Interchangeable automated mobile robots with a plurality of operating modes configuring a plurality of different robot task capabilities

Abstract

A system and method for managing a plurality of automated mobile robots within automated mobile robot storage and retrieval system is provided, which repurposes one or more automated mobile robots operating within the automated inventory management system to perform a plurality of tasks across multiple different areas of an automated store. The same mobile robot is enabled to move horizontally and vertically in a multi-level storage structure, operate in an order fulfillment mode retrieving order totes from an automated fulfillment section and delivering the order totes to the delivery section, operate in a replenishment mode receiving eaches of goods and depositing the eaches of goods in designated storage totes, and operate in a delivery mode receiving delivery bundles and transporting the delivery bundles to designated locations at the transfer station.

What is claimed is: 
     
         1 . An automated store, comprising:
 a storage section with storage shelves configured to store totes, the totes comprising sub-totes configured to store different units of inventory;   a workstation configured for defragmentation of the totes;   a plurality of mobile robots configured to transport totes between the storage section and the workstation; and   a central controller comprising one or more processors configured to implement a defragmentation mode to:
 direct mobile robots of the plurality of mobile robots to transport a first tote and one or more second totes from the storage section to the workstation, and 
 direct consolidation of sub-totes at the workstation by transferring the sub-totes between the first tote and the one or more second totes until the first tote is empty or contains all empty sub-totes. 
   
     
     
         2 . The automated store of  claim 1 , wherein the one or more processors of the central controller are further configured to direct a first subgroup of the mobile robots to return the one or more second totes to the storage section after consolidation of the sub-totes into the one or more second totes. 
     
     
         3 . The automated store of  claim 1 , wherein the one or more processors of the central controller are further configured to transfer the empty first tote to a replenishment station where additional sub-totes are stocked into the first tote. 
     
     
         4 . The automated store of  claim 1 , wherein the workstation is further configured as a replenishment station, receiving inventory newly arrived at the automated store. 
     
     
         5 . The automated store of  claim 4 , wherein the one or more processors of the central controller are further configured to replenish the newly arrived inventory into the empty first tote. 
     
     
         6 . The automated store of  claim 5 , wherein the one or more processors of the central controller are further configured to direct a second subgroup of the mobile robots to return the first sub-tote, replenished with the newly arrived inventory, to the storage section. 
     
     
         7 . The automated store of  claim 1 , wherein the one or more second totes comprise a plurality of totes, each positioned at the workstation by a mobile robot. 
     
     
         8 . The automated store of  claim 1 , further comprising a transfer robot at the workstation configured to transfer sub-totes from the first tote to the one or more second totes under the direction of the central controller. 
     
     
         9 . The automated store of  claim 8 , wherein the transfer robot comprises a Cartesian moving on rails over and between the first tote and the one or more second totes. 
     
     
         10 . The automated store of  claim 8 , wherein the transfer robot comprises an articulated arm robot. 
     
     
         11 . An automated store, comprising:
 a storage section with storage shelves configured to store totes, the totes comprising sub-totes configured to store different units of inventory;   a plurality of mobile robots configured to transport totes to and from the storage section; and   a central controller comprising one or more processors configured to implement a plurality of modes, the plurality of modes comprising:
 a replenishment mode wherein the one or more processors of the central controller direct the transfer of inventory newly received at the automated store into the totes, and storage of the totes with the newly received inventory in the storage section; 
 an order fulfillment mode wherein the one or more processors of the central controller direct the transfer of inventory from totes comprising product totes to totes comprising order totes to satisfy inventory orders; 
 a delivery mode wherein the one or more processors of the central controller direct the transfer of the order totes including inventory satisfying inventory orders to a delivery location for pickup or delivery of the inventory order; and 
 a defragmentation mode wherein the one or more processors of the central controller:
 direct mobile robots of the plurality of mobile robots to transport a first tote and one or more second totes from the storage section to the third workstation, and 
 direct consolidation of sub-totes at the workstation by transferring the sub-totes between the first tote and the one or more second totes until the first tote is empty or contains all empty sub-totes. 
 
   
     
     
         12 . The automated store of  claim 11 , wherein, in the replenishment mode, the one or more processors of the central controller further direct the transfer of customer-returned inventory into the totes, and storage of the totes with the returned inventory in the storage section. 
     
     
         13 . The automated store of  claim 11 , wherein the defragmentation mode is prioritized below the replenishment mode, the order fulfillment mode and the delivery mode, such that the defragmentation mode when mobile robots are not needed to perform the replenishment mode, the order fulfillment mode and the delivery mode. 
     
     
         14 . The automated store of  claim 11 , wherein the one or more processors of the central controller are further configured to direct a first subgroup of the mobile robots to return the one or more second totes to the storage section after consolidation of the sub-totes into the one or more second totes. 
     
     
         15 . The automated store of  claim 11 , wherein the one or more processors of the central controller are further configured to transfer the empty first tote to a workstation for use in implementing the replenishment mode. 
     
     
         16 . The automated store of  claim 11 , wherein the one or more processors of the central controller are further configured to transfer the empty first tote to a workstation for use as an order tote in implementing the order fulfillment mode. 
     
     
         17 . The automated store of  claim 11 , wherein the replenishment mode is implemented at a same workstation as the defragmentation mode. 
     
     
         18 . An automated store, comprising:
 a storage section with storage shelves configured to store totes, the totes comprising sub-totes configured to store different units of inventory;   a workstation;   a plurality of mobile robots configured to transport totes between the storage section and the workstation; and   a central controller comprising one or more processors configured to implement a replenishment mode at the workstation wherein the one or more processors of the central controller:
 direct mobile robots of the plurality of mobile robots to transport totes to the workstation, 
 direct the transfer of inventory returned by customers to the automated store into the totes, and 
 direct the mobile robots to store the totes with returned inventory into the storage section. 
   
     
     
         19 . The automated store of  claim 18 , wherein the returned inventory is received at the automated store at a delivery section for pickup and delivery of ordered inventory to customers, the one or more processors of the central controller directing transfer by the mobile robots of the returned inventory from the delivery section to the workstation. 
     
     
         20 . The automated store of  claim 18 , wherein the workstation comprises a first workstation, the automated store further comprising a second workstation, and further comprising a defragmentation mode wherein the one or more processors of the central controller:
 direct mobile robots of the plurality of mobile robots to transport a first tote and one or more second totes from the storage section to the third workstation, and   direct consolidation of sub-totes at the workstation by transferring the sub-totes between the first tote and the one or more second totes until the first tote is empty or contains all empty sub-totes.   
     
     
         21 . The automated store of  claim 20 , wherein the one or more processors of the central controller direct transfer of the first empty tote after the defragmentation mode to the first workstation for the replenishment of returned inventory into the first tote. 
     
     
         22 . The automated store of  claim 18 , wherein the workstation is further configured for decanting of new inventory into the totes.