users with user devices, over a network.

8. A process for simultaneous storage and retrieval of multiple packages through the apparatus for simultaneous storage and retrieval of multiple packages 200 as claimed in claim 1, said process comprising the steps of:
assigning storage tasks, retrieval tasks, or both storage and retrieval tasks to the at least one cart 300 by the central server, said at least one cart 300 being associated with the apparatus 200 to form the system 100;
navigating the system 100 by the at least one autonomous control unit to the at least one shelf or rack 206 where the plurality of packages or items 207 need to be stored, retrieved, or stored and retrieved, while avoiding obstacles;
verifying the location reading the identification tags or labels on the at least one shelf or rack 206, through the at least one sensor;
determining the manipulators that are required to perform the tasks;
determining the availability of said manipulators;
assigning tasks to the determined and available manipulators to store, retrieve, or store and retrieve the plurality of packages or items 207 simultaneously;
generating commands for the actuators of the manipulators;
performing package verification to determine whether the plurality of packages or items 207 to be retrieved is the correct ones or not;
checking the locations where the plurality of packages or items 207 are to be stored, retrieved, or stored and retrieved to determine whether they are empty or not, by reading the identification tags or labels on the at least one shelf or rack 206, the plurality of packages or items 207, or both the at least one shelf or rack 206 and the plurality of packages or items 207, through the at least one sensor;
updating the central server, if the checks fail;
completing the tasks by the determined and available manipulators, if the checks are positive, and updating the central server; and
instructing the system 100 to go to a waiting area and wait for further work to be assigned, if no more tasks are assigned. , Description:TITLE OF THE INVENTION: APPARATUS AND METHOD FOR SIMULTANEOUS STORAGE AND RETRIEVAL OF MULTIPLE PACKAGES
The present disclosure is an improvement in or modification of the disclosure in our earlier patent application bearing number 201741009468 (Granted Patent 336541) dated March 18, 2017.
FIELD OF THE INVENTION
The present disclosure is related to a system for storage and retrieval of items or packages in facilities. Particularly, the present disclosure is related to a system and method for simultaneous storage and retrieval of multiple packages or items in facilities, such as warehouses, distribution centres, retail stores, supermarkets, hypermarkets, grocery stores, factories, and manufacturing centres.
BACKGROUND OF THE INVENTION
To meet increasing consumer demand and aspirations, companies in industries such as E-commerce, Retail, Apparel, Food & Grocery, Consumer Goods, etc. are continuously introducing new and innovative products, as well as variants of existing products.
Further, in some industries, such as Technology, Consumer Durables, and Auto, companies also have to stock a large number of spare parts for long periods of time to support customers. This leads to ever increasing number of unique stock keeping units (SKUs) in warehouses and distribution centres.
In addition, steady growth in consumption necessitates larger facilities with greater number of storage locations. Even order profiles have changed over time, with the trend being larger number of small volume orders with short delivery/fulfilment time.
As a result of all these factors, warehouses/distribution centres need to employ a larger workforce to store and retrieve items. The problem is compounded by seasonal demand surges, shortage of workers, and pressure to further increase throughput.
Companies are, therefore, looking for ways to automate their warehouse/distribution center operations. This is especially challenging when it comes to handling a large volume of individual items/packages and small boxes/cases of different shapes/sizes.
Existing Automated Storage and Retrieval Systems (ASRS) were primarily designed for handling bulk palletized loads and, hence, do not address the current challenges. More recently, goods-to-person systems using Automated Guided Vehicles (AGV) carrying specially designed shelves to workers have been developed. But these require dedicated areas to operate, which are out of bound of workers. Some other systems use Autonomous Mobile Robots (AMR) to transport goods within facilities. These can work alongside workers, but require workers to manually pick and place items on them.
There is, therefore, a need in the art for an apparatus and system for simultaneous storage and retrieval of multiple packages, which overcome the aforementioned drawbacks and shortcomings.
SUMMARY OF THE INVENTION
An apparatus for simultaneous storage and retrieval of multiple packages is disclosed. The apparatus comprises: a support frame; a plurality of manipulators; and an at least a controller that is associated with an at least an autonomous control unit.
Said support frame is mechanically associated with a chassis of an at least one cart. Further, said support frame is open to the left and right sides of the at least one cart to enable the plurality of manipulators to store a plurality of items or packages on an at least a shelf or rack, retrieve the plurality of items or packages from the at least one shelf or rack, or store and retrieve the plurality the items or packages, on either side of the Y-axis without any hindrance.

Each manipulator is capable of storing, retrieving, or storing and retrieving the plurality of items or packages, said manipulator being configured to move up and down along the Z-axis on a first plurality of linear guides.
Said manipulator comprises: linear bearings; a plurality of lead screw mechanisms; a platform; an at least a sensor; a plurality of grippers; and an electric linear actuator.
The linear bearings support the up and down movement of each manipulator, while the plurality of lead screw mechanisms actuates the up and down movement of each manipulator, with each lead screw mechanism being driven by an electric motor that is controlled by the at least one controller.
The platform holds the plurality of items or packages, said platform being configured to move horizontally along the Y-axis on a second plurality of linear guides, upon actuation.
The at least one sensor is communicatively associated with: the at least one controller, the at least one autonomous control unit, or both the at least one controller and the at least one autonomous control unit.
Said at least one sensor includes an at least a vision sensor that is associated with: an end-effector, the support frame, or both the end-effector and the support frame.
The plurality of grippers is mounted on the end-effector and is configured to move on a horizontal plane along the X-axis and the Y-axis.
The electric linear actuator actuates the end-effector, said electric linear actuator being configured to move along the Y-axis on a third plurality of linear guides.
Said third plurality of linear guides is actuated by an electric actuator, with the electric linear actuator and the electric actuator being connected to the at least one controller.
Said apparatus is mechanically associated with the at least a cart to form a system. Said apparatus is also electronically associated with the at least one autonomous control unit, which, in turn, communicates with a central server over a network.
The at least one vision sensor enables the apparatus and the system to gain a clear view of the at least one shelf or rack and the plurality of items or packages.
Said central server comprises a task management module that is configured to allocate tasks to the system, the apparatus, and/or the at least one cart to ensure that the number of carts and time required to complete the tasks are minimized.
The disclosed apparatus and system increase the productivity and throughput of storage and retrieval operations in facilities.
BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 illustrates an embodiment of an apparatus for simultaneous storage and retrieval of packages, in accordance with the present disclosure;
Figure 2 illustrates the allowing of simultaneous storage and retrieval of multiple packages from shelves or racks on both sides, in accordance with an embodiment of the present disclosure;
Figure 3 illustrates an embodiment of a manipulator, in accordance with the present disclosure;
Figure 4 illustrates an embodiment of an autonomous control unit, in accordance with the present disclosure;
Figure 5 illustrates an embodiment of a system comprising a host ERP or store or warehouse management system, in accordance with the present disclosure; and
Figure 6 illustrates a flowchart of a process for simultaneous storage and retrieval of multiple packages, in accordance with the present disclosure.
DETAILED DESCRIPTION OF THE INVENTION
Throughout this specification, the use of the word "comprise", “have”, “contain” and “include”, and variations such as "comprises", "comprising", “having”, “contains”, “containing”, “includes”, and “including” may imply the inclusion of an element or elements not specifically recited. The disclosed embodiments may be embodied in various other forms as well.
Throughout this specification, the phrases “at least a”, “at least an”, and “at least one” are used interchangeably.
Throughout this specification, the use of the word “apparatus” is to be construed as a set of technical components that are communicatively associated with each other, and function together as part of a mechanism to achieve a desired technical result.
Throughout this specification, the use of the word “facility” and its variations are to be construed as being inclusive of warehouses, distribution centres, retail stores, supermarkets, hypermarkets, grocery stores, factories, manufacturing centres, depots, godowns, and any other environments in which items or packages are required to be simultaneously stored and/or retrieved.
Throughout this specification, the use of the word ‘items’, ‘packages’, and their variations are to construed as being inclusive of various forms of packaging and containers such as cases, cartons, bins, boxes, baskets, totes, trays, etc.
Throughout this specification, the use of the acronym “SSRU” is to be construed as the apparatus for simultaneous storage and retrieval of multiple packages.
Throughout this specification, the use of the word “task” and its variations are to be construed as being inclusive of various material handling and inventory management activities, such as: storing; retrieving; stock replenishment; loading; unloading; inventory counting; person following; transporting inventory; etc. Tasks may be assigned to cart(s), the disclosed apparatus, and/or the disclosed system.
Also, it is noted that embodiments may be described as a process depicted as a flowchart, a flow diagram, a dataflow diagram, a structure diagram, or a block diagram. Although a flowchart may describe the operations as a sequential process, many of the operations may be performed in parallel, concurrently, or simultaneously. In addition, the order of the operations may be re-arranged. A process may be terminated when its operations are completed, but may also have additional steps not included in the figure(s).
An apparatus for simultaneous storage and retrieval of multiple packages is disclosed. As illustrated in Figure 1, an embodiment of the apparatus 200 comprises: a support frame 201; a plurality of manipulators 202, 203, and 204; and an at least a controller that is associated with an at least an autonomous control unit.
The apparatus 200 is mechanically associated with an at least a cart 300 to form a system 100. The apparatus 200 is also electronically associated with the at least one autonomous control unit, which, in turn, communicates with a central server over a network. The central server may be communicatively associated with a warehouse management system or store management system or facility management system.
The central server maintains information of all tasks to be performed in a facility, the locations, and status of all carts in the facility. The central server determines appropriate tasks for the system 100, the apparatus 200, and/or the at least one cart 300 based on a real-time task allocation module and sends commands to the at least one autonomous control unit over the network. The system 100, the apparatus 200, and/or the at least one cart 300 navigates autonomously to a desired shelf location. The at least one autonomous control unit then instructs the system 100, the apparatus 200, and/or the at least one cart 300 to plan and execute the tasks through the plurality of manipulators 202, 203, and 204. The status of the tasks is then updated in the central server.
In another embodiment of the present disclosure, the at least one cart 300 comprises a first plurality of sensors, a camera, a human machine interface 205, a motion control unit, the at least one autonomous control unit, a left motor, a right motor, and a position encoder. The motion control unit comprises a microcontroller and related control circuitry. The first plurality of sensors comprises: an at least a proximity sensor, an at least an inertial measurement unit sensor; and an at least a depth sensor.
The support frame 201 is made of steel or aluminium or metal of appropriate properties to bear the load of the items or packages to be carried. The support frame 201 is mechanically associated with a chassis of the at least one cart 300.
The support frame 201 is open to the left and right sides of the at least one cart 300 to enable the plurality of manipulators 202, 203, and 204 to store a plurality of items or packages 207 (Figure 2) on an at least a shelf or rack 206 (Figure 2), and/or retrieve the plurality of items or packages 207 from the at least one shelf or rack 206, on either side of the Y-axis without any hindrance.
Multiple manipulators may be mechanically associated with the support frame 201 in various configurations. The number of manipulators may also vary in various configurations.
The plurality of manipulators 202, 203, and 204 may be vertically on top of each other facing one side or distributed on both sides. There may be multiple columns and rows facing either side. The height separation between the plurality of manipulators 202, 203, and 204 is set based on the dimensions of the plurality of items or packages 207 on at the least a shelf or rack 206 of the facility.
In yet another embodiment of the present disclosure, as illustrated in Figure 2, the plurality of manipulators 202, 203, and 204 allows simultaneous storage and/or retrieval of multiple items or multiple packages 207 from shelves or racks 206 on both sides.
Figure 3 illustrates an embodiment of a manipulator that is capable of storage and/or retrieval of the plurality of items or packages 207. Each manipulator in the plurality of manipulators 202, 203, and 204 comprises: a platform 406 that holds the plurality of items or packages 207; an at least a sensor; and a plurality of grippers 407.
Each manipulator is configured to move up and down along the Z-axis on a first plurality of linear guides 403. The up and down movement of each manipulator is supported by linear bearings and actuated by a plurality of lead screw mechanisms 405. The plurality of lead screw mechanisms 405 in each manipulator adjusts the manipulator's height to align it with the height of the at least one shelf or rack 206; this ensures ease in storing or retrieving the plurality of items or packages 207 from the at least one shelf or rack 206. Each lead screw mechanism is driven by an electric motor 409 that is controlled by the at least one controller. Each lead screw mechanism may be fixed or manually adjustable.
Upon actuation, the platform 406 is configured to move horizontally along the Y-axis on a second plurality of linear guides 401. The plurality of grippers 407 is mounted on an end-effector and is configured to move on a horizontal plane along the X-axis and the Y-axis. The end-effector is configured to move along the X-axis upon actuation by an electric linear actuator 404. The electric linear actuator 404 is configured to move along the Y-axis on a third plurality of linear guides 402, said third plurality of linear guides 402 being actuated by an electric actuator 410.
All actuators and/or motors are connected to the at least one controller, unless specified otherwise. The at least one controller may be a microcontroller, a System on Chip (SoC), or a single boad computer (SBC).
The platform 406 is made of any suitable material with appropriate properties to bear the load of the plurality of items or packages 207 to be carried.
In yet another embodiment of the present disclosure, the at least one sensor includes an at least a vision sensor 408 that is associated with the end-effector and/or the support frame 201. The at least one vision sensor 408 is disposed in an appropriate location and enables the system 100 and/or the apparatus 200 to gain a clear view of the at least one shelf or rack 206 and the plurality of items or packages 207. The at least one sensor is communicatively associated with the at least one controller and/or the at least one autonomous control unit.
In yet another embodiment of the present disclosure, the at least one sensor includes an at least a proximity sensor to avoid collision with the at least one shelf or rack 206.
In yet another embodiment of the present disclosure, the at least one sensor includes an at least one scanner.
The system 100 and/or the apparatus 200 may stop near the at least one rack or shelf 206 to store and/or retrieve the plurality of items or packages 207, but may not go too near to avoid collision. Therefore, during retrieval and/or storage of the plurality of items or packages 207, the platform 406 moves along the Y-axis on the second plurality of linear guides 401 towards or away from the at least one shelf or rack 206. Similarly, the end-effector can move along the X-axis and the Y-axis to adjust the alignment of the plurality of grippers 407 with the plurality of items or packages 207.
As shown in Figure 4, an embodiment of the at least one autonomous control unit includes: an at least one first processor; a first input/output (I/O) interface; an at least a first memory; an at least a first database; and a communication interface.
In yet another embodiment of the present disclosure, the at least one first processor is configured to fetch and execute computer-readable instructions stored on the at least one first memory.
The first I/O interface may include a variety of hardware interfaces, including, but not limited to: USB ports to communicate with motor controllers; and a second plurality of sensors, such as LIDARs, cameras, and vision sensors, as well as interfaces (for example, web interface, graphical user interface, and/or the like).
The first I/O interface may allow the at least one autonomous control unit to interact with the system 100, the apparatus 200, and/or at least one cart 300. Further, the first I/O interface may enable the at least one autonomous control unit to communicate with the central server. The first I/O interface facilitates multiple communications within a wide variety of networks and protocol types, including wired networks (for example, LAN, cable, etc.), and wireless networks, such as WLAN, cellular, or satellite. The first I/O interface may also include one or more ports for connecting to another server.
The at least one first memory includes any computer-readable medium known in the art, such as static random-access memory (SRAM), dynamic random-access memory (DRAM), read only memory (ROM), erasable programmable ROM, flash memories, hard disks, optical disks, and/or memory cards.
The at least one first database stores data processed, received, and generated by any of the modules within the at least one autonomous control unit.
The at least one autonomous control unit also maintains a 2D or 3D digital map of the facility which is used for autonomous navigation. The map represents a geometrical model of the facility and is created and/or updated periodically and/or on the occurrence of predefined events.
The at least one autonomous control unit also includes modules which perform particular tasks or functions. These include modules for: autonomous navigation; shelf recognition; inventory recognition; person recognition; task and event management; and simultaneous storage and/or retrieval.
The autonomous navigation module processes data from the sensors that are associated with the system 100, the apparatus 200, and/or the at least one cart 300 for mapping, localization, path planning, and obstacle avoidance, and sends appropriate velocity commands to the motion control unit. The motion control unit, in turn, drives the motors.
The shelf recognition module identifies the location of the at least one shelf, rack, and/or storage 206, through the sensors that are associated with the system 100, the apparatus 200, and/or the at least one cart 300.
The inventory recognition module identifies the plurality of items or packages 207, or a plurality of stock keeping units, through the sensors that are associated with the system 100, the apparatus 200, and/or the at least one cart 300.
The person recognition module identifies users or persons, through the sensors that are associated with the system 100, the apparatus 200, and/or the at least one cart 300.
The task and event management module processes data from one or more modules to manage various tasks assigned to the system 100, the apparatus 200, and/or the at least one cart 300. These tasks are assigned by the central server and comprise various material handling and inventory management activities, such as: storing; retrieving; stock replenishment; loading; unloading; inventory counting; person following; transporting inventory; etc. This module also detects occurrence of various predefined events, such as: empty shelves; low storage density; misplaced or damaged inventory; potential inventory discrepancies; etc., and communicates with the central server.
The simultaneous storage and retrieval module plans and executes storage and retrieval of the plurality of packages or items 207 simultaneously through the plurality of manipulators 202, 203, and 204, and the sensors that are associated with the system 100, the apparatus 200, and/or the at least one cart 300. It sends commands to the motors and/or actuators through the at least one controller.
On reaching the desired location to perform storage and/or retrieval tasks, the module first decides which manipulators would be required to perform the tasks at its current location and whether the manipulators are available or not. If the required manipulators are available for the task, it generates commands for the actuation of the manipulators, which are associated with the at least one controller. The at least one controller, in turn, is electronically associated with the at least one autonomous control unit.
Through the sensors, the simultaneous storage and retrieval module determines its position with respect to the at least one shelf or rack 206 and the plurality of packages or items 207; this ensures proper alignment to execute the storage and/or retrieval task. Finally, it checks whether the plurality of packages or items 207 has been stored and/or retrieved successfully, and updates the task and event management module.
If the manipulators are not available to perform the task, for any reason, the simultaneous storage and retrieval module informs the task and event management module and aborts the task.
The components of the central server shall now be explained. An embodiment of the central server comprises: a fleet management module; a facility management module; a task management module; and a system administration module. In other embodiments, the central server may also comprise: an at least a second processor; a second input/output interface; an at least a second memory; a communication module; a location identification module; an inventory management module; and an at least a second database.
The fleet management module is configured to perform functions related to setup, configuration, operation, tracking, and remote management of a fleet of carts.
The facility management module is configured to maintain all details related to the facility in which the carts, the apparatus 200, and/or the system 100 are operating, such as floor plans, 2D and/or 3D maps, geometric mode, locations, zones, areas, routes, traffic rules, speed limits, etc.
The task management module pulls tasks from an enterprise resource planning, store and/or warehouse management system through the communication interface. Tasks comprise various material handling and inventory management activities, such as: storing; retrieving; stock replenishment; loading; unloading; inventory counting; person following; transporting inventory; etc.
The task management module is configured to allocate tasks to carts, the system 100, and/or the apparatus 200 in an optimal manner; this ensures that the number of carts and time required to complete the tasks are minimized and productivity and/or throughput is maximized. One way this is achieved is by grouping all tasks at a specific shelf or location, whether storage and/or retrieval, and allocating them to the nearest cart so that all the tasks in that location are completed by one cart in the least possible time.
While doing so, the number of manipulators, their configuration, and their current state are taken into consideration. If there is additional free capacity, more tasks are allocated in adjacent shelves to the same cart till it is full. This way, more tasks are completed with less number of carts, leading to higher productivity and throughput. This is especially beneficial in areas with fast moving items.
In yet another embodiment of the present disclosure, the task management module groups all retrieval or picking tasks pertaining to a large single order with multiple items or lines and assigns it to one cart so that the complete order can be shipped together in the most efficient way.
In yet another embodiment of the present disclosure, the task management module groups all storage or put away tasks in a particular area or aisle and assigns them to one or more carts.
In yet another embodiment of the present disclosure, the task management module groups all retrieval or picking tasks in a particular area or aisle and assigns them to one or more carts.
In yet another embodiment of the present disclosure, the task management module groups all stock replenishment tasks and assigns them to one or more carts so that packages can be retrieved from one location and stored in another.
In yet another embodiment of the present disclosure, the task management module groups all inventory counting or audit tasks in a particular area, which are assigned to one cart at a time when there is less to no other activity and/or on detecting any specific event indicating potential inventory discrepancies.
In yet another embodiment of the present disclosure, the task management module comprises a machine learning module to constantly learn and improve the task allocations.
The above modules comprise a graphical user interface for supervisors or users to configure, update, and/or monitor their functioning.
Figure 5 illustrates an embodiment of a system comprising a host ERP or store or warehouse management system. As illustrated in Figure 5, the system comprises a host ERP or store or warehouse management system, which sends tasks to the central server.
The central server processes these tasks and executes them through a plurality of carts, systems 100, and users with user devices, over a network.
It may be understood that the central server may also be implemented across a variety of computing systems, such as a laptop computer, a desktop computer, a notebook, a workstation, a mainframe computer, a server, a network server, and the like.
Further, it will also be understood that the central server may comprise a warehouse management system, which is accessed by multiple users through user devices. Alternately, the warehouse management system may also reside on the user devices.
Examples of the user devices include, but are not limited to, desktop computers, laptop computers, mobile phones, smart phones, tablets, phablets, and smart watches. The warehouse management system implemented on the user device is communicatively associated with the central server.
Figure 6 illustrates a flowchart of a process for simultaneous storage and retrieval of multiple packages 500. At step 501, the central server assigns storage and/or retrieval tasks to the system 100, the apparatus 200, and/or the at least one cart 300. The task details comprising package identification, whether to store or retrieve, and the physical location for storage and/or retrieval, are received and processed in the at least one autonomous control unit.
In yet another embodiment of the present disclosure, the task details are displayed through the human machine interface 205.
At step 502, the at least one autonomous control unit navigates the system 100, the apparatus 200, and/or the at least one cart 300 to the at least one shelf or rack 206 where the plurality of packages or items 207 need to be stored and/or retrieved, while avoiding obstacles.
In yet another embodiment of the present disclosure, the at least one autonomous control unit is configured to perform path planning, localization, and obstacle avoidance in an autonomous mode. The at least one autonomous control unit navigates the apparatus 200 through 2D or 3D maps of the facility created earlier.
At step 503, after the system 100, the apparatus 200, and/or the at least one cart 300 reaches the location of the at least one shelf or rack 206, the location is verified by reading the identification tags or labels on the at least one shelf or rack 206, through the at least a vision sensor 408 and/or the at least a scanner. The manipulators that are required to perform the tasks are determined, following which the availability of said manipulators is also determined.
At step 504, the tasks are assigned to the determined and available manipulators to store and/or retrieve the plurality of packages or items 207 simultaneously. Commands are generated for the actuators of the manipulators, which are associated with the at least one controller. The at least one controller, in turn, is electronically associated with the at least one autonomous control unit.
At step 506, package verification is performed to determine whether the plurality of packages or items 207 to be retrieved is the correct ones or not.
At step 507, the locations where the plurality of packages or items 207 is to be stored and/or retrieved are checked to determine whether they are empty or not. This is done by reading the identification tags or labels on the at least one shelf or rack 206 and/or the plurality of packages or items 207, through the at least one vision sensor 408 and/or the at least one scanner. If the checks fail, the central server is updated accordingly, at step 510. If the checks are positive, the tasks are completed by the determined and available manipulators, at steps 508 and 509, and the central server is updated, at step 510.
If no more tasks are assigned to the system 100, the apparatus 200, and/or the at least one cart 300, it is instructed to go to a waiting area and wait for further work to be assigned, at steps 511 and 512.
In yet another embodiment of the present disclosure, the waiting area is equipped with battery charging stations.
In yet another embodiment of the present disclosure, separate pickup and drop areas are designated, which are equipped with conveyors and/or racks for the carts to pickup and/or drop packages.
The disclosed system 100 and the apparatus 200 increase the productivity and throughput of storage and retrieval operations in facilities, by enabling storage and/or retrieval of multiple packages at the same.
More tasks can now be completed in less time and with fewer resources. Further, the disclosed system 100 and the apparatus 200 also reduce the labour required and enable contactless handling of inventory, which is a crucial requirement in the backdrop of pandemics, such as the Covid-19 pandemic.
It will be apparent to a person skilled in the art that the above description is for illustrative purposes only and should not be considered as limiting. Various modifications, additions, alterations and improvements without deviating from the spirit and the scope of the disclosure may be made by a person skilled in the art. Such modifications, additions, alterations and improvements should be construed as being within the scope of this disclosure.
LIST OF REFERENCE NUMERALS
100 – System
200 - Apparatus for Simultaneous Storage and Retrieval of Multiple Packages/Apparatus
201 – Support Frame
202, 203, and 204 – Plurality of Manipulators
205 – Human Machine Interface
206 – At Least a Shelf or Rack
207 – Plurality of Items or Packages
300 – At Least One Cart
401 – Second Plurality of Linear Guides
402 - Third Plurality of Linear Guides
403 - First Plurality of Linear Guides
404 – Electric Linear Actuator
405 – Plurality of Lead Screw Mechanisms
406 – Platform
407 – Plurality of Grippers
408 – At Least One Vision Sensor
409 – Electric Motor
410 – Electric Actuator
500 – Process for Simultaneous Storage and Retrieval of Multiple Packages
501 – Step of Assigning Tasks to the System, the Apparatus and/or the At Least One Cart
502 – Step of the System, the Apparatus, and/or the At Least One Cart Navigating to the At Least One Shelf
503 – Step of Verification of Location, Packages, Tasks, and Status of Manipulators
504 – Step of Assigning Tasks to Individual Manipulators
505 – Step of Determining the Type of Task
506 – Step of Checking if the Packages are Correct or Not
507 – Step of Checking if there is a Place on the At Least One Shelf
508 – Step of Retrieving the Packages from the At Least One Shelf
509 – Step of Storing the Packages on the At Least One Shelf
510 – Step of Updating the Central Server
511 – Step of Checking for Further Tasks
512 – Step of Going to a Waiting Area