System and method for warehouse picking using tote containers

Abstract

A parent tote container is segmented into smaller, child tote containers. Each of the child tote containers includes products that are commonly sold together and are removed from the tote containers at picker stations with the same type of picker mechanism. Items are moved from the child tote containers to a customer order tote container at a picker station.

1 . A system for use in fulfilling customer orders, the system comprising:
 a parent tote container, the parent tote container being divided into or holding multiple child tote containers, each of the child tote containers configured to hold products;   a customer order tote container, the customer order tote container utilized to receive items in fulfillment of a customer order;   a first robotic picker station, wherein the first robotic picker station comprises a first product retrieval mechanism of a first type, the first robotic picker station being configured to move first selected products that are in the customer order from the parent tote container to the customer order tote container;   a second robotic picker station, wherein the second robotic picker station comprises a second product retrieval mechanism of a second type, wherein the second type is different from the first type;   a control circuit coupled to the first robotic picker station and the second robotic picker station, the control circuit configured to:   receive a customer order that indicates fulfillment products desired to be purchased by a customer;   electronically instruct that the parent tote container and the customer order tote container be moved to the first robotic picker station;   electronically instruct the first robotic picker station to move first selected ones of the fulfillment products from the customer order that require use the first product retrieval mechanism from the parent tote container to the customer order tote container;   wherein the selection of products in the child tote containers of the parent tote container is determined first by selecting candidate products that can be picked at the first picker robotic picker station and not at the second robotic picker station, and from the candidate products, products that are typically sold together.   
     
     
         2 . The system of  claim 1 , wherein the first product retrieval mechanism and the second product retrieval mechanism are a suction mechanism or include mechanical fingers. 
     
     
         3 . The system of  claim 2 , wherein the first product retrieval mechanism and the second product retrieval mechanism depend upon a type of packaging and the type of packaging is glass, cylinder, bag, or bottle. 
     
     
         4 . The system of  claim 2 , wherein the first product retrieval mechanism and the second product retrieval mechanism depend upon other physical characteristics of the product, and the other physical characteristics of the product are that the product includes a pull-tab or the product does not include a pull-tab. 
     
     
         5 . The system of  claim 1 , wherein the products that are sold together dynamically change over time. 
     
     
         6 . The system of  claim 1 , wherein the first robotic picker station and the second robotic picker station are disposed in a warehouse. 
     
     
         7 . The system of  claim 1 , wherein an automated vehicle moves the parent tote container and the customer tote container from the first robotic picker station to the second robotic picker station. 
     
     
         8 . The system of  claim 7 , wherein the automated vehicle independently navigates from the first robotic picker station to the second robotic picker station. 
     
     
         9 . The system of  claim 7 , wherein the automated vehicle is an automated ground vehicle or an aerial drone. 
     
     
         10 . The system of  claim 1 , wherein a conveyor belt moves the parent tote container and the customer tote container from the first robotic picker station to the second robotic picker station. 
     
     
         11 . A method for fulfilling customer orders, the method comprising:
 providing a parent tote container, the parent tote container being divided into or holding multiple child tote containers, each of the child tote containers configured to hold products that are typically sold together and require the same product retrieval mechanism;   providing a customer order tote container, the customer order tote container utilized to receive items in fulfillment of a customer order;   providing a first robotic picker station, wherein the first robotic picker station comprises a first product retrieval mechanism of a first type, the first robotic picker station being configured to move first selected products that are in the customer order from the parent tote container to the customer order tote container;   providing a second robotic picker station, wherein the second robotic picker station comprises a second product retrieval mechanism of a second type, the second robotic picker station being configured to move second selected products that are in the customer order from the parent tote container to the customer order tote container, wherein the second type is different from the first type;   at a control circuit, receiving a customer order that indicates fulfillment products desired to be purchased by a customer;   by the control circuit, electronically instructing that the parent tote container and the customer order tote container be moved to the first robotic picker station,   by the control circuit, electronically instructing the first robotic picker station to move first selected ones of the fulfillment products from the customer order that require use the first product retrieval mechanism from the parent tote container to the customer order tote container;   wherein the selection of products in the child tote containers of the parent tote container is determined first by selecting candidate products that can be picked at the first picker robotic picker station and not at the second robotic picker station, and from the candidate products, products that are typically sold together.   
     
     
         12 . The method of  claim 11 , wherein the first product retrieval mechanism and the second product retrieval mechanism are a suction mechanism or include mechanical fingers. 
     
     
         13 . The method of  claim 12 , wherein the first product retrieval mechanism and the second product retrieval mechanism depend upon a type of packaging and the type of packaging is glass, cylinder, bag, or bottle. 
     
     
         14 . The method of  claim 12 , wherein the first product retrieval mechanism and the second product retrieval mechanism depend upon other physical characteristics of the product, and the other physical characteristics of the product are that the product includes a pull-tab or the product does not include a pull-tab. 
     
     
         15 . The method of  claim 11 , wherein the products that are sold together dynamically change over time. 
     
     
         16 . The method of  claim 11 , wherein the first robotic picker station and the second robotic picker station are disposed in a warehouse. 
     
     
         17 . The method of  claim 11 , wherein an automated vehicle moves the parent tote container and the customer tote container from the first robotic picker station to the second robotic picker station. 
     
     
         18 . The method of  claim 17 , wherein the automated vehicle independently navigates from the first robotic picker station to the second robotic picker station. 
     
     
         19 . The method of  claim 17 , wherein the automated vehicle is an automated ground vehicle or an aerial drone. 
     
     
         20 . The method of  claim 11 , wherein a conveyor belt moves the parent tote container and the customer tote container from the first robotic picker station to the second robotic picker station.