How Robots and Mobile Shelves Fulfill Orders in Warehouses

Target's patent describes an automated warehouse system where mobile robots bring shelves and shipping containers to a central robot that picks items directly into orders, all without human hands.

What it covers

The patent describes an order fulfillment system that uses robots to move inventory and assemble orders. A control system, upon receiving an order, directs a "first mobile robot" to pick up a "mobile storage unit" (like a portable shelf) containing the desired item (a "sellable unit"). Simultaneously, a "second mobile robot" brings an "outbound container" (like a shipping box) to a "robotic picking cell." The key mechanism is that a "picking robot" within this cell transfers the item from the mobile storage unit directly into the outbound container while both the storage unit and the container remain engaged with their respective mobile robots. For example, if you order a specific toy, a robot brings the shelf with the toy, another robot brings your shipping box, and a third robot picks the toy from the shelf into your box.

What it doesn't cover

• —Systems where items are picked by humans instead of a robotic picking cell.
• —Systems where the mobile storage unit or outbound container are detached from their respective mobile robots before the picking robot transfers the item.
• —Warehouses where mobile storage units contain multiple different types of sellable units, as each unit must contain 'one or more of a single type'.
• —Systems that do not use separate mobile robots for transporting the mobile storage units and the outbound containers.
• —Systems without a 'dense inventory storage system' where mobile storage units are consolidated in an area.

The clever bit

The novelty lies in the specific choreography: the mobile storage unit and the outbound container are both brought to the picking robot by their own dedicated mobile robots, and the picking occurs while they remain engaged with those robots. This avoids extra steps of docking or transferring units, potentially speeding up the process.

Why it matters

This patent addresses the growing need for speed and efficiency in e-commerce order fulfillment. By automating the movement of inventory and the picking process, companies can reduce labor costs and process orders much faster. This type of system is crucial for retailers like Target to compete with online-only giants and meet customer expectations for rapid delivery.

Real-world examples

• 1.Automated storage and retrieval systems (AS/RS) in e-commerce warehouses
• 2.Kitting operations in distribution centers
• 3.Micro-fulfillment centers
• 4.Target's own fulfillment operations