HYBRID ORDER FULFILLMENT

FIELD OF THE INVENTION

[0001] The present disclosure relates, generally, to methods and systems for order fulfillment and, more particularly, to order fulfillment based on collecting items, for an order, from a plurality of types of product storage regions.

BACKGROUND

[0002] Containers are used to package many different kinds of products. One form of container used in the packaging industry is what is known generically as a “box” and it can be used to hold various products and sometimes other boxes containing products. Some in the packaging industry refer to boxes used to package one or more products as “cartons.” Also in the industry, there are containers/boxes that are known by some as “cases.” In this patent document, including the claims, the words “case,” “cases,” “carton,” “cartons,” “container” and “containers” are used interchangeably to refer to boxes, cartons, trays, envelopes and/or cases and the like that can be used to package any type of items including products and other cartons.

[0003] Cases come in many different configurations and are made from a wide variety of materials. However, many cases are foldable and are formed from a flattened state (commonly called a carton blank). Cases may be made from an assortment of foldable materials, including, but not limited to, cardboard, chipboard, paperboard, corrugated fiberboard, other types of corrugated materials, plastic materials, composite materials and the like and possibly even combinations thereof.

[0004] Cases can be used to fulfil an order initiated by a customer for one or more products by obtaining each product from one or more locations in a storage facility such as a warehouse, loading the product(s) into a case, sealing the loaded case and then shipping the loaded case to a customer.

[0005] However, there are many obstacles to providing efficient methods and systems to fulfil customer orders, particularly where it is desirable to be able to fulfil orders for a large number of customers that may each have orders for a wide range of different kinds and/or numbers of products.

SUMMARY

[0006] According to one aspect of the present invention there is provided an order fulfillment system. The order fulfillment system includes a processor operable to generate carton forming instructions and generate autonomous mobile robot (AMR) instructions. The order fulfillment system further includes a carton forming system configured to receive, from the processor, the carton forming instructions, according to the carton forming instructions, select, from a plurality of magazines, a carton blank and form the carton blank into an erected carton. The order fulfillment system further includes an AMR configured to receive, from the processor, the AMR instructions, according to the AMR instructions, travel to the carton forming system and receive, from the carton forming system, the erected carton, according to the AMR instructions, travel, while holding the erected carton, to a station in a product induction region, receive, at the station, a product into the erected carton and, according to the AMR instructions, travel, while holding the erected carton with the product inside, to a location for further processing of the erected carton.

[0007] According to another aspect of the present invention there is provided an order fulfillment system. The order fulfillment system includes a processor operable to generate shipping container selection instructions and generate autonomous mobile robot (AMR) instructions. The order fulfillment system further includes a shipping container delivery system configured to receive, from the processor, the shipping container selection instructions and, according to the shipping container selection instructions, select, from a plurality of shipping containers, a selected shipping container. The order fulfillment system further includes an AMR configured to receive, from the processor, the AMR instructions, according to the AMR instructions, travel to the shipping container delivery system and receive, from the shipping container delivery system, the selected shipping container, according to the AMR instructions, travel, while holding the selected shipping container, to a station in a product induction region, receive, at the station, a product into the selected shipping container and, according to the AMR instructions, travel, while holding the selected shipping container with the product inside, to a location for further processing of the selected shipping container. [0008] According to a further aspect of the present invention there is provided a carton closing and sealing system. The carton closing and sealing system includes an autonomous mobile robot (AMR), a processor operable to generate AMR instructions, a shipping container delivery system configured and operable to deliver, to the AMR, a shipping container and a sealing apparatus operable such that when the AMR moves through the sealing apparatus with the shipping container thereon the shipping container is sealed. The AMR may be configured and operable to receive, from the processor, the AMR instructions and, according to the AMR instructions, travel to the sealing apparatus and move through the sealing apparatus to seal the shipping container.

[0009] According to a still further aspect of the present invention there is provided an autonomous mobile robot (AMR) for transporting a receptacle. The AMR includes a mobile cart, a control system for controlling operation of the autonomous mobile robot, a first belt having an upper surface, a first lug fastened to the upper surface of the first belt, a second belt having an upper surface and a second lug fastened to the upper surface of the second belt. The control system is operable to control and adjust a position of the first lug relative to the second lug to move between a first position wherein a spacing between the first lug and the second lug is suitable to allow a receptacle to be positioned between, or removed from between, the first lug and the second lug and a second position wherein the spacing between the first lug and the second lug provides for the first lug and the second lug to engage side surfaces of the receptacle to secure the receptacle between the first lug and the second lug.

[0010] According to an even further aspect of the present invention there is provided an autonomous mobile robot (AMR) for transporting a receptacle. The AMR includes a mobile cart, a control system for controlling operation of the autonomous mobile robot and a receptacle securement mechanism operable to releasably secure a receptacle to the mobile cart during movement in a warehouse, when the receptacle carries at least one product in a product order and when the receptacle is empty of any products. The control system is operable to control and adjust the operation of the receptacle securement mechanism between a first state in which the shipping container is secured to the mobile cart and can be moved within the warehouse when the receptacle is both carrying at least one product in a product order and when the receptacle is empty of any products and a second state wherein the receptacle can be removed from the mobile cart.

[0011] According to an even further aspect of the present invention there is provided a product unloading system. The product unloading system includes a product rack for storing products. The product rack includes a plurality of storage levels for storing the products thereon, the plurality of storage levels spaced apart from each other and arranged vertically within the product rack. The product rack further includes a plurality of raised platforms configured for travel of an autonomous mobile robot (AMR) thereon, each one of the plurality of raised platforms positioned proximate to a respective one of the plurality of storage levels. The product unloading system further includes an elevator system comprising an elevating platform for lifting the AMR between a ground level and the plurality of raised platforms. The product unloading system further includes a product retrieval robot for retrieving a product from a storage level of the plurality of storage levels and unloading the product onto a receptacle held by the AMR at a corresponding one of the plurality of storage levels.

[0012] According to an even further aspect of the present invention there is provided an fulfilment system. The order fulfillment system includes a processor operable to generate carton forming instructions, generate product retrieval instructions, and generate autonomous mobile robot (AMR) instructions. The order fulfillment system further includes a carton forming system configured to receive, from the processor, the carton forming instructions, according to the carton forming instructions, select, from a plurality of magazines, a carton blank and form the carton blank into an erected carton. The order fulfillment system further includes a product retrieval robot configured to receive, from the processor, the product retrieval instructions, and retrieve, according to the product retrieval instructions, a product from a product rack in a product storage location. The order fulfillment system further includes an AMR configured to receive, from the processor, the AMR instructions, according to the AMR instructions, travel to the carton forming system and receive, from the carton forming system, the erected carton, according to the AMR instructions, travel, while holding the erected carton, to the product rack, receive, at the product rack, the product from the product retrieval robot into the erected carton, and according to the AMR instructions, travel, while holding the erected carton with the product inside, to a location for further processing of the erected carton. [0013] According to an even further aspect of the present invention there is provided a fulfillment system. The fulfillment system includes a processor operable to generate receptacle delivery instructions and generate autonomous mobile robot (AMR) instructions. The fulfillment system also includes a carton delivery system configured to receive, from the processor, the receptacle delivery instructions and, according to the receptacle delivery instructions, select, from a selection of receptacles a chosen receptacle for delivery. The fulfillment system includes an AMR configured to receive, from the processor, the AMR instructions, according to the AMR instructions, travel to a receptacle delivery system and receive, from the receptacle delivery system, said chosen receptacle, according to the AMR instructions, travel, while holding the chosen receptacle, to a station in a product induction region, receive, at the station, a product into the chosen receptacle and according to the AMR instructions, travel, while holding the chosen receptacle with the product inside, to a location for further processing of the chosen receptacle.

[0014] According to an even further aspect of the present invention there is provided a fulfillment system. The fulfillment system includes a processor operable to generate shipping container selection instructions and generate autonomous mobile robot (AMR) instructions. The fulfillment system also includes a shipping container delivery system configured to receive, from the processor, the shipping container selection instructions and, according to the shipping container selection instructions, select, from a plurality of shipping containers, a selected shipping container. The fulfillment system further includes an AMR configured to receive, from the processor, the AMR instructions, according to the AMR instructions, travel to the shipping container delivery system and receive, from the shipping container delivery system, the selected shipping container, according to the AMR instructions, travel, while holding the selected shipping container, to a station in a product induction region, wherein the product induction region includes a product tower, the product tower including a plurality of compartments for storing products, and wherein at least one of the plurality of compartments includes one or more products, the one or more products corresponding with at least one stock keeping unit, receive, at the station, a first product into the selected shipping container, according to the AMR instructions, travel, while holding the selected shipping container, to a given product storage rack in a storage region, wherein the storage region includes a plurality of product storage racks that store products in pallets, receive, at the given product storage rack, a second product into the selected shipping container and according to the AMR instructions, travel, while holding the selected shipping container with the first product and the second product inside, to a location for further processing of the selected shipping container.

[0015] According to an even further aspect of the present invention there is provided a fulfillment system. The fulfillment system includes a processor operable to generate carton forming instructions, generate product retrieval instructions and generate autonomous mobile robot (AMR) instructions. The fulfillment system also includes a carton forming system configured to receive, from the processor, the carton forming instructions, according to the carton forming instructions, select, from a plurality of available carton blanks, a carton blank and form the carton blank into an erected carton. The fulfillment system also includes a product retrieval robot configured to receive, from the processor, the product retrieval instructions and retrieve, according to the product retrieval instructions, a product in a product storage location. The fulfillment system further includes a reusable container, the reusable container including a plurality of products used to fulfil a plurality of orders, the reusable container becoming an empty reusable container upon the plurality of products being removed from the reusable container to fulfil the plurality of orders and an AMR configured to receive, from the processor, the AMR instructions, according to the AMR instructions, travel to the carton forming system and receive, from the carton forming system, the erected carton, according to the AMR instructions, travel, while holding the erected carton, to a product loading station, receive, at the product loading station, the product into the erected carton, according to the AMR instructions, travel, while holding the erected carton with the product inside, to a location for further processing of the erected carton, wherein the further processing of the erected carton includes removal of the erected carton from the AMR, thereafter, according to the AMR instructions, travel and receive, the empty reusable container and according to the AMR instructions, travel, while holding the empty reusable container, to a location for further processing of the empty reusable container.

[0016] According to an even further aspect of the present invention there is provided a fulfillment system. The fulfillment system includes a processor operable to generate shipment container delivery instructions, generate product retrieval instructions and generate autonomous mobile robot (AMR) instructions. The fulfillment system also includes a shipment container delivery system configured to receive, from the processor, the shipment container delivery instructions and according to the shipment container delivery instructions, select, from a plurality of available shipment containers, a shipment container. The fulfillment system also includes a product retrieval robot configured to receive, from the processor, the product retrieval instructions and retrieve, according to the product retrieval instructions, a product in a product storage location. The fulfillment system also includes a reusable container, the reusable container including a plurality of products used to fulfil a plurality of orders, the reusable container becoming an empty reusable container upon the plurality of products being removed from the reusable container to fulfil the plurality of orders. The fulfillment system further includes an AMR configured to receive, from the processor, the AMR instructions, according to the AMR instructions, travel to the shipment container delivery system and receive the shipment container, according to the AMR instructions, travel, while holding the shipment container, to a product loading station, receive, at the product loading station, the product into the shipment container, according to the AMR instructions, travel, while holding the shipment container with the product inside, to a location for further processing of the shipment container, wherein the further processing of the shipment container includes removal of the shipment container from the AMR, thereafter, according to the AMR instructions, travel and receive, the empty reusable container on the AMR and according to the AMR instructions, travel, while holding the empty reusable container, to a location for further processing of the empty reusable container.

[0017] According to an even further aspect of the present invention there is provided a method of receiving products into a fulfillment center. The method includes transmitting instructions to a first autonomous mobile robot (AMR), the instructions causing the first AMR to navigate to a crate retention structure in a first transport trailer, the crate retention structure retaining a crate in which is stored a plurality of a product and transport the crate retention structure to a product induction region at which individual products among the plurality of products may be removed from the crate. The method further includes transmitting instructions to a second AMR, the instructions causing the second AMR to navigate to the crate retention structure in the product induction region, the crate no longer storing the product, transport the crate retention structure to a second transport trailer and navigate away from the second transport trailer without the crate retention structure.

[0018] According to an aspect of the present disclosure, there is provided an autonomous mobile robot for transporting a shipping container. The autonomous mobile robot includes a mobile cart, a control system for controlling operation of the autonomous mobile robot and an outer case mounted to the cart. The outer case includes a vacuum reservoir defining a plurality of apertures, a vacuum pump in pneumatic communication with the vacuum reservoir, the vacuum pump configured to, responsive to an instruction received from the control system, create a negative pressure within the vacuum reservoir and a plurality of suction cups corresponding to the plurality of apertures, the plurality of suction cups mounted to the outer case.

[0019] According to an aspect of the present disclosure, there is provided an outer case for mounting to a mobile cart of an autonomous mobile robot (AMR) for transporting a shipping container, the AMR including a control system for controlling operation of the AMR. The outer case includes a vacuum reservoir defining a plurality of apertures, a vacuum pump in pneumatic communication with the vacuum reservoir, the vacuum pump configured to, responsive to an instruction received from the control system, create a negative pressure within the vacuum reservoir and a plurality of suction cups corresponding to the plurality of apertures, the plurality of suction cups mounted to the outer case.

[0020] According to an aspect of the present disclosure, there is provided an autonomous mobile robot for transporting a shipping container. The autonomous mobile robot includes a base, at least three wheels configured for supporting the base, at least one of the wheels being a drive wheel, the drive wheel being operably connected to a drive motor, a control system for controlling operation of the drive motor to control the movement of the drive wheel and corresponding movement of the base, a vacuum reservoir inter-connected to the base and defining a plurality of openings, a vacuum pump in pneumatic communication with the vacuum reservoir, the vacuum pump configured to, responsive to an instruction received from the control system, create a negative pressure within the vacuum reservoir and a plurality of suction cups corresponding to the plurality of openings, the plurality of suction cups inter-connected to the base.

[0021] According to an aspect of the present disclosure, there is provided a method of fulfilling an order. The method includes moving an autonomous mobile robot to a shipment container loading station, receiving, onto the autonomous mobile robot, an empty shipment container, generating a suction force at each suction cup of at least some of the suction cups of the plurality of suction cups to hold the empty shipment container on the autonomous mobile robot and, while the suction force is being generated at each suction cup of at least some of the suction cups of the plurality of suction cups to hold the shipment container on the autonomous mobile robot, moving the autonomous mobile robot to a goods loading station.

[0022] Other aspects and features of the present invention will become apparent to those of ordinary skill in the art upon review of the following description of specific embodiments of the invention in conjunction with the accompanying figures.

BRIEF DESCRIPTION OF THE DRAWINGS

[0023] In the figures which illustrate by way of example only, embodiments of the present invention,

[0024] FIG. 1 A illustrates, in a top right front perspective view, part of a carton forming system, in accordance with an example embodiment of the present application;

[0025] FIG. IB illustrates, in a schematic flow chart, a power and control sub-system of the part of the carton forming system of FIG. 1 A, in accordance with aspects of the present application;

[0026] FIG. 2 illustrates, in a top right rear perspective view, the carton forming system of FIG. 1A;

[0027] FIG. 3 illustrates, in a top right side perspective view, the carton forming system of FIG. 1A;

[0028] FIG. 4 illustrates, in a front schematic elevation view, the carton forming system of FIG. 1 A, but with several components omitted;

[0029] FIG. 5 illustrates, in a rear schematic elevation view, the carton forming system of FIG. 1 A, but with several components omitted;

[0030] FIG. 6 A illustrates, in a top right perspective view, a magazine sub-system, in accordance with aspects of the present application; [0031] FIG. 6B illustrates, in a top right perspective view, the magazine sub-system of FIG. 6A, but with several components omitted;

[0032] FIG. 6C illustrates, in a right side elevation view, the magazine sub-system of FIG. 6A, but with several components omitted;

[0033] FIG. 6D illustrates, in a top plan view, the magazine sub-system of FIG. 6 A;

[0034] FIG. 7 illustrates, in a right side perspective view, the carton forming system of FIG.

1 A, but with several components omitted to show a blank intake system, two erector heads with movement apparatuses and a folding and sealing apparatus;

[0035] FIG. 8 illustrates, in a top right rear perspective view, components of FIG. 7;

[0036] FIG. 9 illustrates, in a top right front perspective view, components of FIG. 7;

[0037] FIG. 10A illustrates, in a plan view, a blank for a regular slotted case in a generally flattened tubular configuration;

[0038] FIG. 10B illustrates, in front elevation view, the blank for a regular slotted case of FIG. 10 A;

[0039] FIG. 10C illustrates, in a side elevation view, the blank for a regular slotted case of FIG. 10 A;

[0040] FIG. 10D illustrates, in a perspective view, the blank for a regular slotted case of FIG. 10 A;

[0041] FIG. 10E illustrates, in another perspective view, the blank for a regular slotted case of FIG. 10 A;

[0042] FIG. 11 illustrates, in a schematic right perspective view, the blank of FIG. 10A configured in an open configuration;

[0043] FIG. 12 illustrates, in a schematic right perspective view, the blank of FIG. 11 after a step in a sequentially process of turning the blank into an erected carton; [0044] FIG. 13 illustrates, in a schematic right perspective view, the blank of FIG. 12 after a step in a sequential process of turning the blank into an erected carton;

[0045] FIG. 14 illustrates, in a schematic right perspective view, the blank of FIG. 13 after a step in a sequential process of turning the blank into an erected carton;

[0046] FIG. 15 illustrates, in a schematic right perspective view, the blank of FIG. 14 after a step in a sequential process of turning the blank into an erected carton;

[0047] FIG. 16 illustrates, in a schematic right perspective view, the blank of FIG. 15 after a step in a sequential process of turning the blank into an erected carton;

[0048] FIG. 17 illustrates, in a schematic right perspective view, the carton forming system of FIG. 1 A, but showing only a single movement apparatus, erector head and some parts of the folding and sealing apparatus, in a sequential stage of processing the blank of FIG. 10A into an erected carton, in accordance with aspects of the present application;

[0049] FIG. 18 illustrates, in a schematic right perspective view, the carton forming system of FIG. 17 in a sequential stage of processing the blank of FIG. 10A into an erected carton, in accordance with aspects of the present application;

[0050] FIG. 19 illustrates, in a schematic right perspective view, the carton forming system of FIG. 17 in a sequential stage of processing the blank of FIG. 10A into an erected carton, in accordance with aspects of the present application;

[0051] FIG. 20 illustrates, in a schematic right perspective view, the carton forming system of FIG. 17 in a sequential stage of processing the blank of FIG. 10A into an erected carton, in accordance with aspects of the present application;

[0052] FIG. 21 illustrates, in a schematic right perspective view, the carton forming system of FIG. 17 in a sequential stage of processing the blank of FIG. 10A into an erected carton, in accordance with aspects of the present application; [0053] FIG. 22 illustrates, in a schematic right perspective view, the carton forming system of FIG. 17 in a sequential stage of processing the blank of FIG. 10A into an erected carton, in accordance with aspects of the present application;

[0054] FIG. 23 illustrates, in a schematic right perspective view, the carton forming system of FIG. 17 in a sequential stage of processing the blank of FIG. 10A into an erected carton, in accordance with aspects of the present application;

[0055] FIG. 24 illustrates, in a schematic right perspective view, the carton forming system of FIG. 17 in a sequential stage of processing the blank of FIG. 10A into an erected carton, in accordance with aspects of the present application;

[0056] FIG. 25 illustrates, in a schematic right perspective view, the carton forming system of FIG. 17 in a sequential stage of processing the blank of FIG. 10A into an erected carton, in accordance with aspects of the present application;

[0057] FIG. 26 illustrates, in a rear elevation view, components of the carton forming system of FIG. 17;

[0058] FIG. 26 A illustrates, in a schematic perspective view, part of a folding and sealing apparatus of the carton forming system of FIG. 1A;

[0059] FIG. 27 illustrates, in a schematic right perspective view, the carton forming system of FIG. 17 in a sequential stage of processing the blank of FIG. 10A into an erected carton, in accordance with aspects of the present application;

[0060] FIG. 28 illustrates, in a schematic right perspective view, the carton forming system of FIG. 17 in a sequential stage of processing the blank of FIG. 10A into an erected carton, in accordance with aspects of the present application;

[0061] FIG. 29 illustrates, in a schematic right perspective view, the carton forming system of FIG. 17 in a sequential stage of processing the blank of FIG. 10A into an erected carton, in accordance with aspects of the present application; [0062] FIG. 30 shows a top right perspective view of a first embodiment of an erector head, in accordance with aspects of the present application;

[0063] FIG. 31 is a side elevation view of the erector head of FIG. 30;

[0064] FIG. 32 is a bottom right perspective view of the erector head of FIG. 30;

[0065] FIG. 33 is a bottom plan view of the erector head of FIG. 30;

[0066] FIG. 34A is a top right perspective view of a second embodiment of an erector head, in accordance with aspects of the present application;

[0067] FIG. 34B is a right side elevation view of the erector head of FIG. 34A;

[0068] FIG. 35 A illustrates the erector head of FIG. 34 A in a stage of opening a carton blank, in accordance with aspects of the present application;

[0069] FIG. 35B illustrates the erector head of FIG. 34A in another stage of opening a carton blank, in accordance with aspects of the present application;

[0070] FIG. 35C illustrates the erector head of FIG. 34A in a further stage of opening a carton blank, in accordance with aspects of the present application;

[0071] FIG. 36 illustrates the erector head of FIG. 34A and a sealing apparatus in a stage of erecting a carton blank to, thereby, form an erected carton, in accordance with aspects of the present application;

[0072] FIG. 37 illustrates the erector head of FIG. 34A and a sealing apparatus in a stage of erecting a carton blank to, thereby, form an erected carton, in accordance with aspects of the present application;

[0073] FIG. 38 illustrates the erector head of FIG. 34A and a sealing apparatus in a stage of erecting a carton blank to, thereby, form an erected carton, in accordance with aspects of the present application; [0074] FIG. 39 illustrates the erector head of FIG. 34A and a sealing apparatus in a stage of erecting a carton blank to, thereby, form an erected carton, in accordance with aspects of the present application;

[0075] FIG. 40 illustrates the erector head of FIG. 34A and a sealing apparatus in a stage of erecting a carton blank to, thereby, form an erected carton, in accordance with aspects of the present application;

[0076] FIG. 41 illustrates the erector head of FIG. 34A and a sealing apparatus in a stage of erecting a carton blank to, thereby, form an erected carton, in accordance with aspects of the present application;

[0077] FIG. 42 illustrates the erector head of FIG. 34A and a sealing apparatus in a stage of erecting a carton blank to, thereby, form an erected carton, in accordance with aspects of the present application;

[0078] FIG. 43 illustrates the erector head of FIG. 34A and a sealing apparatus in a stage of erecting a carton blank to, thereby, form an erected carton, in accordance with aspects of the present application;

[0079] FIG. 44 illustrates the erector head of FIG. 34A and a sealing apparatus in a stage of erecting a carton blank to, thereby, form an erected carton, in accordance with aspects of the present application;

[0080] FIG. 45 illustrates, in a schematic perspective view, an alternative embodiment of a carton forming system, in accordance with aspects of the present application;

[0081] FIG. 46 illustrates, in a plan view, a carton blank for a tray that may be processed in accordance with aspects of the present application;

[0082] FIG. 47 illustrates, in a perspective view, a carton blank for an over-wrapping regular slotted case (RSC) that may be processed in accordance with aspects of the present application;

[0083] FIG. 48 illustrates, in a perspective view, a carton blank for an over- wrapping regular slotted case (RSC) that may be processed in accordance with aspects of the present application; [0084] FIG. 49 illustrates, in a perspective view, an HSC case that may be formed in accordance with aspects of the present application;

[0085] FIG. 50 illustrates a carton forming system, which is presented as an alternative to the carton forming system of FIG. 1 A, according to an aspect of the present application;

[0086] FIG. 51 illustrates, in a plan view, a carton forming system, which is presented as an alternative to the carton forming system of FIG. 50, according to an aspect of the present application;

[0087] FIG. 52 illustrates, in a schematic plan view, an order fulfillment location, in accordance with aspects of the present application;

[0088] FIG. 53 illustrates, in a top-right perspective view, an example autonomous mobile robot having a cart carrying an outer case, in accordance with aspects of the present application;

[0089] FIG. 53 A illustrates, in a top-right perspective view, the example autonomous mobile robot of FIG. 53 with the addition of a shipping container;

[0090] FIG. 54 illustrates, in a sectional perspective view, the autonomous mobile robot of FIG. 53, in accordance with aspects of the present application;

[0091] FIG. 55 A illustrates, in section view, a portion of the outer case of the autonomous mobile robot of FIG. 53, in accordance with aspects of the present application;

[0092] FIG. 55B illustrates, in section view, a portion of the outer case of the autonomous mobile robot of FIG. 53, in accordance with aspects of the present application;

[0093] FIG. 56 illustrates, in a schematic plan view, a portion of a fulfillment center;

[0094] FIG. 56A illustrates, in a schematic plan view, an embodiment of an order fulfillment center;

[0095] FIG. 57 illustrates example steps in a method of fulfilling an order, in accordance with aspects of the present application; [0096] FIG. 58 illustrates a further example autonomous mobile robot, in accordance with aspects of the present application;

[0097] FIG. 59 illustrates, in a schematic plan view, a carton forming system with a plurality of magazines, the carton forming system of FIG. 59 being an alternate embodiment to the carton forming system of FIG. 1 to 44 with some components of magazines omitted for clarity, in accordance with aspects of the present application;

[0098] FIG. 60 illustrates, in a rear right side perspective view, the carton forming system of FIG. 59, in accordance with aspects of the present application;

[0099] FIG. 60A illustrates, in an enlarged view, a portion of the carton forming system of FIG. 60 with additional components illustrated, in accordance with aspects of the present application;

[0100] FIG. 61 illustrates, in a rear left side perspective view, the carton forming system of FIG. 59, in accordance with aspects of the present application;

[0101] FIG. 62 illustrates, in a rear perspective view, the carton forming system of FIG. 59, in accordance with aspects of the present application;

[0102] FIG. 63 illustrates, in a rear perspective view, part of the carton forming system of FIG. 59, in accordance with aspects of the present application;

[0103] FIG. 64 illustrates, as a schematic diagram, an order fulfillment system, in accordance with aspects of the present application;

[0104] FIG. 65 illustrates a sample label that may be generated and used in the system of FIG. 64, in accordance with aspects of the present application;

[0105] FIG. 66 illustrates another sample label that may be generated and used in the system of FIG. 64, in accordance with aspects of the present application;

[0106] FIG. 67 illustrates a sample of a case packing diagram that may be generated and used in the system of FIG. 64; [0107] FIG. 68 illustrates, in a front left perspective view, an example arrangement for a case top sealer, in accordance with aspects of the present application;

[0108] FIG. 69 illustrates a schematic plan view of an order fulfilment location, in accordance with an example embodiment of the present application;

[0109] FIG. 70 illustrates a perspective view of part of a product unloading system of the order fulfilment center of FIG. 69, in accordance with an example embodiment of the present application;

[0110] FIG. 71 illustrates a plan schematic view of an embodiment of the order fulfillment center of FIG. 69, in accordance with an example embodiment of the present application;

[0111] FIG. 72 illustrates a perspective view of a plurality of case induction stations of the order fulfilment center FIG. 69;

[0112] FIG. 73 illustrates a perspective view of an order verification, case sealing and labelling station of the order fulfilment center of FIG. 69;

[0113] FIG. 74 illustrates a perspective view of a routing staging station of the order fulfilment center of FIG. 69;

[0114] FIG. 75 illustrates a perspective view of a tower that may be used to store products, in accordance with an example embodiment of the present application;

[0115] FIG. 76 illustrates, in a schematic plan view, an order fulfilment location that may be seen as a hybrid of the order fulfilment center 5200 of FIG. 52 and the order fulfilment center 6900 of FIG. 69, in accordance with an example embodiment of the present application;

[0116] FIG. 76A illustrates, in a schematic plan view, the order fulfilment location of FIG. 76 with additional reference to a plurality of zones, in accordance with an example embodiment of the present application; [0117] FIG. 77 illustrates a robotic picker arm which may be used in depalletization processes involving a pallet, in accordance with an example embodiment of the present application;

[0118] FIG. 78 A illustrates, in a side view, a destrapper-debander end effector, which may be engaged by the robotic picker arm of FIG. 77 for depalletization processes, in accordance with an example embodiment of the present application;

[0119] FIG. 78B illustrates, in a top view, the destrapper-debander end effector of FIG. 78 A;

[0120] FIG. 79 illustrates, in a perspective view, a standardized storage case, in accordance with an example embodiment of the present application;

[0121] FIG. 80 illustrates, in a perspective view, a pallet, the pallet constructed with the standardized storage case of FIG. 79 and a standardized pallet base, in accordance with an example embodiment of the present application;

[0122] FIG. 81 illustrates, in a perspective view, a plurality of crates stacked on the autonomous mobile robot of FIG. 53, in accordance with an example embodiment of the present application;

[0123] FIG. 82 A illustrates, in a schematic plan view, an order fulfilment location as an alternative to the order fulfilment center of FIG. 76, in accordance with an example embodiment of the present application;

[0124] FIG. 82B illustrates, in a schematic plan view, an order fulfilment location as an alternative to the order fulfilment center of FIG. 82 A, in accordance with an example embodiment of the present application;

[0125] FIG. 83 illustrates, in a perspective view, a plurality of crates maintained in a structure on the autonomous mobile robot of FIG. 53, in accordance with an example embodiment of the present application; [0126] FIG. 84 illustrates, in a perspective view, a plurality of crates maintained in a further structure on an autonomous mobile robot, in accordance with an example embodiment of the present application;

[0127] FIG. 85 illustrates a layout for a transport trailer, in accordance with an example embodiment of the present application;

[0128] FIG. 86 illustrates a customer order processing matrix, in accordance with an example embodiment of the present application; and

[0129] FIG. 87 illustrates, as a schematic diagram, an order fulfilment center at the center of a network of suppliers of products to be stored at the order fulfilment center, in accordance with an example embodiment of the present application.

DETAILED DESCRIPTION

[0130] The adage “garbage in, garbage out” (often abbreviated as GIGO) is a common phrase used in the field of computer science and information technology. It conveys a simple but important principle: the quality of output or results is determined by the quality of input data.

[0131] In essence, if you feed a computer system or algorithm with inaccurate, incomplete, or low-quality data, you should expect the output or results to be similarly flawed or unreliable. Regardless of how sophisticated the processing capabilities of a system may be, if the input data is flawed, the output will likely be flawed as well.

[0132] This principle holds true for various systems, not just computers. It is also applicable in areas such as decision-making, problem-solving, general information processing and automation. Therefore, it highlights the importance of ensuring that all inputs are accurate, well- structured, and relevant to the problem at hand in order to obtain meaningful and reliable results. Chaos refers to a state of extreme disorder or unpredictability in a system. The automation industry knows from experience that chaos cannot be fully automated. Chaos theory describes complex systems that are highly sensitive to initial conditions, meaning that small changes in the starting state can lead to vastly different outcomes over time. These systems are nonlinear, and their behavior is difficult to predict with precision. [0133] Automation involves the use of machines, computers, and/or algorithms to perform tasks without human intervention. Automation relies on established rules, algorithms, or processes to execute tasks efficiently and consistently. The inherent unpredictability and sensitivity to initial conditions in chaotic systems make them challenging to automate effectively. Since automation relies on predictability and well-defined processes, it may be seen as difficult to create algorithms or machines that can handle chaotic situations accurately.

[0134] In order fulfilment, and more particularly, order fulfilment based on collecting items for an order from a plurality of types of product storage regions, there may be various challenges to providing efficient methods and systems to fulfil orders. There may be challenges in automating the consolidation of products required to fulfil an order, particularly given the number of different products a fulfilment center may store and manage. For example, some fulfilment centers may store and manage millions of different products for order fulfilment. Additionally, there may be little no control as to how products to be stored in the fulfilment center arrive to the fulfilment center.

[0135] FIGS. 1A, IB, 2 and 3 illustrate, in various forms and from various angles, an example of a carton/case forming system 100 that may be used as part of a product order fulfillment system. The carton forming system 100 may include a frame 109. The frame 109 may have, integrated with it, a series of panels 103 that may be made from a plastic or glass and that may or may not be transparent or semi-transparent. One or more of the panels 103 may be configured to operate as a hinged door so that interior portions of the carton forming system 100 can be accessed. The carton forming system 100 may also include a magazine 110 adapted to receive, hold and move a plurality of carton blanks 111 while the carton blanks 111 are in a substantially flat orientation. The carton forming system 100 may include at least a first erector head 120a and a second erector head 120b for retrieving carton blanks from the magazine 110. The erector heads 120a, 120b may pick up the carton blanks 111 from the magazine 110 and then manipulate the carton blanks 111 in such a way that, with the assistance of other components of the carton forming system 100, the carton blanks 111 are transformed into erected cartons.

[0136] The erector heads 120a, 120b may be moved by a movement sub-system. The movement sub-system may include one or more movement apparatuses. For example, the first erector head 120a may be mounted to and moved by a first moving apparatus 115a. The second erector head 120b may be mounted to and moved by a second moving apparatus 115b. In some embodiments, only a single erector head and movement apparatus may be provided, but this may result in a lower production rate of erected cartons compared to when multiple, particularly two or possibly more, movement apparatuses and erector heads are provided, as illustrated in the drawings.

[0137] The carton forming system 100 may also include a folding and sealing apparatus 130, which may be configured to fold one or more flaps of each carton blank and provide for sealing of one or more flaps as part of the process in forming fully erected cartons. In co-operation with the erector heads 120a, 120b, the folding and sealing apparatus 130 may be configured to handle in alternating sequence, the carton blanks 111 carried by both the first erector head 120a and the second erector head 120b. The carton forming system 100 may also include a carton discharge conveyor 117 for receiving and moving away the carton blanks 111 once the carton blanks 111 have been fully erected.

[0138] The structural/mechanical components of the carton forming system 100 may be made from any suitable materials. For example, frame members, and many of the parts that make up the erector heads 120a, 120b, the moving apparatuses 115a, 115b, many of the components and parts that make up the folding and sealing apparatus 130 and the magazine 110, may be made of steel or aluminum, or any other suitable materials. Aluminum is particularly suitable for most parts. However, plates that hold the suction cups on the erector head and flanges that mount on gearbox shafts can be made from stainless steel for strength and hardness. Parts and components may be attached together in conventional ways such as for example by bolts, screws, welding and the like.

[0139] An example of a scheme for the power and data/communi cation configuration for the carton forming system 100 is illustrated in FIG. IB. The operation of the components of the carton forming system 100, and of the carton forming system 100 as a whole, may be controlled by a programmable logic controller (“PLC”) 132. The PLC 132 may be accessed by a human operator through a Human Machine Interface (HMI) module 133 secured to the frame 109. The HMI module 133 may be in electronic communication with the PLC 132. The PLC 132 may be any suitable PLC and may, for example, include a unit chosen from the Logix 5000 series devices made by Allen-Bradley/Rockwell Automation, such as the ControlLogix 5561 device. The HMI module 133 may be a Panelview part number 2711P-T15C4D1 module also made by Allen- Bradley/Rockwell Automation. It should be noted that not all of the sensors, motors, servo motors, drives, vacuums, vacuum generators and vacuum cups described hereinafter are specifically identified in FIG. IB.

[0140] Electrical power can be supplied to the PLC 132/HMI 133 and to all the various servo motors and DC motors that are described further herein. Compressed/pressurized air can also be supplied to the vacuum generators and pneumatic actuators through valve devices such as solenoid valves that are controlled by the PLC 132, all as described further herein. Servo motors may be connected to, and in communication with, servo drives that are in communication with and controlled by the PLC 132. Similarly, DC motors may be connected to DC motor drives that are in communication with, and controlled by, the PLC 132; again all as described further herein. Additionally, various other sensors are in communication with the PLC 132 and may (although not shown) also be supplied with electrical power.

[0141] With reference now to FIG. 10A through to FIG. 10E and 11 A, an example of one kind of tubular carton blank 111 that can be processed by the system 100 to form a regular slotted case (RSC) is disclosed. It should be clear that other kinds of carton blanks, tubular carton blanks and tubular carton blanks of different sizes can be processed by system 100.

[0142] Each carton blank 111 may be generally initially formed and provided in a flattened tubular configuration as shown in FIGS. 10A, 10B, 10C, 10D, 10E. Each carton blank 111 has a height dimension “H”; a length dimension “L”; and a major panel length “Q” (see FIG. 10A). Responsive to the inputting of each of these three dimensions for a given carton blank 111 to be processed by the carton forming system 100, into the PLC 132, the PLC 132 may determine whether the carton forming system 100 can process the given carton blank 111 without the necessity for manual intervention to make an adjustment to one or more components of the carton forming system 100. If the PLC 132 determines that the adjustment can be made without human intervention, the PLC 132 may make the necessary adjustments to positions and/or movements of at least some of the components forming the carton forming system 100, including the path of movement of the erector heads 120a, 120b as the erector heads move and cycle through their processing sequences. 1 [0143] However, in some carton forming systems 100, for some sizes of carton blanks 111, the PLC 132 may determine that human intervention of some kind may facilitate the making of set-up adjustments to the positioning/orientations of at least some of the components of the system 100 to, thereby, enable the carton forming system 100 to process the carton blank 111 and may, accordingly, inform an operator of the carton forming system 100.

[0144] The carton blank 111 may have opposed major panels A and C integrally interconnected to a pair of opposed minor panels B and D to form a generally cuboid shaped blank when opened. An overlap strip of carton blank material may be provided between panel B and panel A that can be sealed by conventional means such as a suitable adhesive, to provide an overlapping seam joint in the vicinity of “P” (see FIG. 10A). This overlap may join the panels A, B, C and D into a continuous blank that is of generally flattened tubular configuration as shown in FIG. 10 A. A number of such carton blanks 111, in a flattened configuration, can be delivered to the vicinity of the carton forming system 100 that may erect the carton blanks 111 into the generally open tubular configuration shown, for example, in FIG. 11.

[0145] Also, as shown in FIGS. 10A-10E and 11, the carton blank 111 may have a first set of upper side major and minor flaps E, H, L, I that are provided on one side of the respective major and minor panels A, B, C, D. A second set of major and minor flaps F, G, K and J are also provided on the opposite, lower/bottom sides of the major and minor panels A, B, C, D. Notably, in other embodiments, cartons having other side panel configurations can be formed. The panels and flaps can be connected to adjacent flaps and/or panels by predetermined fold/crease lines (shown in broken lines). These fold/crease lines may, for example, be formed by a weakened area of material and/or the formation of a crease with a crease forming apparatus. The effect of the fold lines is such that one panel, such as, for example, panel A can be rotated relative to an adjacent panel, such as, for example, panel D or panel B along the fold lines. Flaps may also fold and rotate about fold lines that connect the flaps to their respective panels.

[0146] As shown in FIG. 11, the carton blank 111 may be designated with a first datum line “Wl” that passes through the mid-point of the fold line between panel D and flap K, and the midpoint of the fold line between panel B and flap J. The first datum line W 1 may be determined by the PLC 132 for a particular carton blank 111 or a group of carton blanks 111 to be processed, based on the input of the dimensions H, L and Q of the carton blanks 111. The carton blank 111 may be designated with a second datum line “W2” that may be determined by the PLC 132 and which second datum line W2 passes along, and is generally parallel to, the fold line between panel A and flap F. The first datum line W1 will be parallel to the second datum line W2. The PLC 132 may also determine the relative position of the bottom of the erected carton, as this will be aligned with a vertical datum plane passing through the first datum line W1 and the second datum line W2. Aligning the position of the second datum line W2 and the position of the datum plane with other components in the carton forming system 100 may be shown to ensure that the carton is properly positioned during processing through the system 100. Also, the vertical distance R between the first datum line W1 and the second datum line W2 may be calculated by the PLC 132. This calculating can ensure that the PLC 132 knows where it needs to position the erector head so that the top panel A, and accordingly, the first datum line W 1 are properly positioned throughout the processing of the blank by the carton forming system 100.

[0147] The carton forming system 100 may be shown to be able to track and modify the position of the carton blank 111 and, in particular, the vertical position of the first datum line W 1 of the carton blank 111 as the carton blank 111 moves longitudinally through the carton forming system 100 and as various components of the carton forming system 100 engage the carton blank 111 during the movements of the carton blank 111. This may be shown to ensure that the carton blank 111 being processed is appropriately positioned relative to the system components so that the system components engage the carton blank 111 at the correct position on the carton blank 111 during processing of the carton blank 111.

[0148] As will be described hereinafter, the carton blank 111 may be transformed from a generally flattened tubular configuration to an open tubular configuration and the flaps may be folded and sealed to form a desired erected carton configuration. The erected carton may be configured as an open top carton suitable to be delivered to a carton loading conveyor with an upwardly facing opening or with a sidewards facing opening suitable for side loading.

[0149] The carton blanks 111 may have flaps that provide material that can, in conjunction with a connection mechanism (such as for example with application of an adhesive, sealing tape or a mechanical connection such as is provided in so-called “Klick-lok TM” carton blanks), interconnect flap surfaces to join or otherwise interconnect flaps to adjacent flaps (or in some embodiments flaps to panels), to hold the carton in its desired erected configuration. [0150] The carton blanks 111 may be made of any suitable material(s) configured and adapted to permit the required folding/bending/displacement of the material to reach the desired configuration. Examples of suitable materials are chipboard, cardboard or creased corrugated fiberboard. It should be noted that the carton blank 111 may be formed of a material that, itself, is rigid or semi-rigid and not per se easily foldable but that is divided into separate panels and flaps separated by creases or hinge-type mechanisms so that the carton blank 111 can be erected and formed.

[0151] Turning now to the components of the carton forming system 100, various specific constructions of a suitable magazine 110 might be employed in the carton forming system 100. With particular reference now to FIG. 3, FIGS. 6A, 6B, 6C, 6D and FIG. 7, the magazine 110 may be configured to hold a plurality of carton blanks 111 in a vertically stacked, flattened configuration and be operable to move the stack of the carton blanks 111 longitudinally in a direction generally parallel to longitudinal axis, Y, under the control of the PLC 132, to a pick-up position where the first erector head 120a or the second erector head 120b can retrieve the carton blanks 111 from the magazine 110.

[0152] The magazine 110 may comprise a single conveyor, or other blank feed apparatus, configured to deliver the carton blanks 111 to the pick-up position. In the embodiment illustrated in FIGS. 1 A through 9, two conveyors are disclosed: an in-feed conveyor 204; and an alignment conveyor 206. However, as will described hereinafter in relation to other embodiments, the blank feed apparatus may be configured with multiple in-feed conveyors, to feed carton blanks 111 from multiple magazines that hold the carton blanks 111 having different configurations. This enables the carton forming system 100 to, by automation, selectively and sequentially erect cartons that differ, in size, type and/or configuration, from each other.

[0153] Returning to the carton forming system 100 of FIGS. 1 A through 9, the in-feed conveyor 204 may be configured and operable to move a stack of the carton blanks 111 from a stack input position (where a stack may be loaded onto the in-feed conveyor 204, such as by human or robotic placement) to a position where the stack of carton blanks I l l is transferred to horizontally and transversely aligned alignment conveyor 206. The alignment conveyor 206 may be positioned longitudinally downstream in relation to the in-feed conveyor 204 and may be used to move the stack of carton blanks 111 to the pick-up position. The magazine 110 may be loaded with, and initially hold, a large number of the carton blanks 111 in a vertical stack, with the stack resting on the in-feed conveyor 204. A rear wall 212 mounted to a lower portion of a magazine frame generally designated 202, can be configured to retain the one or more stacks from falling backwards when initially loaded on the in-feed conveyor 204. The rear wall 212 may have a generally planar, vertically and transversely oriented surface facing the stack of carton blanks 111. The rear wall 212 and the in-feed conveyor 204 may be of an appropriate length to be able to store a satisfactory number of stacks of the carton blanks 111 in series on the in-feed conveyor 204. The PLC 132 can control the operation of the in-feed conveyor 204 to move one stack at a time to the alignment conveyor 206.

[0154] The in-feed conveyor 204 may have one or more stacks of carton blanks 111 arranged longitudinally on an in-feed conveyor belt 214 so that they can, in turn, be fed onto the alignment conveyor 206. A sensor may be provided in the vicinity of the in-feed conveyor 204 to monitor the number of stacks waiting on the in-feed conveyor 204 and that sensor may be operable to send a warning signal to the PLC 132 that can alert an operator that the magazine 110 is low and needs to be replenished (e.g., because, on the alignment conveyor 206, the stack being processed by the erector head 120 is the only stack left). The sensor may be a part number 42GRP-9000-QD made by Allen-Bradley.

[0155] Of particular note, a plurality of stacks of the carton blanks 111 might be provided on the in-feed conveyor 204. Each stack may be included with some kind of information indicator that can be read by an information reader, such as an electronic reading device or an optical reading device. For example, a bar code may be provided on a stack of carton blanks 111 such as on the top carton blank 111 or on the bottom carton blank 111 of the stack. The bar code may be read by a suitably positioned bar code reader. The bar code reader may be in communication with the PLC 132. The bar code may provide information indicative of a characteristic of the carton blanks 111 in the stack. For example, the bar code may identify the size and/or type of carton blank 111 in a particular stack. Other information indicators and reading systems may be used, such as, for example, radio frequency identifier (RFID) tags/chips and RFID readers. The information can then be automatically provided, by the information reader, to the PLC 132, which can determine whether the current configuration of the carton forming system 100 can handle the processing of the particular type/size of carton blanks 111 without having to make manual adjustments to any of the components. It is contemplated that, within a certain range of types/ sizes of carton blanks 111, the carton forming system 100 may be able to handle the processing of different types/sizes of carton blanks 111 without manual adjustment of any components of the system 100. The bar code/RFID tag may provide the information about the dimensions of the carton blank 111 as discussed above and then the PLC 132 can determine adjustments, if any, that may be made: (a) to the erector device operation; (b) to the magazine 110 and the tamping apparatuses in the magazine 110; (c) to provide a suitable path for the movement of the movement sub-system to provide for suitable pick up of a blank from the magazine and suitable handling by the erector device and the folding and sealing apparatus; and (d) to the components of the folding and sealing apparatus to be able to process a particular carton blank 111 or a particular stack of carton blanks 111. The result is that the carton forming system 100 may be able to automatically process at least some different types/sizes/configurations of carton blanks 111 to form different erected cartons, without having to make manual operator adjustments to any components of the carton forming system 100.

[0156] The in-feed conveyor 204 may include a series of transversely and horizontally oriented rollers 210 mounted to the lower portion of a magazine frame 202 for free rotation. The rollers 210 may allow for generally horizontal longitudinal downstream movement of the stack towards the alignment conveyor 206. The in-feed conveyor belt 214 may be provided and may be driven by a suitable in-feed motor 291, such as a direct current (DC) motor or a variable frequency drive motor (see FIG. IB). The in-feed motor 291 may be DC motor and may be controlled through a DC motor drive (all sold by Oriental under model AXH-5100-KC-30) by the PLC 132.

[0157] The in-feed conveyor belt 214 may have an upper belt portion supported on the rollers 210. Once the PLC 132 is given an instruction (such as by a human operator through HMI module 133), the upper belt portion of the in-feed conveyor belt 214 may move longitudinally downstream towards the alignment conveyor 206. In this way, the in-feed conveyor belt 214 can move a stack of carton blanks 111 longitudinally downstream, with the stack of carton blanks 111 at its outer transverse portions also being supported on the rollers 210. The PLC 132 can control the in-feed motor 291 through the motor drive and, thus, the in-feed conveyor 204 can be operated to move and transfer the stack towards, and for transfer to, the alignment conveyor 206.

[0158] The alignment conveyor 206 may also include a series of transversely oriented rollers 208 that are mounted for free rotating movement to a lower portion of the magazine frame 202. An alignment conveyor belt 216 may be driven by an alignment motor 292 that may be like the in-feed motor 291 and with a corresponding motor drive. The alignment motor 292 may also be controlled by the PLC 132. The alignment conveyor belt 216 may be provided with an upper belt portion supported on the rollers 208 and upon which the stack of carton blanks 111 may be supported. The in-feed conveyor belt 214 may be operated to move the stack of carton blanks 111 further longitudinally until the front face of the stack abuts with a generally planar, vertically and transversely oriented inward facing surface of the front end wall 218.

[0159] The in-feed conveyor belt 214 of the in-feed conveyor 204 and the alignment conveyor belt 216 of the alignment conveyor 206 may be made from any suitable material such as for example Ropanyl.

[0160] A gap sensor 242, such as an electronic eye model 42KL-D1LB-F4 made by Allen- Bradley, may be located within a horizontal gap between the in-feed conveyor belt 214 and the alignment conveyor belt 216. The gap sensor 242 may be positioned and operable to detect the presence of the front edge of a stack of carton blanks 111 as the stack of carton blanks 111 begins to move over the gap between the in-feed conveyor belt 214 and the alignment conveyor belt 216. Upon detecting the front edge, the gap sensor 242 may send a digital signal to the PLC 132 (see FIG. IB), thereby signaling that a stack has moved to a position where the alignment conveyor 206 can start to move. The PLC 132 can then cause the alignment motor 292 for the alignment conveyor 206 to be activated such that the top portion of the alignment conveyor belt 216 starts to move the stack downstream. In this way, there can be a “hand-off’ of the stack of carton blanks 111 from the in-feed conveyor 204 to the alignment conveyor 206.

[0161] Once the rear edge of the stack of blanks 111 has passed the gap sensor 242 a signal may be sent to the PLC 132 (see FIG. IB), which can then respond by sending a signal to shut down the in-feed motor 291 that drives the in-feed conveyor belt 214 of the in-feed conveyor 204. The in-feed conveyor 204 is then in a condition ready to be loaded with another stack of blanks 111. Meanwhile, the alignment conveyor belt 216 can continue to operate as the alignment conveyor belt 216 moves the stack of carton blanks 111 to the pick-up position.

[0162] The presence of a stack of carton blanks 111 at the pick-up position may be detected by a presence sensor 240 that may be the same type of sensor as the gap sensor 242. The presence sensor 240 may detect the presence of the front edge of a stack of carton blanks 111 at the pickup position and may send a digital signal to the PLC 132, thereby signaling that a stack is at the pick-up position. At the pick-up position, the stack of carton blanks 111 may be “squared up” and thereafter, once properly aligned, single carton blanks 111 may be retrieved in series from the stack of carton blanks 111 by the alternate engagement of the erector heads 120a, 120b with the upper-most carton blank 111 in the stack.

[0163] The magazine 110 may be configured and operable to enable the stack of carton blanks 111 to be properly positioned and oriented in the pick-up position for proper engagement by one of the erector heads 120a, 120b. During movement of the stack of carton blanks 111 longitudinally by the in-feed conveyor 204 and the alignment conveyor 206, the left hand side of the stack of carton blanks 111 may be supported and guided by a left hand side guide wall 200. The left hand side guide wall 200 may be mounted to a lower portion of the lower frame 202 and the left hand side guide wall 200 may be oriented generally vertically and may extend longitudinally for substantially the full lengths of the in-feed conveyor 204 and the alignment conveyor 206.

[0164] The right hand side of the magazine 110, adjacent to the in-feed conveyor 204, may be left generally open; however, to the right hand side of the alignment conveyor 206, there may be a right hand side guide wall 201.

[0165] Possible mounting arrangements for the left hand side guide wall 200 and the right hand side guide wall 201 are illustrated in further detail in FIGS. 6A-6D. In this regard, the lower frame portion 202 may include bottom support plates 251, 255, 259 and 263 that are supported on the ground terrain/floor with bottom support plates 251, 255, 259 and 263 being spaced from each other and oriented in a generally transverse, parallel relationship to each other. Each of the support plates 251, 255, 259 and 263 has mounted to an upper surface thereof, one of the tracks 253, 257, 261 and 265. The left hand side guide wall 200 may be supported by connector blocks 267 that fit onto, and are capable of sliding laterally on and in relation to, tracks 253 and 261. Similarly, the right hand side guide wall 201 may be supported by connector blocks 269 that fit onto, and are capable of sliding laterally on and in relation to, tracks 257 and 265.

[0166] A drive mechanism may be provided to drive each of the left hand side guide wall 200 and the right hand side guide wall 201 on their respective tracks. For the left hand side guide wall 200, a drive mechanism that is in electronic communication with the PLC 132 can be provided. By way of example, a servo motor 258 with gear head may be provided and be in electronic communication with the PLC 132 through a servo drive (see FIG. IB). Examples that could be used are servo motor MPL-B 1530U- VJ42AA made by Allen-Bradley, in combination with servo drive 2094-BC01-MP5-S also made by Allen-Bradley and gear head AE050-010 FOR MPL-A1520 made by Apex.

[0167] A lead screw rod 262 may be inter-connected to the servo motor/gear head 258. The lead screw rod 262 may pass through a nut such as a brass nut 264. The brass nut 264 may be fixedly secured to a plate 293. The plate 293 may be interconnected to spaced, generally vertically oriented bar members 294. The bar members 294 may be interconnected to support a frame (not shown) forming part of the left hand side guide wall 200. By activating the servo motor/gear head 258, the rotation of the servo may rotate the screw rod 262. As the screw rod 262 passes through the nut 264, the nut 264 is moved laterally, either inwards or outwards, thereby causing the left hand side guide wall 200 to slide on the tracks 252, 261 inwards or outwards, depending upon the direction of rotation of the screw rod 262. An encoder may be provided within, or in association with, the servo motor 258 and the encoder may rotate in relation to the rotation of the respective drive shaft of the servo drive. The encoder may be in communication with, and provide signals to, the servo drive, which can then pass on the information to the PLC 132. Thus, the PLC 132 may be able to determine the longitudinal position of the screw rod 262 in real time and, thus, the PLC 132 may be able to determine the transverse position of the left hand side guide wall 200 and can operate the servo motor 258 to adjust the position of the left hand side guide wall 200. The particular type of encoder that may be used is known as an “absolute” encoder. Once the encoder is calibrated so that a position of the screw rod 262 is “zeroed,” it follows that, even if power is lost to the carton forming system 100, the encoder can maintain its zero position calibration. However, as the left hand side guide wall 200 is not moved during processing of a carton blank 111, the mechanism for adjusting the transverse position of the left hand side guide wall 200 may, alternatively, be a simple hand crank mechanism instead of a servo drive motor in communication with the PLC 132. It should be noted that a proper position for the left hand side guide wall 200 during the processing of a stack of carton blanks I l l is that shown in FIG. 7, with the left hand side guide wall 200 in abutment with the left side edges of the carton blanks 111 in each stack. The proper positioning of the left hand side guide wall 200 may be shown to ensure that, when the blanks are flattened, the first datum line W1 is properly transversely aligned to be picked up by the erector heads 120a, 120b and moved through the folding and sealing apparatus 130, as described hereinafter in detail, to achieve proper folding and sealing of the carton blank 111 into an erected carton.

[0168] Similarly, for the right hand side guide wall 201, a drive mechanism 260 (that may be the same types of components that used for the left hand side guide wall 200) that is also in electronic communication with the PLC 132 may be provided. By way of example, a servo motor with gear head designated “drive mechanism 260” may be provided and also be in electronic communication through a servo drive with the PLC 132. A lead screw rod 266 may be interconnected to the servo motor/gear head 266 (which may be like the servo motor/gear head 268). The lead screw rod 266 may pass through a nut such as a brass nut (not visible in the figures) like the nut 264. The nut may be fixedly secured to a plate 295. The plate 295 may be interconnected to spaced, generally vertically oriented bar members 296. The bar members 296 may be interconnected to a side wall support frame, generally designated 271 (see FIG. 6C) that forms part of the right hand side guide wall 201. By activating the drive mechanism 260, the rotation of the servo may rotate the screw rod 266. As the screw rod 266 passes through the nut, the nut is moved laterally either inwards or outwards, thereby causing the right hand side guide wall 201 to slide on the tracks 257, 265. An encoder may be provided within or in association with the drive mechanism 260 and the encoder may rotate in relation to the rotation of the respective drive shaft of the servo motor. The encoder may be in communication with a servo drive and, thus, provide signals to the PLC 132. Thus, the PLC 132 may be able to determine the longitudinal position of the screw rod 266 in real time and, thus, the PLC 132 may be able to determine the transverse position of the right hand side guide wall 201. Thus, the PLC 132 can operate the drive mechanism 260 to adjust the position of the right hand side guide wall 201. An “absolute” encoder may also be used in this application. [0169] During operation of the carton forming system 100 in erecting a carton, the left hand side guide wall 200 may remain stationary, but the right hand side guide wall 201 may be moved laterally as part of a blank stack alignment procedure to, thereby, provide for generally longitudinal alignment of the side edges of the carton blanks 111 in the stack as the carton blanks 111 are held between the left hand side guide wall 200 and the right hand side guide wall 201.

[0170] A lateral tamping apparatus may be secured to the right hand side guide wall 201 and may be used to affect lateral alignment of the front edges and the rear edges of the carton blanks 111 in the stack, /.< ., the front edges and the rear edges of the carton blanks 111 in the stack are generally aligned with a vertical axis, Z, in FIG. 7. A lateral tamping apparatus, generally designated 275, may include a horizontally and longitudinally oriented support plate 270 that may be attached, at either end, to vertical members of the side wall support frame 271. Attached to an outer surface of the horizontally and longitudinally oriented support plate 270 may be a block track 272. Secured to the block track 272, for sliding longitudinal movement along the block track 272, may be a slider block 273. Attached to the slider block 273 may be a pair of upstanding support plates, which, at their upper ends, are secured to a double acting, pneumatic actuator 276, such as the model DFM-25-80-P-A-KF Part # 170927, made by Festo. The double acting, pneumatic actuator 276 may have one or more piston arms (not visible in FIGS. 6B and 6C because the piston arms are retracted). The piston arms of the double acting, pneumatic actuator 276 may reciprocate between retracted and extended positions - backwards and forwards in a longitudinal direction. With reference to FIG. IB, a pneumatic actuator may be supplied with pressurized air communicated through electronic solenoid valves for causing the piston arms to retract and extend. The solenoid valves may be implemented as a model CPE14-MlBh-5J-l/8 made by Festo and may be controlled by the PLC 132. Alternatively, a linear servo drive system - similar to one described in connection with the movement of the left hand side guide wall 200 and the right hand side guide wall 201 - may be provided for the double acting, pneumatic actuator 276. Such a servo drive system could be controlled by the PLC 132. The PLC 132 could make adjustments to the movement of both the left hand side guide wall 200 and the right hand side guide wall 201 as well as the double acting, pneumatic actuator 276 for the lateral tamping apparatus, such that the magazine 110 could be automatically adjusted to process a wide range of sizes of carton blanks 111. [0171] It should be noted that, during the operation of the carton forming system 100 in erecting cartons, the slider block 273 will not move along the block track 272. The slider block 273 and the components attached directly or indirectly thereto, including the double acting, pneumatic actuator 276, may be shown to not move longitudinally during operation. However, the longitudinal position of the slider block 273 can be adjusted during the set-up of the carton forming system 100 when processing particular sizes of the carton blanks 111.

[0172] Attached to the end of the piston arms of the double acting, pneumatic actuator 276 may be a transverse plate 278 that may pass through a longitudinally extending slot 279 through the right hand side guide wall 201. An end of the transverse plate 278, distal from the piston arms attachment, is attached to a vertical tamping plate 280 that is positioned transversely inwards from the inner surface of the right hand side guide wall 201. Retraction of the piston arms of the double acting, pneumatic actuator 276 can cause the transverse plate 278 to engage the rear side edges of the carton blanks 111 in the stack and, as the front edges of those carton blanks 111 are pushed up against the inner surface of the front end wall 218, the front edges and the rear edges of the carton blanks 111 can be laterally aligned. While the actuator 276 is illustrated as being pneumatic, it should be clear that other, non-pneumatic alignment devices could be used. For example, a linear servo drive in communication with the PLC 132 might be employed. It may be shown that a linear servo drive would perform the same function as the double acting, pneumatic actuator 276 but the linear servo drive could electronically position the vertical tamping plate 280 and, consequently, the operator may not have to manually adjust the vertical tamping plate 280 during system set up.

[0173] By operation of the PLC 132, suitable adjustment of the right hand side guide wall 201 and the vertical tamping plate 280, the carton blanks 111 can be moved to precisely the known pick-up position and the orientation of the carton blanks 111 may be “squared-up” in a stack of blanks that is held against the front end wall 218 and may, thus, ensure that the carton blanks 111 are in the proper location for being engaged by the erector heads 120a, 120b.

[0174] In particular, once the stack of carton blanks 111 has generally reached the pick-up position, the PLC 132 can send a signal to the drive mechanism 260 to cause the drive mechanism 260 to cause the right hand side guide wall 201 to move laterally inwards towards the side of stack of carton blanks 111. The PLC 132 may be shown to cause the drive mechanism 260 to move a sufficient distance to cause the edges of the carton blanks 111 to become in contact, along their length, with the longitudinally aligned inner surface of the right hand side guide wall 201. However, the PLC 132 will not cause the right hand side guide wall 201 to be moved to such an extent that a force is created on the stack of carton blanks 111 that causes the carton blanks 111 to buckle and/or be damaged. Such damage may be shown to occur responsive to the carton blanks 111 being compressed to a significant extent between the left hand side guide wall 200 and the right hand side guide wall 201. The PLC 132 may be able to determine how much to move the right hand side guide wall 201 towards the left hand side guide wall 200 by virtue of the size dimensions, for the carton blanks 111, that have been inputted into the PLC 132, including dimension H (see FIG. 10A). The amount of slight compression can be fine-tuned, such as by trial and error, for different sized carton blanks 111. It should be noted that, for many sizes of the carton blanks 111, the manufacturers of the carton blanks 111 comply with industry standard carton sizes.

[0175] Once the longitudinal alignment has been completed by movement of the right hand side guide wall 201, the PLC 132 can cause the double acting, pneumatic actuator 276 to be activated to cause the vertical tamping plate 280 to engage the rear edges of the carton blanks 111 in the stack. The PLC 132 may cause the drive mechanism 260 to move a sufficient distance to cause the rear edges of the carton blanks 111 to come in contact along their length with the laterally aligned inner surface of the vertical tamping plate 280. However, the amount of retraction of the piston arms may be shown to not cause the vertical tamping plate 280 to be moved to such an extent that the amount of retraction creates a force on the stack of carton blanks 111 that would cause the carton blanks 111 to buckle and/or be damaged. Notably, buckling and/or damage may occur response to the carton blanks 111 being compressed too much between the vertical tamping plate 280 and the front end wall 218. An appropriate manual positioning and securement, such as by tightening screws appropriately positioned through the slider block 273, can secure the double acting, pneumatic actuator 276 at an appropriate longitudinal position on the block track 272.

[0176] By way of review, the double acting, pneumatic actuator 276 may ride on the left hand side guide wall 200. For a carton blank 111 of a particular size/shape, the double acting, pneumatic actuator 276 can be adjusted manually in a fore-aft direction so that when the double acting, pneumatic actuator 276 is retracted, the vertical tamping plate 280 is in the right position to push the carton blanks 111 up against the front end wall 218, without squeezing the carton blanks 111.

[0177] The sliding assembly of components that includes the double acting, pneumatic actuator 276 may also have a pointer or indicator and on the stationary part of the magazine 110 there may be a numeric scale to assist in rapidly manually adjusting the double acting, pneumatic actuator 276 to the correct position on the block track 272 for a known carton size.

[0178] In review, example steps in a tamping sequence, for ensuring that the carton blanks 111 are properly squared up at the pick-up position, include the following:

[0179] 1. The right hand side guide wall 201, under control of the PLC 132, expands wide enough to allow the stack of carton blanks 111 to enter on the alignment conveyor 206, even if the stack is misaligned and/or the carton blanks 111 in the stack are not perfectly square with each other and in relation to the X and Y axes.

[0180] 2. The alignment conveyor belt 216 advances the stack of carton blanks 111 until the carton blanks 111 abut the front end wall 218.

[0181] 3. The double acting, pneumatic actuator 276 is extended and then the right hand side guide wall 201 is contracted to make contact with the side of the stack of carton blanks 111 and press the right hand side guide wall 201 against the left hand side guide wall 200. This aligns the carton blanks 111 so that the side edges of the carton blanks 111 are aligned with each other and aligned with the longitudinal side wall of the left hand side guide wall 200 and the right hand side guide wall 201.

[0182] 4. The double acting, pneumatic actuator 276 may then be retracted and the vertical tamping plate 280 presses the stack of carton blanks 111 forward, thereby aligning the carton blanks 111 in the stack so that the front edges and the rear edges of the carton blanks 111 are vertically aligned with each other and with the inner face of the vertical tamping plate 280 and the inside surface of the front end wall 218. [0183] 5. The carton blanks 111 are then properly positioned so that the erector heads 120a,

102b can begin picking up blanks from the stack.

[0184] Turning now to other components of the carton forming system 100, to retrieve blanks from the magazine 110, at least a first engagement device may be provided to engage a panel of a carton blank 111 and, thus, hold and move the blank. Where the carton blank 111 is a tubular blank, the carton forming system 100 may be provided with a first engagement device for engaging one panel (e.g., Panel A) of the carton blank 111 and the carton forming system 100 may be provided with a second engagement device for engaging a second panel (e.g., Panel B) of the carton blank 111. The first engagement device and the second engagement device may comprise one or more suction cups for providing a suction force onto a panel acting generally normal to the surface of the panel that is engaged, as described further in the following. Other types of suitable engagement devices might be employed. The first engagement device and the second engagement device may be rotatable relative to each other so that the first panel can be rotated relative to the second panel. The first engagement device and the second engagement device may be mounted to a single common erector head.

[0185] With reference to FIG. 7, the carton forming system 100 may be provided with a movement sub-system that may be implemented as a pair of movement apparatuses, with each movement apparatus supporting and moving one of the erector heads 120a, 120b. Each of the erector heads 120a, 120b may have a dedicated, independently driven and controlled movement apparatus. Thus, the first erector head 120a may be supported and moved by a first movement apparatus 115a. Similarly, the second erector head 120b may be supported and moved by a second movement apparatus 115b. The first movement apparatus 115a may be constructed in a manner that is substantially identical to the manner in which the second movement apparatus 115b is constructed. The first movement apparatus 115a may be configured as mirror image of the second movement apparatus 115b. In this way, the first movement apparatus 115a may support the first erector head 120a from a right hand side and the second movement apparatus 115b may support the second erector head 120b from a left hand side, in such a manner that the erector heads 120a, 120b may both be moved along a common longitudinal and vertical path. The common path of the erector heads 120a, 120b, may be a cyclical path that lies substantially in, or is parallel to, a plane that is parallel to both the vertical axis Z and the longitudinal axis Y in FIG. 7. Thus, movement of the erector heads 120a, 120b may only be in the vertical Z directions and the longitudinal Y direction (z.e., directions parallel to the Z axis and the Y axis in FIG. 7) and there may be no substantial movement in a lateral X direction (z.e., a direction parallel to the X axis in FIG. 7). If the movement of the erector heads 120a, 120b is restricted to only the Z direction and the Y direction, a moving apparatus for each can be constructed that is relatively less complex than if movement in all three directions is required.

[0186] The movement of the erector heads 120a, 120b by the respective movement apparatuses 115a, 115b may be synchronized such that the erector heads 120a, 120b may travel along the same longitudinal and vertical path while moving out of phase with each other so that one erector head does not interfere with the other erector head, as will be described further in the following. Thus, the relative positions of the two erector heads 120a, 120b can be arranged so that the erector heads 120a, 120b do not collide or otherwise interfere with each other during operation of the carton forming system 100.

[0187] Only the detailed construction of the second movement apparatus 115b will be described herein, it being understood that the first movement apparatus 115a may be constructed in a substantially identical manner as a mirror image of the second moving apparatus 115b. With particular reference to FIG. 4, 5, 7, 8, 9 and 17, the second movement apparatus 115b may include a vertical movement device and a horizontal movement device. The vertical movement device may include a generally hollow vertically oriented support tube 169 that may be generally rectangular in cross section. The support tube 169 may be formed from a unitary tubular piece of material or may be formed into opposed, vertically extending and oriented surfaces 164, 165, 166 and 168 that may be inter-connected together using conventional mechanisms such as bolts, welding, etc. The support tube 169 may be secured to a horizontally extending brace plate 182. The horizontally extending brace plate 182 may be interconnected to a vertically extending brace plate 180. A bottom portion of the vertically extending brace plate 180 may be interconnected, by way of a series of angled plates 183, to a lower end of the support tube 169.

[0188] At an upper end of the support tube 169 may be mounted a freely rotatable “b” pulley wheel 155b. At a bottom end of the vertically extending and oriented surfaces 164, 166, the second erector head 120b may be fixedly attached to the support tube 169 by means of a horizontally extending mounting plate. The horizontally extending mounting plate may be connected to the support tube 169. The support tube 169 may engage with a pair of spaced mounting blocks 190a, 190b that may be joined with bolts through bolt holes 191a, 191b in the mounting blocks 190a, 190b. The bolt holes 191a, 191b may also pass through the mounting plate at the bottom of the support tube 169. Thus, as the second erector head 120b is interconnected to the support tube 169, the second erector head 120b may be shown to move in space with the support tube 169.

[0189] To support the support tube 169 and the second erector head 120b that is connected thereto and to facilitate movement of the support tube 169 and the second erector head 120b in horizontal motion, a horizontal movement device may be provided. The horizontal movement device may include a slide block 158 that may use a rail system to move horizontally. The horizontal movement device may be provided with a pair of spaced, longitudinally and horizontally extending short inner blocks, each inner block fitting on one longitudinally extending rail 160, 162 that holds the inner blocks securely but allows the inner blocks to slide horizontally relative to the longitudinally extending rails 160, 162. An example of a suitable rail system is the Bosch Rexroth ball rail system in which the rails are made from steel and the blocks have a race of ceramic balls inside allowing the block to slide on the rails. The longitudinally extending rails 160, 162 are generally oriented horizontally and may be attached to the frame 109. The slide block 158 may be mounted to the longitudinally extending rails 160, 162 for horizontal sliding movement along the longitudinally extending rails 160, 162. Secured to the front face of the slider block 158 are four freely rotatable pulley wheels: an “a” pulley wheel 155a; a “c” pulley wheel 155c; a “d” pulley wheel 155d; and an “f” pulley wheel 155f. A drive belt may be shown to pass around the four freely rotatable pulley wheels, as described hereinafter. The slide block 158 may also use a rail system to allow the support tube 169 to be connected to the slide block 158 and also move vertically relative to the slide block 158. Accordingly, extending vertically along a back surface of the support tube 169 may be a vertically and longitudinally extending rail. A support block may have a runner block interconnected to the vertical rail on the support tube 169. Thus, the support tube 169 can slide horizontally relative to the slide block 158. Again, a suitable rail system is the Bosch Rexroth ball rail system referenced hereinbefore. [0190] A drive apparatus may also be provided to drive the horizontal movement device and the vertical movement device. For example, the drive apparatus may include a pair of drive motors interconnected to a drive belt, with the drive belt being inter-connected to the horizontal and vertical movement devices. For example, the drive apparatus may include a left belt drive motor 150 (which may be a servo motor such as the model MPL-B330P-MJ24AA made by Allen-Bradley), which may be mounted to a longitudinally extending beam member 108 that is connected to the frame 109 (see FIGS, la, 2 and 3). The left belt drive motor 150 may have a left drive wheel 152. Similarly, a right belt drive motor 154, which may be a servo motor like the left belt drive motor 150, may also be mounted to the beam member 108 connected to the frame 109. The right belt drive motor 154 may have a right drive wheel 156. The left drive wheel 152 may be longitudinally spaced from, and may be horizontally aligned with, the right belt drive motor 154. Both the left belt drive motor 150 and the right belt drive motor 154 can be driven in both directions at varying speeds, such rotation being controllable through servo drives by the PLC 132 (see FIG. IB). Both the left belt drive motor 150 and the right belt drive motor 154 may be provided with two separate ports 364a, 364b. One of the ports 364a, 364b may be for supplying a power line and the other of the ports 364a, 364b may be for a communication line to facilitate communication with the PLC 132. It should be noted that all of the servo motors described in this document may be similarly equipped. The left belt drive motor 150 and the right belt drive motor 154 may also have a third input, which may allow for an electric braking mechanism.

[0191] The first movement apparatus 115a may also include a continuous drive belt 153. The continuous drive belt 153 may, for example, be made from urethane with steel wires running through the drive belt 153. The drive belt 153 may be engaged and may be driven by the left belt drive motor 150 and the right belt drive motor 154 under control of the PLC 132. The PLC 132 may independently control, through respective servo drives, the operation of both the left belt drive motor 150 and the right belt drive motor 154. The drive belt 153 may be shown to extend, continuously, from a start location at the bottom left side of the support tube 169, where the drive belt 153 is fixedly attached to a right belt block 159a that is attached to the support tube 169. From the start location, the drive belt 153 extends upwardly, on a first drive belt portion 153g, to the “f” pulley wheel 155f, around the upper side of the “f” pulley wheel 155f. From the “f” pulley wheel 155f, the drive belt 153 extends horizontally, along a second drive belt portion 153h, to the left drive wheel 152. The drive belt 153 then passes around, and is engaged by, the left drive wheel 152, on a third drive belt portion 153a on the underside of the “a” pulley wheel 155a, upwards along a fourth drive belt portion 153b to the “b” pulley wheel 155b. From there, the drive belt 153 extends around the “b” pulley wheel 155b, downwards on a fifth drive belt portion 153c to the “c” pulley wheel 155c, around the “c” pulley wheel 155c along a sixth drive belt portion 153d to the right drive wheel 156. After passing around and being engaged by the right drive wheel 156, the drive belt 153 extends continuously from around the right drive wheel 156, on to a seventh drive belt portion 153e to the upper side of the “d” pulley wheel 155d. From the “d” pulley wheel 155d, the drive belt 153 then extends vertically downwards along an eighth drive belt portion 153f to the right belt block 159a, where the belt terminates. The drive belt 153 vertically supports the support tube 169 both at the bottom as it is interconnected to support tube 169 with the right belt block 159a and a left belt block 159a, and at the top of support tube 169 where the drive belt 153 passes the “b” pulley wheel 155b. Thus, the drive belt 153 may be shown to be indirectly also vertically supporting the second erector head 120b. Furthermore, by adjusting the relative rotations of the left drive wheel 152 and the right drive wheel 156, the relative lengths of all belt portions can be adjusted through the operation of the left belt drive motor 150 and the right belt drive motor 154. Thus, the relative vertical position of the support tube 169 relative to the slide block 158 can be adjusted. Additionally, by adjusting the relative rotations of the left drive wheel 152 and the right drive wheel 156, through the operation of the left belt drive motor 150 and the right belt drive motor 154, the horizontal position of the slide block 158 on the rails 160, 162 can be adjusted, thus altering the horizontal position of the support tube 169 and the second erector head 120b. It may be appreciated that, by adjusting the direction and speeds of rotation of the drive wheels 152, 156 relative to each other, the support tube 169 can be moved vertically and/or horizontally in space within the physical constraints imposed by, among other things, the position of the left drive wheel 152 and the right drive wheel 156, the length of the drive belt 153 and the length of support tube 169. The following will be appreciated with reference to FIG. 17. In particular:

[0192] - If the left drive wheel 152 and the right drive wheel 156 both remain stationary, then the position of support tube 169 may be shown to not be altered;

[0193] - If the left drive wheel 152 and the right drive wheel 156 both rotate in the same clockwise direction and at the same speed relative to each other, then the support tube 169, and, correspondingly, the second erector head 120b, may be shown to move horizontally from right to left;

[0194] - If the left drive wheel 152 and the right drive wheel 156 both rotate in the same counter-clockwise direction and at the same speed relative to each other, then the support tube 169, and, correspondingly, the second erector head 120b, may be shown to move horizontally from left to right;

[0195] - If the left drive wheel 152 rotates counter-clockwise and the right drive wheel 156 rotates in opposite clockwise rotational directions, but both the left drive wheel 152 and the right drive wheel 156 rotate at the same rotational speed relative to each other, then the support tube 169, and, correspondingly, the second erector head 120b, may be shown to move straight vertically downward; and

[0196] - If the left drive wheel 152 rotates clockwise and the right drive wheel 156 rotates in opposite counter-clockwise rotational directions, but both the left drive wheel 152 and the right drive wheel 156 rotate at the same rotational speed relative to each other, then the vertically extending and oriented surfaces 164, 166 may be shown to move straight vertically upwards.

[0197] It will be appreciated that, if the speeds and directions of the left drive wheel 152 and the right drive wheel 156 are varied in different manner, then a motion of the support tube 169, and, correspondingly, the second erector head 120b, can be created that has both a vertical upwards component or a vertical downwards component as well as a horizontally right to left or left to right component. It follows that any desired path within these two degrees of freedom (vertical and horizontal) can be created for the support tube 169, and, correspondingly, the second erector head 120b. For example, a path having curved path portions may be created. By controlling, independently of each other, the rotational direction and speed of the left belt drive motor 150 and the right belt drive motor 154, the PLC 132 can cause the support tube 169, and, correspondingly, the second erector head 120b, to move along any path in vertical and horizontal directions to allow for the second erector head 120b to carry a carton blank 111 through the various processing steps performed by the carton forming system 100. Notably, the path has physical constraints imposed by the spacing of the left drive wheel 152 and the right drive wheel 156, the “b” pulley wheel 155b and the bottom of the support tube 169. [0198] It will also be appreciated that, by providing two opposed moving apparatuses 115a, 115b, the movements of each of the first erector head 120a and the second erector head 120b can be coordinated and synchronized, so that, even though the first erector head 120a and the second erector head 120b move along the same path, the movement of first erector head 120a and the second erector head 120b are out of phase. For example, the first erector head 120a and the second erector head 120b may be out of phase by 180 degrees.

[0199] Thus, the movements of one erector head 120 will not interfere with the movement of the other erector head 120. An encoder may be provided for each of the left belt drive motor 150 and the right belt drive motor 154 and the encoders may rotate in relation to the rotation of the respective the left drive wheel 152 and the right drive wheel 156. The encoders may be in communication with the PLC 132. Accordingly, the PLC 132 may, in real time, know/determine/monitor the position of the drive belt 153 in space and, thus, may determine and know the position of the second erector head 120b in space at any given time. The particular types of encoders that may be used are known as “absolute” encoders. Thus, the carton forming system 100 can be zeroed, such that, due to the calibration of both encoders of both the left belt drive motor 150 and the right belt drive motor 154, the zero-zero position of the erector head 120 in both the Z direction and the Y direction is set within the PLC 132. The zero-zero position can be set with the erector head 120 at its most horizontally left and vertically raised position. The PLC 132 can then substantially, in real time, keep track of the position of the second erector head 120b as the second erector head 120b moves through the processing sequence for a given carton blank 111.

[0200] The PLC 132, the encoders associated with the left belt drive motor 150 and the right belt drive motor 154 and the respective servo drives on each of the apparatuses 115a, 115b may be capable of being set at zero-zero positions for each of the two separate erector heads 120a, 120b. The PLC 132 can then, substantially in real time, keep track of the position of both of the erector heads 120a, 120b as the erector heads 120a, 120b independently move through the processing sequence for a given carton blank 111.

[0201] Also associated with the second movement apparatus 115b is a first, generally horizontally oriented caterpillar device 114 having a first caterpillar input end 114a and a first caterpillar output end 114b. A second, generally vertically oriented caterpillar device 118 is also provided and has a second caterpillar input end 118a and a second caterpillar output end 118b. The first caterpillar device 114 and the second caterpillar device 118 may each have a hollow cavity extending along their length. Within the cavities of the first caterpillar device 114 and the second caterpillar device 118, hoses carrying pressurized air/vacuum and wires carrying el ectrical/communi cation can be housed. The first caterpillar device 114 may allow such hoses and wires to move longitudinally as the support tube 169 and the second erector head 120b are moved longitudinally. The second caterpillar device 118 may allow such hoses and wires to move vertically as the support tube 169 and the second erector head 120b are moved vertically. The hoses and wires may extend from external sources to enter at the first caterpillar input end 114a and emerge at the first caterpillar output end 114b. Once having emerged from the first caterpillar output end 114b, the hoses and wires may extend to enter at the second caterpillar input end 118a and emerge at the second caterpillar output end 118b. These hoses and wires may then pass from the second caterpillar output end 118b into a first input hose 191 and a second input hose 192 on the second erector head 120b (see FIG. 30). In this way, both pressurized air/vacuum and/or electrical communication wires may be brought from locations external to the frame 109 onto the moving second erector head 120b. An example of a suitable caterpillar device that could be employed is the E-Chain Cable Carrier System model # 240-03-055-0 made by Ignus Inc. It should be noted that electrical communication between the PLC 132 and the second erector head 120b could, in other embodiments, be accomplished using wireless technologies that are commercially available.

[0202] The second erector head 120b is illustrated in isolation in FIGS. 30, 31, 32 and 33. The first erector head 120a may be constructed in the same manner as the second erector head 120b, but may be supported from the right hand side by the first movement apparatus 115a, in contrast to the second erector head 120b, which may be supported from the left hand side by the second movement apparatus 115b.

[0203] The second erector head 120b may have a body generally designated as 300. The body 300 may comprise of a number of components. Many of the components of the second erector head 120b may be made from a strong material, such as a metal (e.g., aluminum, steel, efc.), a hard and strong plastic or other suitable materials, including composite materials. [0204] The second erector head 120b may be generally configured to handle a range of sizes of the carton blanks 111 that can be formed into a carton. The second erector head 120b may be configured by providing easy attachment to the support tube 169 using the mounting blocks 190a, 190b and bolts etc. to permit for the easy interchange of the erector heads 120. The easy interchange of the erector heads 120 may be shown to allow the carton forming system 100, in some circumstances, to be readily adapted to forming differently sized/shaped cartons from differently configured carton blanks 111.

[0205] In one embodiment, the second erector head 120b may include a rotatable paddle 310 connected to a distal end portion 314a of a paddle arm 314. The paddle arm 314 may have a proximal end portion 314b opposite to the distal end portion 314a. The proximal end portion 314b may be formed with a circular opening that facilitates the paddle arm 314 being connected to a paddle shaft 316. The paddle 310 can rotate with the paddle shaft 316 about the longitudinal axis of the paddle shaft 316. The paddle shaft 316 may be connected to a rotary actuator 399 such as a double acting rotary pneumatic actuator manufactured by Festo under engineering part # DSM-32-270-CC-FW-A-B. The rotary actuator 399 can cause rotation of the paddle shaft 316 clockwise and counter-clockwise, up to 270 degrees around an axis of the paddle shaft 316. The rotary actuator 399 may be supplied with pressurized air via hoses (not shown) connected to a first port 395 and a second port 397. Those hoses may also be connected to a solenoid valve device 340, which may be controlled by the PLC 132. In this way, the rotation clockwise and counter-clockwise of the paddle 310 may be controlled by the PLC 132.

[0206] Also formed as part of the body 300 of the second erector head 120b is a bottom suction plate 327 that is generally shaped in a square cross configuration to provide flanged openings for suction cups. In each of the flanged openings of the bottom suction plate 327 is positioned a suction plate suction cup 312. It should be noted that, while many types of suction cups may be employed on the second erector head 120b, a preferred type of suction cup is the model B40.10.04AB made by Piab. Two of the suction plate suction cups 312 are mounted to a first generally longitudinally oriented support block 319a and the other two suction cups are mounted to a second generally longitudinally oriented support block 319b.

[0207] The first support block 319a and the second support block 319b are generally oriented longitudinally in a spaced-apart, parallel relation to each other and the first support block 319a and the second support block 319b are joined to other components of the body 300. The first support block 319a and the second support block 319b each have open passageways that interconnect each suction plate suction cup 312 with an outlet from a vacuum generator 330. The vacuum generator 330 may be any suitable vacuum generator device, such as, for example, model VCH12-016C made by Pisco. Each of the suction plate suction cups 312 may be shown to have an inlet interconnected to a hose (not shown) that can carry pressurized air to the vacuum generator 330. The vacuum generator 330 converts pressurized air, supplied to a vacuum inlet port, into a vacuum at one of a plurality of vacuum outlet ports. The vacuum outlet port is interconnected, through the passageway in the first support block 319a and the second support block 319b, to a given suction plate suction cup 312, among the plurality of suction plate suction cups 312, so that the given suction plate suction cup 312 can implement a vacuum force. Interposed along the pressurized air channel running between the vacuum generator 330 and the source of pressurized air, which may be an air compressor (see FIG. IB), may be located a solenoid valve device 340 that may, for example, be a model CPE14-M1BH-5L-1/8 made by Festo. The solenoid valve device 340 may be in electronic communication with the PLC 132 and be controlled by the PLC 132. In this way, the PLC 132 can turn on and off the supply of vacuum force to each of the suction plate suction cups 312. To channel the compressed air appropriately, valves in the solenoid valve device 340 can be driven between open and closed positions by solenoids responsive to signals from the PLC 132. Electrical lines carrying signals to and from the PLC 132 could also pass through the first input hose 191 to operate the solenoid valve device 340.

[0208] A first downward extending end portion 323a of the first support block 319a has a first opening 331a that is configured to receive a transversely mounted shaft 342. The transversely mounted shaft 342 may be mounted for rotation within the first opening 33 la. A second downward extending end portion 323b of the second support block 319b has a second opening 331b that is configured to receive the transversely mounted shaft 342. The transversely mounted shaft 342 may be mounted for rotation within the second opening 33 lb.

[0209] At one end of the transversely mounted shaft 342 may be mounted a gear wheel device 360 that is configured to rotate with transversely mounted shaft 342. The gear wheel 360 may be interconnected to a drive wheel of a gear box 362 to form a miter gear connection. The gear box 362 may be driven by a servo motor 364 mounted above the gear box 362. The servo motor 364 may also be a model MPL-B1530U-VJ44AA made by Allen-Bradley and the gear box 362 may be a model AER050-030 FOR MPL-A1520 AB SERVO MOTOR made by Apex.

[0210] In FIG. 30, the servo motor 364 is shown with two separate servo motor ports 364a, 364b (individually or collectively, 364). One of the servo motor ports 364 may be for supplying a power line and the other servo motor port may be for a communication line to facilitate communication with a servo drive and the PLC 132. It should be noted that all of the servo motors described in this application may be similarly equipped. The servo motor 364 may, through connection with a servo drive (see FIG. IB), be controlled by and be in communication with the PLC 132. An encoder may be provided within or in association with the servo motor 364. The encoder may rotate in relation to the rotation of the respective drive shaft of the servo motor 364. The encoder may be in communication with, and provide signals to, the servo drive and, thus, to the PLC 132. The PLC 132 may be able to determine the rotational position of the transversely mounted shaft 342. Thus, when appropriate signals are provided from the PLC 132, the servo motor 364 can be operated and can cause the transversely mounted shaft 342 to rotate in a particular desired direction at a particular desired rotational speed for a desired amount of time. Thus, the PLC 132 can control the rotational position of transversely mounted shaft 342.

[0211] Mounted to the transversely mounted shaft 342, between the first end portion 323a and the second end portion 323b, is a rotator device generally designated 350. The rotator device

350 is fixedly attached to the transversely mounted shaft 342 and may be shown to rotate with the transversely mounted shaft 342. The rotator device 350 includes a rotator arm 351 having one end fixedly mounted to the transversely mounted shaft 342. The opposite end of the rotator arm

351 has a mounting block 353 attached thereto.

[0212] Secured to mounting block 353 may be a mounting block pneumatic actuator device 325 that may, for example, be a model DFM-12-80-P-A-KF, or part # 170905 made by Festo. The mounting block pneumatic actuator device 325 may be supplied with pressurized air to, thereby, activate the device that may be controlled by the solenoid valve device 340 in the supply line. The solenoid valve device 340 may be in communication with, and be controlled by, the PLC 132 (see FIG. IB). The mounting block pneumatic actuator device 325 may be actuated to reciprocate piston arms 326 between an extended position and a retracted position. The PLC 132 may send a signal to the solenoid valve device 340 to operate the mounting block pneumatic actuator device 325 to extend the piston arms 326 at a particular angular position of the rotator arm 351 and/or at a particular location of the second erector head 120b. The particular angular position or the particular location may be provided by the encoder associated with the servo motor 364. Similarly, the PLC 132 may send a signal to the solenoid valve device 340 to cause the piston arms 326 to be retracted to a particular angular position of the transversely mounted shaft 342 and/or to cause the piston arms 326 to be retracted to a particular angular position of the rotator arm 351 and/or to cause the piston arms 326 to be retracted to a particular location of the second erector head 120b.

[0213] The PLC 132 may cause, by acting through the solenoid valve device 340, the mounting block pneumatic actuator device 325 to be actuated at approximately the same time as the suction plate suction cups 312 have contacted the surface of downward facing panel D and/or when rotation of the rotator arm 351 is just about to begin or has just commenced. Piston arms 326 may be completely extended by the time the rotator arm 351 has rotated about 45 degrees.

[0214] Mounted to a distal end of each piston arms 326 is a mounting block 328, which may be configured to support a pair of piston arm suction cups 320. Each mounting block 328 may have an open passageway (not shown) that interconnect each piston arm suction cup 320 with an outlet from the vacuum generator 330. The vacuum generator 330 may be any suitable vacuum generator device, such as, for example, the model VCH12-016C made by Pisco. As indicated above, the vacuum generators 330 each have an inlet port interconnected to a hose (not shown) that can carry pressurized air to the vacuum generator 330. The vacuum generators 330 convert the pressurized air supplied the inlet port to a vacuum at one of the outlet ports. The outlet port is interconnected, through the passageway in the mounting block 328, to one of the piston arm suction cups 320 so that the suction cup can implement a vacuum force. Interposed along the pressurized air channel, running between each vacuum generator 330 associated with piston arm suction cups 320 and the source of pressurized air, may be located the solenoid valve device 340. The solenoid valve device 340 may be interconnected electronically (either via a wireless communication connection or via a wired communication connection) to the PLC 132 and be controlled by the PLC 132. In this way, the PLC 132 can also turn on and off the supply of vacuum force to each of the piston arm suction cups 320. [0215] With reference to FIG. 11, the suction plate suction cups 312 can be employed to engage and hold onto the top panel A of the carton blank 111. Once the carton blank 111 has been retrieved from the top of the stack of carton blanks 111, the rotator arm 351 can be rotated approximately 180 degrees, such that the piston arm suction cups 320 of the rotator device 350 can engage and hold onto the underside panel D of the carton blank 111. Once the piston arm suction cups 320 have engaged the panel D, the rotator arm 351 can be rotated 90 degrees backwards in the opposite rotational direction. The opposing vacuum forces, created by the suction plate suction cups 312 above and the piston arm suction cups 320 below, may be shown to cause the carton blank 111 to be transformed from a flattened configuration to an open configuration, as panel D is rotated substantially 90 degrees relative to panel A. The air suction force that may be developed at the outer surfaces of the piston arm suction cups 320 and the suction plate suction cups 312 may be shown to be sufficient so that, when activated, the piston arm suction cups 320 and the suction plate suction cups 312 can engage and hold top panel A in a stationary position, relative to the second erector head 120b, and rotate panel D relative to panel A to open up the tubular carton blank 111 to a generally rectangular configuration. The vacuum generated at the piston arm suctions cups 320 and the suction plate suction cups 312 can also be de-activated by the PLC 132 sending signals, at appropriate times, to the solenoid valve device 340.

[0216] Each erector head 120a, 120b may be configured to be able to handle a wider range of different sized/dimensioned carton blanks 111 by providing for additional piston arm suction cups and suction plate suction cups positioned at different locations on the erector heads 120a, 120b. The piston arm suction cups 320 and the suction plate suction cups 312 could each be “self-sealing” of “self-plugging” suction cups, which, if not engaging and sealing with a surface of a particular blank that is being processed, may automatically become blocked. This automatic blocking may be shown to allow the vacuum/ suction forces to be maintained on other suctions cups that may have the source of pressurized air/vacuum interconnected thereto and that are engaging a panel of a carton blank 111. In this way, each of the erector heads 120a, 120b may be adapted to handle a wider variety of sized/dimensioned carton blanks 111 and cartons/cases that can be formed therefrom. [0217] The opening of the carton blank 111 may be assisted by the extension of the piston arms 326 of the mounting block pneumatic actuator device 325 during rotation of the rotator arm 351. Preferably, when the rotator arm 351 has been rotated somewhere in the range of about 30- 60 degrees back to the 90 degree position and, preferably, when the rotator arm 351 is at approximately 40-50 degrees and, most preferably, when the rotator arm 351 is at about 45 degrees, then the piston arms 326 may be fully extended. This extension of the piston arms 326 and, thus, of the piston arm suction cups 320, in a generally tangential direction relative to the rotation of the rotator arm 351 may be shown to compensate for an offset of the axis of rotation of the rotator arm 351 compared to the axis of rotation of the carton blank 111 that extends along the fold line between panels A and D. The effect of the extension of the piston arms 326 once the rotator arm 351 has been rotated, such as to 90 degrees, ensures that the panel D is also oriented at 90 degrees to panel A.

[0218] Once a carton blank 111 has been opened to the configuration shown in FIG. 11, then the PLC 132 can send a signal to the solenoid valve device 340, which signal causes the rotary actuator 399 to rotate the paddle shaft 316 and, thus, rotate the paddle 310. The paddle 310 can then engage the trailing flap K of the carton blank 111 and cause the trailing flap K to fold about its fold line where the trailing flap K joins to panel D. Thus, the trailing flap K can be folded inwards towards the bottom opening of the carton blank 111. The leading bottom flap J may also be folded about its fold line, which joins the leading bottom flap J with panel B by engagement of the leading bottom flap J with upper folding rails/ploughs 700 and lower folding rails/ploughs 701, that form part of the folding and sealing apparatus 130. As the carton blank 111 held by the second erector head 120b is moved longitudinally downstream into the folding and sealing apparatus 130, the leading bottom flap J can be folded inwards, so that both bottom flaps K and J are folded inwards to start the formation of the bottom of the carton.

[0219] Another feature of the second erector head 120b that can be noted is that a carton location sensor apparatus may be provided and may include a reciprocating sensor rod 380. The reciprocating sensor rod 380, when not in contact with a carton blank 111, extends downwards through an aperture 381 in the bottom suction plate 327, below the level of the plane of the suction plate suction cups 312. When the second erector head 120b is brought vertically downwards to retrieve a carton blank 111 on a stack of carton blanks 111 in the magazine 110, the movement of the second erector head 120b just prior to the suction plate suction cups 312 contacting with the upper surface of the carton blank 111 may be shown to be generally vertically downwards. Prior to the suction plate suction cups 312 contacting the surface of panel A of a carton blank 111, the sensor rod 380 may be shown to engage the surface of panel A and cause the sensor rod 380, which may be resiliently displaced due to a spring mechanism biasing the sensor rod 380 downwards, to be pushed upwards. This movement upwards of the sensor rod 380 relative to the bottom suction plate 327 may be shown to physically cause a sensor (not shown) to be activated and, responsively, a signal to be sent to the PLC 132. The sensor may be an inductive proximity sensor. A metal cylinder fixed on the sensor rod 380 may be sensed by sensor circuitry because movement of the metal cylinder may be shown to change the inductance of an induction loop inside the sensor. The sensor may be 871FM-D8NP25-P3 made by Allen- Bradley. The PLC 132 may respond to receipt of the signal by causing the left belt drive motor 150 and the right belt drive motor 154 to slow down so that the final few centimeters (e.g., 3.5 cm) of movement downwards towards contact between the suction plate suction cups 312 and the upper surface of panel A occurs at a much slower rate and also the PLC 132 knows how much further vertically downwards the second erector head 120b is to be lowered to establish proper contact between the suction plate suction cups 312 and panel A. It should also be noted that the sensor rod 380 and the associated sensor device can also be used to ensure that the PLC 132 is aware of whether, once a carton blank 111 has been engaged in the magazine 110, the carton blank 111 stays engaged with the second erector head 120b until an appropriate release location is reached, such as once erection of the carton has been completed.

[0220] The particular arrangement of suction cups and rotating paddle on erector heads 120 can be designed based upon the configuration of the carton blank and the particular panels and flaps that need to be rotated. It will also be appreciated that, on the erector head 120 that is illustrated, the suction cups are used to apply a force to hold onto and/or rotate panels of a carton blank 111. However, it should be clear that alternative engagement mechanisms to the suction plate suction cups 312 and the piston arm suction cups 320 could be employed.

[0221] With particular reference to FIGS. 1 to 15 and 17, at the folding and sealing apparatus 130, rail and plough apparatus may be configured to cause all remaining flaps of a carton blank 111 to be appropriately folded in preparation for sealing to, thereby, produce an open carton configuration that is suitable for delivery to a discharge conveyor, such as the discharge conveyor 117. The folding and sealing apparatus 130 may include the following components: upper folding rails/ploughs 700; lower folding rails/ploughs 701; a carton support plate 703; a discharge chute 750; an upper flap closing device 705; a lower flap closing device 707; a right hand compression device 706; a left hand compression device 704; and a glue applicator 709 (see FIG. 1). The glue applicator 709 may have one or more nozzles positioned to apply adhesive to flaps such as flaps J and K. Each of the rails and actuator devices of the folding and sealing apparatus 130 may be supported by rods or other members to interconnect the components to the support frame 109.

[0222] The upper flap actuation device 705 may include an upper pneumatic actuator device 704a having its piston arms connected to an upper plough 708a. Similarly, the lower flap actuation device 707 may include a lower pneumatic actuator device 704b having its piston arms connected to an upper plough 708b. The upper pneumatic actuator device 704a and the lower pneumatic actuator device 704b may be the model DFM-25-100-P-A-KF, part # 170928 made by Festo.

[0223] The right hand compression device 706 may include a central pneumatic actuator device 710 with telescoping extendible support rods 712, 714 horizontally aligned and disposed on either side of the central pneumatic actuator device 710. The central pneumatic actuator device 710 may be a model DNC-32-100-PPV-A part # 163309 made by Festo. With particular reference to FIG. 26, the central pneumatic actuator device 710 may have piston arms that, along with ends of the support rods 712, 714, connect to a longitudinally extending sealing plate 716. The longitudinally extending sealing plate 716 may have, attached thereto, a longitudinally extending upper rail 717a and a longitudinally extending lower rail 717b. The upper rail 717a may be positioned to be able to engage upper major flap F and the lower rail 717b may be positioned to engage lower major flap G when piston arms of the central pneumatic actuator device 710 are extended horizontally and transversely inwards to push flaps F and G into engagement with flaps K and J that are positioned underneath.

[0224] The left hand compression device 704 has a left hand actuator arm 711, which may be actuated by an left hand actuator device 719 with a vertically and longitudinally disposed left hand compression plate 720 attached to the end of the actuator arm. The left hand actuator device 719 may be a double acting pneumatic actuator (not shown) that may be provided with pressurized air through hoses, with the air flow being controlled by the solenoid valve device 340 that may be controlled by the PLC 132. Other embodiments are possible. For example, with reference to FIG. 26 A, a servo-driven actuator for the left hand actuator arm 711 may be provided that includes a mounting block 741 that can travel along a rail guide 745 that is secured to a horizontal and longitudinally extending plate forming part of a left hand support frame 746. The mounting block 741 can slide horizontally along the rail guide 745. An L-shaped plate 743 may interconnect the left hand actuator arm 711 to the mounting block 741. The mounting block 741 may also be connected, such as with nuts and bolts, on its underside to a continuous drive belt 757 made of any suitable material, such as, for example, the same material that may be used in the belts for first movement apparatus 115a and the second movement apparatus 115b, namely a urethane timing belt with steel wires running therethrough. The continuous drive belt 757 may extend between a freely rotating pulley 759, mounted to an end of the left hand support frame 746, and a drive wheel of a left hand servo motor 761. Through a servo drive and an absolute encoder, the left hand servo motor 761 may be an Allen-Bradley model AB MPL-B320P- MJ22AA and may be interconnected, with a servo drive, to the PLC 132. The servo drive may be Allen-Bradley model AB. 2094-BM01-S. The left hand servo motor 761 may be coupled to a drive wheel for the belt thorough an APEX GEARBOX model AE070-005.

[0225] The PLC 132 may control the rotation of the drive wheel driven by the left hand servo motor 761 through use of an encoder (that may be an absolute encoder). Thus, the movement of the continuous drive belt 757 may be controlled and the PLC 132 may determine, in real time, the position of the left hand actuator arm 711. It follows that the PLC 132 may determine, in real time, the position of the left hand compression plate 720. Depending upon the type, and thickness, of material from which the carton blank I l l is formed, the positioning of the left hand compression plate 720, relative to the plate of the right hand compression device 706, may be adjusted by the PLC 132 to ensure an appropriate degree of compression of the flaps of the carton blank 111 positioned there between.

[0226] Each of the upper pneumatic actuator device 704a, the lower pneumatic actuator device 704b and the central pneumatic actuator device 710 may be double acting cylinders and they may be supplied with pressurized air that is controlled through an electronic valve device (not shown). The electronic valve device may a model CPE14-MlBh-5J-l/8 valve unit that may be in communication with, and be controlled by, the PLC 132. Accordingly, the PLC 132 may cause the piston arms to be extended and retracted during the processing of the carton blanks 111 to achieve closure and sealing of the flaps.

[0227] The upper pneumatic actuator device 704a and the upper plough 708a may be appropriately positioned and angled downwards (such as at about 45 degrees to the vertical) to be able to fold down major flap F sufficiently to be able to be engaged by the right hand compression device 706. Similarly, the lower pneumatic actuator device 704b and the lower plough 708b may be appropriately positioned and angled upwards (such as at about 45 degrees to the vertical) to be able to fold up major flap G sufficiently to be able to be engaged by the right hand compression device 706, substantially simultaneously, or at least allowing for the right hand compression device 706 to be able to compress both flaps F and G at the same time towards minor flaps J and K that have upper surfaces containing some adhesive.

[0228] The glue applicator 709 may have nozzles appropriately positioned and the operation of the nozzles may be controlled by the PLC 132. The glue applicator 709 may apply a suitable adhesive to the flaps, such as leading minor flap J and trailing minor flap K, once these flaps have been folded inwards to form part of the carton bottom. An example of a suitable known applicator, which may be employed for the glue applicator 709, is the model ProBlue 10 applicator made by Nordson Inc. An example of a suitable adhesive that could be employed on a carton blank 111 made of cardboard is Cool-Lok 034250A-790 adhesive available from Lanco Adhesives, Inc. The glue applicator 709 may be in electronic communication with the PLC 132, which may be operable to signal the glue applicator 709 to apply adhesive at an appropriate time during the positioning of the erector heads 120a, 120b.

[0229] The left hand compression device 704 may be used to enter the carton from the left side and compress flaps F, G, J and K between the left hand compression plate 720, the upper rail 717a of the right hand compression device 706 and the lower rail 717b of the right hand compression device 706. This compression may be shown to assist in ensuring that the panels are compressed together to allow the adhesive to appropriately bond the flaps together to make a solid carton bottom. [0230] In some embodiments, once the left hand compression device 704 and the right hand compression device 706 have completed the compression of the flaps, the PLC 132 may send a signal to solenoid valve devices, thereby causing the left hand compression device 704 and the right hand compression device 706 to be withdrawn. The carton blank 111 may be shown to then have been fully opened to for an erected carton suitable to be loaded with one or more items. The second erector head 120b may then carry the erected carton to a discharge chute 750 and then release the erected carton, such that the erected carton falls onto the discharge conveyor 117, which can then move the erected carton away for further processing. In other embodiments, such as the embodiment illustrated, the erected carton 111 may be released and fall onto the support plate 703 and remain on the support plate 703 until the next carton blank 111, carried by another erector head moved by another movement apparatus (such as the first erector head 120a moved by the first movement apparatus 115a), moves the next carton blank 111 into the location where the next carton blank 111 is to be folded, sealed and compressed. In doing so, the next carton blank 111 pushes the previous erected carton downstream, where the previous erected carton may fall onto the discharge conveyor 117. Carton discharge conveyors are well known in the art and any suitable known carton conveyor may be utilized for the discharge conveyor 117.

[0231] Other examples of transfer devices, which might be employed to transfer the erected carton from the folding and sealing apparatus 130 to a carton discharge conveyor, include a “blow-off’ system that may use one or more jets of compressed air, a suction cup system, the use of pushing arm or simply allowing for freefall of the erected carton.

[0232] A discharge sensor 243 (see FIG. 2), such as an electronic eye model 42KL-P2LB-F4 made by Allen-Bradley, may be located near the bottom of the discharge chute 750. The discharge sensor 243 may be positioned and operable to detect the presence or absence of an erected carton at the input to the discharge conveyor 117. In this way, the PLC 132 can be digitally signaled that an erected carton is in place at the bottom of the discharge chute 750, such that another erected carton cannot be discharged down the discharge chute 750. If an erected carton is in place at the bottom of the discharge chute 750, the carton forming system 100 can be stopped by the PLC 132 until any fault at the discharge conveyor 117 can be rectified.

[0233] The overall operation of the carton forming system 100 will now be described further. [0234] As an initial step, the PLC 132 may be accessed by an operator, through the HMI 133, to activate the carton forming system 100. Responsive to activation, the carton forming system 100 may be initialized by the PLC 132 establishing that all components are put in their “start” positions. A stack of carton blanks 111 may be placed at the input end of the in-feed conveyor 204 and the carton forming system 100 may then be allowed to commence operation, such as by the PLC 132 being instructed, through the HMI 133, to commence the processing of the stack of the carton blanks 111.

[0235] The PLC 132 may then send an instruction to the drive motor of the in-feed conveyor 204 to commence to drive the in-feed conveyor belt 214, thereby causing the stack of carton blanks 111 to move downstream. Sometime prior to the stack of carton blanks 111 reaching the alignment conveyor 206, the right hand side guide wall 201, under control of the PLC 132, may be shown to be driven, by the drive mechanism 260, to expand wide enough to allow the stack of carton blanks 111 to enter the alignment conveyor 206, even if the stack is misaligned and/or the carton blanks 111 in the stack are not perfectly square with each other. The stack of carton blanks 111 may then be moved downstream, until the front edge of the stack of blanks passes the downstream edge of the in-feed conveyor 204, the gap sensor 242 may be shown to send a signal to the PLC 132, the signal indicating that the front edge of the stack has reached the input to alignment conveyor 206. In response to receiving the signal, the PLC 132 may send an instruction to the drive motor of the in-feed conveyor 204 to commence to drive the alignment conveyor belt 216 causing the stack of carton blanks 111 to move downstream towards the front end wall 218 of the magazine 110. Once the front edge of the stack of carton blanks 111 reaches the front end wall 218, the presence sensor 240 may be shown to send a signal to the PLC 132 indicating that the front edge of the stack of blanks has reached the front end wall 218. In response to receiving the signal, the PLC 132 may initiate the tamping sequence to “square up” the stack of carton blanks 111, as detailed hereinbefore.

[0236] In review, the tamping sequence, for ensuring that the carton blanks 111 are properly squared up at the pick-up position, may include the following steps. The tamping actuator 276 may be extended upon having been activated by pressurized air controlled by the PLC 132 and the associated valve. Then, the right hand side guide wall 201 may contract to make contact with the side of the stack of carton blanks 111 to, thereby, press the stack of carton blanks 111 against the left hand side guide wall 200. This pressing may be shown to align the carton blanks 111 so that the side edges of the carton blanks 111 are aligned with each other and the respective longitudinal side walls of the left hand side guide wall 200 and the right hand side guide wall 201. The tamping actuator 276 may then retract and the vertical tamping plate 280 may press the stack of carton blanks 111 forward, thereby aligning the carton blanks 111 in the stack so that their front edges and rear edges are vertically aligned with each other and with the inner face of the vertical tamping plate 280 and the inside surface of the front end wall 218. The stack of blanks 111 is then properly positioned so that the erector heads 120a and 120b can begin picking up blanks from the stack.

[0237] One of the erector heads, such as the second erector head 120b may be shown to be positioned, by the control of the PLC 132 over the second movement apparatus 115b, at the zero position calibrated for the second erector head 120b. The PLC 132 may then cause the left belt drive motor 150 and the right belt drive motor 154 to be operated to achieve the following sequence of operations.

[0238] - First, the second erector head 120b may be moved to the pick-up position, as illustrated in FIG. 17.

[0239] - As the second erector head 120b is being brought vertically downwards to retrieve the top carton blank 111 on the stack of carton blanks 111 in the magazine 110, the movement of the second erector head, just prior to the suction plate suction cups 312 contacting with the upper surface of the carton blank 111 may be shown to be generally vertically downwards. Prior to the suction plate suction cups 312 contacting the surface of panel A of the carton blank 111, the sensor rod 380 may be shown to engage the surface of panel A, thereby causing the sensor rod 380 to be pushed upwards. This upward movement of the sensor rod 380 relative to the bottom suction plate 327 may be shown to physically cause the sensor rod 380 to be activated and, responsively, send a signal to the PLC 132. The PLC 132 may respond to receiving the signal by causing the left belt drive motor 150 and the right belt drive motor 154 to slow down, so that the final few centimeters (e.g., 3.5 cm) of movement downwards towards contact between the suction plate suction cups 312 and the upper surface of panel A occurs at a much slower rate. Also, the PLC 132 knows how much further vertically downwards the second erector head 120b is to be lowered to establish proper contact between the suction plate suction cups 312 and panel A. It should also be clear that the sensor rod 380, and the associated sensor device, can also be used to establish that the PLC 132 is aware of whether, once a give carton blank 111 has been engaged in the magazine 110, the given carton blank 111 stays engaged with the second erector head 120b until the appropriate release location is reached, such as once erection of the carton blank 111 has been completed.

[0240] - The PLC 132 may also be shown to operate the solenoid valve device 340 on the second erector head 120b to, thereby, cause a suction force to be developed at the suction plate suction cups 312 and, optionally, also at the piston arm suction cups 320 (although suction at the piston arm suction cups 320 can be delayed).

[0241] - With the second erector head 120b in the pick-up position, as illustrated in FIG. 17, and the suction force being applied at the suction plate suction cups 312, the second erector head 120b may engage the panel A (see location of suction cup outline on FIG. 10 A) and then commence to lift the given carton blank 111 upwards, as illustrated in FIG. 18. The PLC 132 may be shown to know how high to lift the upper surface of the given carton blank 111 to, thereby, ensure that, once opened up, the first datum line W 1 will be appropriately vertically located, so that components of the folding and sealing apparatus 130 will be able to fulfil their respective functions, as described hereinbefore.

[0242] - Preferably, when the second erector head 120b has reached a determined vertical position and, preferably, while the second erector head 120b is not moving longitudinally towards the folding and sealing apparatus 130, the PLC 132 sends a signal to cause the servo motor 364 to rotate. Rotation of the servo motor 364 may be shown to cause the transversely mounted shaft 342 to rotate in a particular desired direction at a particular desired rotational speed for a desired amount of time. The PLC 132 may control a rotational position of the transversely mounted shaft 342 to cause the rotator device 350, which is fixedly attached to the transversely mounted shaft 342, to rotate with the transversely mounted shaft 342. Thus, the rotator device 350 may be rotated to the position shown in FIG. 19 and, at that position, the piston arm suction cups 320, which will have suction engaged, may be shown to attach to the underside of the given carton blank 111 and, in particular, to panel D. [0243] - In the next operation, the “blank opening” operation, through control of the PLC

132, opposed forces provided by the suction plate suction cups 312 acting upwards on the top and the piston arm suction cups 320 acting in an opposite downward direction may be shown to start to pull the flat given carton blank 111 apart. The forces are then continued by the suction plate suction cups 312 above and the piston arm suction cups 320 below, as the rotator device 350 is given a backwards rotation of 90 degrees to, thereby, move the given carton blank 111 into the position illustrated in FIG. 20.

[0244] - During the backwards rotation of the rotator device 350, the mounting block pneumatic actuator device 325 may be supplied with pressurized air controlled through the solenoid valve device 340. The PLC 132 may send a signal to the solenoid valve device 340 to operate the mounting block pneumatic actuator device 325 to extend the piston arms 326 at a particular angular position of the rotator arm 351 and/or a particular angular position of the second erector head 120b that is provided by the encoder associated with the servo motor 364. The PLC 342 may cause, by acting through the solenoid valve device 340, the mounting block pneumatic actuator device 325 to be actuated at approximately the same time as the piston arm suction cups 320 have contacted the surface of downward facing panel D and the rotation of the rotator arm 351 is just about to begin or has just commenced. The piston arms 326 may be completely extended by the time the rotator arm 351 has rotated about 45 degrees. The piston arms 326 may continue to be extended and stay extended when the rotator device 350 is at the 90 degrees position, illustrated in FIG. 20.

[0245] - Once the given carton blank 111 has been opened, the second erector head 120b can securely hold the blank by the suction forces exerted to panel A by the suction plate suction cups 312 and exerted to panel D by the piston arm suction cups 320. Also, once opened, the flaps K and J need to be folded inwards towards the bottom opening of the given carton blank 111. In the embodiment illustrated in FIG. 21, the trailing minor flap K is closed by actuation of the paddle 310. Accordingly, the PLC 132 can send a signal to the solenoid valve device 340. The signal causes the rotary actuator 399 to rotate the paddle shaft 316 and, thus, rotate the paddle 310. The paddle 310 can then engage trailing minor flap K of the given carton blank 111 and cause trailing minor flap K to fold about its fold line where trailing minor flap K joins to panel D. Thus, trailing minor flap K can be folded inwards towards the bottom opening of the given carton blank 111. [0246] - Leading bottom flap J may also be folded about its fold line, which joins leading bottom flap J with panel B, by engagement of the leading bottom flap J with the upper folding rails/ploughs 700 and the lower folding rails/ploughs 701 that form part of the folding and sealing apparatus 130. This folding may occur as the second erector head 120b is moved longitudinally downstream towards the folding and sealing apparatus 130. As the given carton blank 111, held by the second erector head 120b, is moved longitudinally downstream into the folding and sealing apparatus 130, the leading bottom flap J can be folded inwards by the upper folding rails/ploughs 700 and the lower folding rails/ploughs 701, so that both bottom flaps K and J have been folded inwards to start the formation of the bottom of the carton, as illustrated in FIG. 22.

[0247] - Also, when the flaps K and J have been folded inwards, under the control of the

PLC 132, or pursuant to another control or trigger, the adhesive applicator 709 can, through appropriately positioned nozzles, apply a suitable adhesive at appropriate positions on the flaps K and J. The application of glue can occur before, during or after the PLC 132 has caused the second movement apparatus 115b to move the second erector head 120b to a downstream location where the major flaps F and G can be folded and compressed onto minor flaps K and J. As illustrated in FIG. 23, glue may be applied while the second movement apparatus 115b is moving the second erector head 120b to the downstream location for closing the bottom opening by folding and compression.

[0248] - Next, the upper flap actuation device 705 may be activated by the PLC 132 acting through a valve device to cause the upper pneumatic actuator device 704a to extend piston arms connected to the upper plough 708a. Similarly, the lower flap actuation device 707 may be activated by the PLC 132, such that the lower pneumatic actuator device 704b extends its piston arms connected to the lower plough 708b, as shown in sequential FIGS. 24 and 25.

[0249] - Next, as shown in FIG. 26, the right hand compression device 706, with the central pneumatic actuator 710, may have piston arms extended so that the longitudinally extending sealing plate 716, having attached thereto the upper rail 717a and the lower rail 717b, engages upper major flap F and lower major flap J. The upper rail 717a may be positioned to be able to engage upper major flap F and the lower rail 717b may be positioned to engage lower major flap G when piston arms of the actuator device 710 are extended horizontally and transversely inwards to push major flaps F and G into engagement with flaps K and J that are positioned underneath. The upper flap actuation device 705 and the lower flap actuation device 707 may be withdrawn by the PLC 132 when the compression device 706 has engaged major flaps F and G.

[0250] - Next, as illustrated in FIG. 27, the left hand compression device 704 may be used to enter the carton blank 111 from the left side and compress flaps F, G, J and K between the left hand compression plate 720 of the left hand compression device 704, the upper rail 717a of the right hand compression device 706 and the lower rail 717b of the right hand compression device 706. This compression may be shown to assist in establishing that the panels are compressed together to ensure that the adhesive appropriately bonds the flaps together to make a solid carton bottom.

[0251] - Once the compression has been held for a short time (for example, about 0.5 seconds), to allow the glue to sufficiently set/harden and bond the flaps together, the compression can be released by withdrawing the left hand compression device 704 and the right hand compression device 706 as illustrated in FIG. 28. The carton may then be considered to be a fully erected carton and released from the folding and sealing apparatus 130 and from the second erector head 120b. The release may be shown to occur responsive to the PLC 132 causing the piston arm suction cups 320 and the suction plate suction cups 312 to have their suction force turned off by the solenoid valve device 340. Additionally, the PLC 132 may cause the rotator device 350 to be rotated backwards a further 90 degrees to the horizontal ready position illustrated in FIG. 29.

[0252] - Thereafter, the second erector head 120b may release the erected carton, which can then fall onto the support plate 703 and remain there, on the support plate 703, until the next carton blank 111, carried by another erector head moved by another movement apparatus (such as the first erector head 120a moved by the first movement apparatus 115a) moves the next carton blank 111 into the location where the next carton blank 111 will be folded, sealed and compressed and, in doing so, pushes the fully erected carton downstream to the discharge chute 750, where the erected carton may fall onto the discharge conveyor 117.

[0253] The entire sequence of movement of a given carton blank 111, as the given carton blank 111 is processed by the carton forming system 100, is illustrated in isolation in FIGS. 10A, 10B, 10C, 10D and FIGS. 11 to 16. In FIGS. 10A, 10B, 10C, 10D, the given carton blank 111 is illustrated in its flattened tubular configuration. In FIG. 11, the given carton blank 111 is illustrated in its opened configuration, after being opened by an erector head like the second erector head 120b. In FIG. 12, the given carton blank I l l is illustrated with the trailing minor flap K folded inwards and in FIG. 13, the given carton blank 111 is illustrated with leading minor flap J also folded inwards. In FIG. 14, the given carton blank 111 is illustrated with the major bottom flaps F and G folded inwards. In FIG. 15, the given carton blank 111 is illustrated when the flaps J, K, F and G are being, or have been, compressed to seal the bottom of the erected carton. Finally, in FIG. 16, the erected carton is illustrated with its opening facing upwards, so that the erected carton may be loaded with one or more items.

[0254] While the foregoing handling of a carton blank 111 by the second erector head 120b has been occurring, the first erector head 120a, being supported and moved by the first movement apparatus 115a, can be carrying out the same process out of phase with the second erector head 120b. For example, cyclical movement and operation of the first erector head 120a may be 180 degrees out of phase with the movement and operation of the second erector head 120b. By providing the first erector head 120a and the second erector head 120b operating simultaneously, but out of phase, it may be shown that one does not interfere with the other. It follows that the capacity of the carton forming system 100 to process the carton blanks 111 can be shown to be increased significantly relative to a system with only a single erector head. Notably, the use of only a single erector head, the processing capacity of the carton forming system 100 may still be considered to be relatively high. In part, the relatively high processing capacity is also due to a relatively short “stroke” (/.< ., longitudinal distance) that the erector heads travel when carrying out the blank retrieval, erection, folding, sealing and compression. This relatively short stroke means that the components do not travel as great a distance as travelled by components in conventional carton erectors. When using two erector heads with moving apparatuses, the carton forming system 100 may be capable of processing about 35 cartons blanks per minute.

[0255] It will be appreciated that, by making a relatively small number of changes to the components of the carton forming system 100, the carton forming system 100 may be altered from being able to process blanks for open top cartons to being able to process blanks that can be turned into open top trays. FIG. 46 illustrates a plan view of a blank for a tray that may be processed according to some embodiments. Examples of other blanks that may be processed, cartons that may be formed are illustrated in FIGS. 47, 48 and 49 and include blanks for a so- called wrap around half slotted case (HSC) and HSC blanks, as well as blanks for a wraparound RSC.

[0256] It should be clear that carton forming systems may be arranged in a manner distinct from the carton forming system 100 of FIG. 1A. For example, several arrangements for carton forming systems are disclosed in United States Patent Application Serial No. 16/230,979, filed December 21, 2018 [issued as United States patent no. 10,556,713 on February 11, 2020], and United States Patent Application Serial No. 16/808,140, filed March 3, 2020 [published as United States patent publication no. US 2021/0138756 Al on May 13, 2021], all of which documents are hereby incorporated in their entirety herein by reference.

[0257] With reference to FIG. 50, in overview, a carton forming system 6000, which is presented as an alternative to the carton forming system 100 of FIG. 1 A, has a magazine 6110 adapted to receive and hold a plurality of knock-down carton blanks 111 and an end effector 6120 for retrieving the knock-down carton blanks 111 from a pick-up area and placing the knockdown carton blanks 111 on a shuttle 6140. As will be described hereinafter, the end effector 6120 and the shuttle 6140 co-operate to manipulate the knock-down carton blanks 111 in such a way as to erect the knock-down carton blanks 111 into sleeves.

[0258] The carton forming system 6000 may also include a folding apparatus, generally designated 6130 and configured to fold one or more flaps of each sleeve, and a sealing station 6135 at which flaps of the carton blanks 111 are sealed. The carton forming system 6000 may also include a carton re-orienting station 6116 and a carton discharge conveyor 6117 for receiving and moving cartons away once they have been fully erected.

[0259] The operation of the components of the carton forming system 6000 may be controlled by a PLC. The PLC may be accessed by a human operator through a Human Machine Interface (HMI) module secured to a frame 6109 of the carton forming system 6000. The HMI module may be in electronic communication with the PLC. The PLC may be any suitable PLC and may for example include a unit chosen from the Logix 5000 series devices made by Allen- Bradley / Rockwell Automation, such as the ControlLogix 5561 device. The HMI module may be a Panelview part number 2711P-T15C4D1 module also made by Allen-Bradley / Rockwell Automation.

[0260] Turning now to the various portions of the carton forming system 6000, with reference to FIG. 50, the magazine 6110 may be configured to hold a stack including a plurality of vertically stacked knock-down carton blanks 111 and may be operable to move the stack of the carton blanks 111 in a horizontal direction generally parallel to horizontal axis X under the control of the PLC, to a pick-up location where the end effector 6120 can retrieve cartons from the magazine 6110.

[0261] The magazine 6110 may comprise a single conveyor or other blank feed apparatus to deliver the carton blanks 111 to a pick-up location. In the illustrated embodiment, two conveyors are disclosed: an in-feed conveyor 6204; and an alignment conveyor 6206. The in-feed conveyor 6204 may be configured and operable to move a stack of the carton blanks 111 from a stack input position (where a stack may be loaded onto the in-feed conveyor 6204 such as by human or robotic placement) to a position where the stack of the carton blanks I l l is transferred to the alignment conveyor 6206 for horizontally aligning and transversely aligning. The alignment conveyor 6206 may be positioned downstream in relation to the in-feed conveyor 6204 and may be used to move the stack of the carton blanks 111 to the pick-up location. The magazine 6110 may be loaded with, and initially hold, a large number of the carton blanks 111 in vertical stacks, with the stacks resting on the in-feed conveyer 6204. A rear wall 6202 mounted to the frame 6109 may be configured to prevent a stack from falling backwards when initially loaded on the in-feed conveyor 6204. The rear wall 6202 may have a generally planar, vertically and transversely oriented surface facing the stack of the carton blanks 111. The in-feed conveyor 6204 may be of an appropriate length to be able to store a satisfactory number of stacks of the carton blanks 111 in series on the in-feed conveyor 6204. The PLC can control the operation of the in-feed conveyor 6204 to move one stack at a time to the alignment conveyor 6206.

[0262] With the in-feed conveyor 604 having one or more stacks of the carton blanks 111 arranged longitudinally thereon, the stacks can be fed, in turn, onto the alignment conveyor 6206. A sensor (not shown) may be provided in the vicinity of the in-feed conveyor 6204 to monitor whether there is a stack waiting on the in-feed conveyor 6204 and that sensor may be operable to send a warning signal to the PLC that can alert an operator that the magazine 6110 is low and needs to be replenished. The sensor may be a part number 42GRP-9000-QD made by Allen Bradley.

[0263] Of particular note, a plurality of stacks of blanks might be provided on the in-feed conveyor 6204 and each stack may be have associated information that can be read by an information reader 6205, such as electronic or an optical reading device. For example, a bar code may be provided on each stack of the carton blanks 111, such as on the top or bottom carton blank 111 of the stack. The bar code may be read by a bar code reader associated with the in-feed conveyor 6204. The bar code reader may be in communication with PLC. The bar code may provide information indicative of a characteristic of the carton blanks 111 in the stack. For example, the bar code may identify the size and/or type of the carton blanks 111 in a particular stack. Other information indicators may be used, such as, for example, RFID tags/chips and RFID readers. The information can then be automatically provided, by the information reader, to the PLC, which can determine whether the current configuration of the carton forming system 100 can handle the processing the particular type/ size of blanks without having to make manual adjustments to any of the components. It is contemplated that, within a certain range of types/sizes of carton blanks 111, the carton forming system 6000 of FIG. 50 is able to handle the processing of different types/sizes of carton blanks 111 without manual adjustment of any components of the carton forming system 6000 of FIG. 50. The bar code/RFID tag may provide the information about the dimensions of the carton blank 111, as discussed hereinbefore, and then the PLC can determine adjustments, if any, that need to be made to (a) the components of the magazine 6110; (b) the movement of the end effector 6120; (c) the movement of the shuttle 6140; and (d) at least some of the components of the folding apparatus 6130 and some components at the sealing station 6135 to be able to process a particular carton blank 111 or a particular stack of carton blanks 111. The result is that the carton forming system 6000 of FIG. 50 may be able to automatically process at least some different types of carton blanks 111 to form different erected cartons, without having to make manual operator adjustments to any components of the carton forming system 6000. [0264] The belt of the in-feed conveyor 6204 may be driven by a suitable motor, such as a

DC motor or a variable frequency drive motor controlled through a DC motor drive (all sold by Oriental under model AXH-5100-KC-30) by the PLC.

[0265] Once the PLC has given an instruction (such as, by a human operator through the HMI module), the in-feed conveyor 6204 may be activated to move a stack of the carton blanks 111 horizontally downstream. The PLC can control the motor through the motor drive and, thus, control the in-feed conveyor 6204 to move and transfer the stack towards, and for transfer to, the alignment conveyor 6206.

[0266] The alignment conveyer 6206 may be driven by a motor with a corresponding motor drive. The motor for the alignment conveyer 6206 may also be controlled by the PLC. The alignment conveyer 6206 may be operated to move the stack of the carton blanks 111 further horizontally until the front face of the stack abuts a planar front stop picket wall 6218.

[0267] The respective belts of the in-feed conveyor 6204 and the alignment conveyer 6206 may be made from any suitable material, such as, for example, Ropanyl.

[0268] During movement of the stack of the carton blanks 111 horizontally by the in-feed conveyor 6204 and the alignment conveyor 6206, the left hand side of the stack of the carton blanks 111 may be supported and guided by a left hand side wall 6200, which may be fixed to the frame 6109. The left hand side wall 6200 may be oriented generally vertically and may extend horizontally for substantially the full length of the in-feed conveyor 6204 and the full length of the alignment conveyor 6206.

[0269] The outer side of the magazine 6110 adjacent to the in-feed conveyor 6204 may be left open; however, the outer side of the alignment conveyor 6206 is illustrated as having a moveable outer guide wall 6201.

[0270] During operation of the carton forming system 6000 of FIG. 50, the left hand side wall 6200 is fixed and the outer guide wall 6201 may be moved laterally as part of a blank stack alignment procedure to provide for generally longitudinal alignment of the end edges of the carton blanks 111 in the stack being prepared for processing as the stack is held between the left hand side wall 6200 and the outer guide wall 6201. Specifically, the PLC may position the outer guide wall 6201 based on a height dimension of the knock-down carton blanks 111 in the stack being readied for processing, based on information previously read by the information reader 6205.

[0271] In order to pick-up blanks, the end effector 6120 may have one or more suction cups providing a suction force to a panel acting generally normal to the surface of the panel that is engaged. Other types of suitable engagement devices might be employed.

[0272] The end effector 6120 is illustrated as having a dedicated, independently driven and controlled movement apparatus 6115 that allows the end effector 6120 to move in a plane defined by both vertical axis, Z, and horizontal axis, Y. Thus, movement of the end effector 6120 can only be in the vertical, Z, and horizontal, Y, directions - the end effector 6120 cannot move in a horizontal, X, direction. If the movement of the end effector 6120 is restricted to only Z and Y directions, a moving apparatus can be constructed that is relatively less complex than if movement in all three directions is desired.

[0273] The movement apparatus 6115 includes a vertically oriented support tube that may be generally rectangular in cross section and to which the end effector 6120 may be mounted by mounting blocks such that the end effector 6120 moves in space with the support tube.

[0274] The folding apparatus 6130 is illustrated as having opposed horizontally reciprocating fin ploughs, namely an upstream fin plough and a downstream fin plough. These fin ploughs are slidably supported on a horizontal rail 6512 that extends in the X-direction.

[0275] The horizontal rail 6512 on which the fin ploughs run is attached at either end to the base of L-shaped supports. One of the L-shaped supports is associated with reference numeral 6560a. The L-shaped supports ride in channels 6562 of vertical ribs 6109a, 6109b of the frame 6109. A servo motor 6568 is geared to a common drive shaft 6570 to turn pinions (not shown) inside hubs 6572a, 6572b. The pinions mesh with ring gear portions of shafts 6574a, 6574b to turn, and thereby adjust, the vertical position of the shafts 6574a, 6574b. The shafts 6574a, 6574b are rotatably connected to the top of the L-shaped supports. The result is that operation of the servo motor 6568 in one rotational direction raises the L-shaped supports - and, therefore, the fin ploughs - and operation of the servo motor 6568 in the opposite rotational direction lowers the L- shaped supports.

[0276] Similarly, a vertical rail, on which folding ploughs run via support arms and carriages, is attached to a linear support that rides in a channel of a vertical rib of the frame 6109. A common drive shaft also turns a pinion (not shown) inside a hub 6572c and this pinion meshes with a ring gear portion of a shaft 6574c in order to turn, and thereby adjust, the vertical position of the shaft 6574c. The shaft 6574c is rotatably connected to the top of a linear support. The result is that operation of the servo motor 6568 in one rotational direction raises the linear support - and, therefore, the folding ploughs - and operation of the servo motor 6568 in the opposite rotational direction lowers the linear support. Moreover, since all of the supports are adjusted by the common drive shaft 6570, these supports are all adjusted to the same vertical extent by operation of the servo motor.

[0277] The sealing station 6135 has a tape sealer 6640 and flap folding rods 6632, which are supported by the fin supporting rail 6512 and move vertically with the fin ploughs. The sealing station 6135 also has a pair of opposed conveyor belts, an upper conveyor belt driven by an upper conveyor belt servo motor 6602 and a lower conveyor belt 6610 driven by a lower conveyor belt servo motor 6612, with the tape sealer 6640 disposed between the upper conveyor belt and the lower conveyor belt. The lower conveyor belt 6610 and a supporting platform 6614 are supported by the factory floor. The upper conveyor belt is mounted to a sub-frame 6622. The servo motor 6568 has a second drive shaft that is operatively associated with a drive train (not shown) so that operation of the servo motor 6568 adjusts the vertical position of the sub-frame 6622 and, therefore, adjusts the vertical position of the upper conveyor belt with respect to the lower conveyor belt 6610. Moreover, it will be noted that the drive shaft and the common drive shaft 6570 are driven by the same servo motor 6568, such that a vertical adjustment of the upper conveyor belt is mirrored by a vertical adjustment of the fin ploughs. However, the drive train is configured with a 2: 1 drive ratio so that the drive shaft rotates twice for any rotation of the common drive shaft 6570. The result is that a vertical adjustment of n cm of the fin ploughs, folding ploughs, tape sealer and flap supporting rods results in a vertical adjustment of 2n cm of the upper conveyor belt. This ensures that the centerline of a carton sleeve remains at the level of the fins and tape sealer for any position of the upper conveyor belt. [0278] The sealing station 6135 terminates at the carton re-orienting station 6116. The carton re-orienting station 6116 has a pair of deflection plates 6650, 6652, which re-orient an erected carton as the erected carton falls off the end of the sealing station to the discharge conveyor 6117 from a position lying on its side at the sealing station 6135 to an upright position on the discharge conveyor 6117 with the open top of the erected carton facing upwardly. The discharge conveyor 6117 may be implemented as a simple endless belt conveyor driven by a discharge conveyor servo motor 6648.

[0279] In another aspect of the present application, illustrated schematically in FIG. 51, a carton forming system 5100 is constructed substantially the same as the carton forming system 6000 of FIG. 50, except as described hereinafter. In the carton forming system 5100 of FIG. 51, a plurality of magazines M1-M5 may be supported by one or more frame structures above a common in-feed conveyor 6204’, which may be constructed generally like the in-feed conveyor 6204 of FIG. 50. The magazines M1-M5 may be arranged in spaced longitudinal relation to each other vertically above the in-feed conveyor 6204’. The in-feed conveyor 6204’ feeds an alignment conveyor 6206’, which may be like the alignment conveyor 6206 of FIG. 50. Except as described hereinafter, the remainder of the carton forming system 5100 of FIG. 51 may be the same as the carton forming system 6000 of FIG. 50.

[0280] The magazines Ml -Ml 5 may each contain one or more stacks of product packaging, such as case blanks which each may generally be like the carton blanks 111 processed by as the carton forming system 6000 of FIG. 50, with at least some and possibly each of the magazines M1-M15 containing different types/sizes and/or configurations of packaging/case blanks compared to other magazines. The size, configurations and types of the case blanks (and the cases that can be formed therefrom) can vary to provide a range of case sizes, configurations and types that can be automatically processed by the carton forming system 5100 of FIG. 51 without the need for any manual intervention to modify any components of the carton forming system 5100 of FIG. 51. A PLC for the carton forming system 5100 of FIG. 51 may be programmed such that the particular dimensions/overall size/configuration (e.g., such as, regular slotted carton or “RSC”)/type of each of the carton blanks held in each one of the magazines M1-M5 is stored in the memory of the PLC. [0281] Each magazine M1-M5 may provide a vertical stack of case blanks above the in-feed conveyor 6204’ and be operable to dispense single case blanks on demand under the control of the PLC, in a flattened orientation onto the in-feed conveyor 6204’. An example arrangement of a suitable type of vertical case dispensing magazine is the magazine that forms part of the 310E case erector made by Wepackit Inc. of Orangeville, Ontario, Canada (see www.wepackitmachinery.com/310E/310E.pdf ).

[0282] The PLC may give an instruction to form a case and, if required, the PLC may cause one of the magazines M1-M5 to dispense a carton blank of an appropriate configuration/size onto the in-feed conveyor 6204’ for delivery to the alignment conveyor 6206’. The PLC is expected to selectively move and transfer a single carton blank at a time onto the in-feed conveyor 6204’ from any one of the magazines Ml to M5. Therefore, separate individual case blanks may be fed, in series and longitudinally, in a desired sequence by the in-feed conveyor 6204’ to the alignment conveyor 6206’. The particular sequence/order of the carton blanks that are placed onto the in- feed conveyor 6204’ of the carton forming system 5100 of FIG. 51 may be determined and selected by the PLC or another control system, such that the case blanks may arrive at the alignment conveyor 6206’ in such a desired sequence in which it is desired to process the blanks within the carton forming system 5100 of FIG. 51.

[0283] The PLC may maintain, in its memory, records of the sequence of the case blanks that have been placed onto the in-feed conveyor 6204’. For example, this information may include the type/size/configuration of the case blank and, where the carton forming system 5100 of FIG. 51 includes a labeler, some label information for a label that is to be applied to the carton blank. A new record can be added each time a request for a new carton is received and, optionally, records can be removed once a carton has been formed (and labeled). Thus, such records may be organized and maintained in sequence in the memory of the PLC using a conventional shift registering technique. In this way, the record for the next carton blank scheduled to arrive at the alignment conveyor 6206’ may be provided at the output of the shift registers as that carton blank arrives and the type/configuration/size of that carton blank and the label information for that carton blank may be determined from the provided output.

[0284] Additional features that may be employed in carton forming system 6000 are provided in United States patent publication no. US 2021/0138756 Al published May 13, 2021, in the name of H. J. Paul Langen, the entire contents of which are hereby incorporated herein by reference.

[0285] FIG. 52 illustrates, in a plan view, an order fulfillment location 5200. The order fulfillment location 5200 may be considered to be physically organized, in a logical manner, into areas or regions associated with various functions. The order fulfillment location 5200 includes a product storage induction region 5202, a tower storage region 5204, a shipping container induction region 5206, a product induction region 5208, an autonomous mobile robot movement region 5210 and a route distribution accumulation region 5212. In practice, depending upon the size of the order fulfillment location 5200, the order fulfillment location 5200 may include multiples of the regions illustrated in FIG. 52 and may, in some cases, omit one or more regions.

[0286] At the product storage induction region 5202, various products may be shown to arrive at the order fulfillment location 5200 in, say, a plurality of transport trailers.

[0287] The products that have arrived, often organized upon a pallet, may be stored into a plurality of towers, which towers are located at the tower storage region 5204. Personnel and/or robots 5999 may unload products delivered (such as by transport trailers and which products may be delivered on pallets) to the order fulfilment system 5200. The personnel and/or robots 5999 may store, in the towers, the unloaded products. Upon being filled with products, a given tower may then be moved, by a tower-transportation AMR (discussed hereinafter), so that the given tower is located within the tower storage region 5204. The process of storing the products, which have arrived at the order fulfillment location 5200, into the plurality of towers, is described in more detail hereinafter.

[0288] The shipping container induction region 5206 may be populated with a plurality of carton forming systems, perhaps following the design of the carton forming system 100 disclosed hereinbefore.

[0289] According to aspects of the present application, a plurality of autonomous mobile robots (AMRs) may be deployed for movement within the autonomous mobile robot movement region 5210. [0290] As will be discussed in detail hereinafter, an AMR may be controlled to visit the shipping container induction region 5206 to obtain a shipping container.

[0291] The combination of the AMR and the shipping container may then be controlled to visit one or more stations in the product induction region 5208. At a given station in the product induction region 5208, one or more products may be received within the shipping container carried by the AMR. The stations in the product induction region 5208 may be associated with provision of products that are stored in the tower storage region 5204.

[0292] Upon the receipt of a product that completes an order, the AMR may then be controlled to move around the autonomous mobile robot movement region 5210 so that further order fulfillment functions may be carried out. For a few examples, the AMR may then be controlled to move the shipping container to a location within the autonomous mobile robot movement region 5210 at which location the weight of the shipping container may be verified. The shipping container may then be sealed and labelled.

[0293] The weight-verified, sealed and labelled shipping container may then be received at the route distribution accumulation region 5212, where the shipping container may be loaded, by personnel and/or robots 5998, upon a delivery vehicle.

[0294] FIG. 53 illustrates, in a top-right perspective view, an AMR 5300 in accordance with aspects of the present application.

[0295] FIG. 53 A illustrates, in a top-right perspective view, the AMR 5300 of FIG. 53 with the addition of a shipping container 5309.

[0296] The AMR 5300 may have a base that forms part of a mobile cart 5304. Other components may be attached to the base of the cart 5304 or interconnected with the base of the cart 5304. The AMR 5300 may include an outer case 5302 carried by the cart 5304. Features of the cart 5304 may be familiar from known autonomous mobile robots. Indeed, the cart 5304 may be expected to include a rechargeable power source, such as a battery (not explicitly shown), and a transmission (not explicitly shown). The transmission, or a drive motor, may be configured to cause a set of drive wheels (not shown) to move the cart 5304. The rechargeable power source, the transmission and drive wheels may be mounted to the base of the cart 5304. A typical, modern-day AMR can run up to three hours between charges. The AMR 5300 may be configured to return to a designated charging station as required. At the designated charging station, the AMR 5300 may establish a connection between charging circuitry (not shown) and an external energy source, such as an electrical wall receptacle.

[0297] In addition to the set of drive wheels, the cart 5304 may also feature a set of stability wheels 5306S, which may be caster wheels, to allow for ease of rotational movement of cart 5304 during operation. There may, in total, be at least three wheels, including drive wheels and stability wheels 5306S, which, in combination, both support and drive the movement of the cart 5304 over a surface. The cart 5304 may also be expected to include a control system (not explicitly shown), which may be implemented as a processor in communication with a memory. The AMR 5300 may include a transceiver for use in establishing a wireless connection with a controller that forms part of an overall system to be discussed, in detail, hereinafter.

[0298] Details of an example design for the AMR 5300 may be found in US Provisional Patent Application Serial No. 63/424676, the contents of which are hereby included herein by reference. The details of the example design include a description of a plurality of suction cups mounted to the outer case 5302. It may be shown that the suction cups act to maintain the shipping container 5309 on the AMR 5300, as illustrated in FIG. 53 A.

[0299] FIG. 54 illustrates, in a sectional perspective view, the AMR 5300. The outer case 5302, which may be made from a suitable material, such as molded plastic, fiberglass, aluminum or other metal, is illustrated using stippled lines to illustrate contents of the outer case 5302 held within an interior cavity of the outer case 5302. Contents of the outer case 5302 may include a vacuum reservoir 5402 and a plurality of suction cups 5404 mounted to the outer case 5302. The suction cups 5404 may be mounted in a generally vertically upwards direction with an upwardly directed contact surface. In other embodiments, the suction cups 5404 may be oriented additionally, or alternately, in other directions, such as sideways.

[0300] Preferably, the plurality of suction cups 5404 mounted to the outer case 5302 in a manner with upward facing contact surfaces of the suction cups 5404 that maintains a flush top surface 5412 of the outer case 5302. Indeed, the top surface 5412 of the outer case 5302 may appear to have a plurality of recesses corresponding to the plurality of suction cups 5404. The suction cups 5404 may be implemented using, for example, 2” piGRIP suction cups manufactured by PIAB of Taby, Sweden. Mounted to the cart 5304 of the AMR 5300 may be a vacuum pump 5406 in pneumatic communication with the vacuum reservoir 5402. The vacuum pump 5406 may be driven by an integral electric motor (not shown). Examples of electric vacuum pumps that are suitable for use as the vacuum pump 5406 are those available from McMaster-Carr of Cleveland, OH and Thomas of Sheboygan, WI. The vacuum reservoir 5402 is also in pneumatic communication with the plurality of suction cups 5404 via a corresponding plurality of apertures/openings in the vacuum reservoir 5402. Interposing between the apertures/openings in the vacuum reservoir 5402 and each respective suction cup 5404 (and respective valve 5502 as referenced below) in the plurality of suction cups 5404 is a slide plate 5408. The slide plate 5408 may be made from a suitable material, such as molded plastic, fiberglass, aluminum or other metal, and may be configured with a perforation/opening corresponding to each aperture in the vacuum reservoir 5402. The slide plate 5408 may be movable between a closed position/state, in which the openings in the vacuum reservoir and the opening to each respective valve 5502/suction cup 5404 combination (as described further below) are blocked, and an open position/state, in which the openings in the vacuum reservoir and the opening to each respective valve 5502/suction cup 5404 combination (as described further below) are unblocked, thereby allowing a suction force to be developed at the top contact surface of each respective valve 5502/suction cup 5404 combination.

[0301] The slide plate 5408 may be moved between the open position and the closed position through actuation of an electric actuator 5410. One example of the type of actuator that may be employed, as the electric actuator 5410, is a solenoid valve type of actuator such as the model al4092600ux0438 Open Frame Actuator Linear Mini Push Pull Solenoid Electromagnet, DC 4.5 V, 40 g/2 mm made by uxcell of Hong Kong, China. Another example of the type of electric actuator that may be employed, as the electric actuator 5410, is a linear stepper motor type of actuator such as the model VSM0632 6mm micro linear stepper motor screw motor with bracket, which is made by Changzhou Vic Tech Motor Co. Ltd. of Jiangsu, China. A further example of the type of electric actuator that may be employed, as the electric actuator 5410, is a linear potentiometer type of actuator such as a model in the LMCR8 Series from P3 America of San Diego, California. [0302] FIG. 55A illustrates, in section view, a portion of the outer case 5302 in conjunction with a plurality of the suction cups 5404, the vacuum reservoir 5402 and the slide plate 5408. The section view of FIG. 55 A illustrates that each suction cup 5404 incorporates a one-way valve 5502. The one-way valves 5502 may be implemented, for example, using piSave sense flow control/check valves manufactured by PIAB of Taby, Sweden.

[0303] In FIG. 55A, the slide plate 5408 is in a first open position. In the first open position, perforations in the slide plate 5408 align with apertures in the vacuum reservoir 5402. The alignment illustrated in FIG. 55 A may be shown to allow a possibility of a flow of air, through each suction cup 5404, into and through the one-way valves 5502 of the suction cups 5404, and into the negative air-pressure vacuum reservoir 5402. Notably, when the slide plate 5408 is in the first open position, flow of air through the suction cups 5404 is controlled by the one-way valves 5502.

[0304] FIG. 55B illustrates, in section view, the same portion of the outer case 5302 that is illustrated in FIG. 55 A. In FIG. 55B, the slide plate 5408 is in a second closed position. In the second closed position, perforations in the slide plate 5408 do not align with apertures in the vacuum reservoir 5402. The lack of alignment illustrated in FIG. 55B may be shown to disallow or block the flow of air, into the suction cups 5404, through the one-way valves 5502 of the suction cups 5404, and into the vacuum reservoir 5402.

[0305] In operation, pressure within the vacuum reservoir 5402 is reduced through action carried out by the vacuum pump 5406. Indeed, the vacuum pump 5406 may, responsive to an instruction received from the control system, cause the integral electric motor to create negative pressure within the vacuum reservoir 5402. The slide plate 5408 may be maintained in the second position, thereby reducing leakage of vacuum pressure, as the control system controls the drive wheels 5306D to maneuver the AMR 5300.

[0306] FIG. 56A illustrates an embodiment of a basic concept of a fulfillment center 7000 that utilizes AMR devices such as the AMR 5300 of FIG. 53 and/or an AMR 5800, which is illustrated in FIG. 58 and described hereinafter. [0307] Each AMR, such as AMR 5800 (and/or AMR 5300), of the multiple AMRs in the system can be programmed to move from station to station along a path 7680 as follows:

1. Each AMR 5300/5800 moves to one of several case induction stations 7628, where a case erector transfers an erected and bottom sealed carton onto the AMR 5300/5800.

2. Each AMR 5300/5800 then moves to one or more product induction stations in a product induction region 7608, which may be manual product induction stations and/or robotic product induction stations, where an operator and/or a robot places the one or more order products into the erected carton.

3. Each AMR 5300/5800 then moves to one of a plurality of order verification stations 7630 to verify that the contents of the case corresponds to the products of the order products.

4. Each AMR 5300/5800 then moves to and through a top sealer 7620 and a case labeler 7624.

5. Each AMR 5300/5800 then moves to a finished case discharge conveyor 7626.

6. Each AMR 5300/5800 may then move to a charging station 7622 or return to one of the case induction stations 7628, where a case erector may transfer, onto the AMR 5300/5800, an erected and bottom sealed case, to allow the cycle to be repeated.

[0308] The case erector at the case induction station 7628 may be a model MC-17169 case erector made by AFA Systems Ltd. of Ontario, Canada or it may be another case erector described herein. The case top sealer 7620 and the case labeler 7624 may be apparatuses also available from AFA Systems Ltd. The case erector at the case induction station 7628 may be a case erector as disclosed in United States patent publication no. US 2021/0138756 Al published May 13, 2021, the entire contents of which are hereby incorporated herein by reference.

[0309] FIG. 68 illustrates, in a front left perspective view, an example arrangement for the case top sealer 7620 (and which may also provide an example case sealer for other order fulfillment systems described herein). The example case top sealer 7620 of FIG. 68 may be understood to have many of the same features and components of known case top sealers. However, the example case top sealer 7620 of FIG. 68 may be distinguished from known case top sealers in that the erected carton is maintained on the AMR 5300/5800 while the erected carton is being acted upon by the components of the example case top sealer 7620 of FIG. 68. That is, the example case top sealer 7620 of FIG. 68 may be considered to be a “drive-through” sealing apparatus. The AMR 5300/5800 may utilize solely its own drive mechanism to move and be powered through the sealing apparatus 7620.

[0310] The components of the example case top sealer 7620 of FIG. 68 may include a pair of transversely spaced, longitudinally extending guide belts 6802. The pair of transversely spaced, longitudinally extending guide belts 6802 may be made of a suitable material, such as rubber. Each guide belt 6802 may be arranged to loop around a pair of freely rotatable pulley wheels, which may be rotatable about a generally vertically oriented axle. The guide belts 6802 may be shown to be operable to guide the erected carton during longitudinal movement of the AMR 5300/5800 with the erected carton thereon, through the example case top sealer 7620. The guide belts may be shown to be in contact with respective opposed side surfaces of the erected carton during longitudinal movement of the AMR 5300/5800 with the erected carton secured thereon, through the example case top sealer 7620 of FIG. 68.

[0311] In aspects of the present application, movement and the positioning of the guide belts 6802 may be sensed by a guide belt movement sensor (not shown). Output from the guide belt movement sensor, which may be shown to be indicative of the movement of the AMR 5300/5800 and the erected carton through the through the case top sealer 7620, may be transmitted to an order fulfillment processor, operation of which will be discussed in greater detail hereinafter. Conveniently, the position of the pulley wheels may be transversely adjustable to change the distance between the guide belts 6802 to, thereby, accommodate erected cartons of different dimensions.

[0312] In common with known case top sealers, the components of the example case top sealer 7620 of FIG. 68 may include one or more folding rails 6806, one or more flap kickers such as a rear flap kicker 6808 and a sealing system 6804. In operation, as the guide belts 6802 guide the erected carton during longitudinal movement of the AMR 5300/5800 with the erected carton thereon, through the example case top sealer 7620, the rear flap kicker 6808 may act to close the trailing top flap and the folding rails 6806 (and/or one or more other flap kicker devices) may act to close the leading top flap and the side top flaps. In common with known case top sealers, subsequent to, or in conjunction with, the top flaps being closed, the sealing system 6804 may act to seal the carton with the application of tape or other adhesive to hold the top flaps in a closed position. [0313] In a manner similar to the manner in which the example case top sealer 7620 of FIG. 68 may be considered to be a “drive-through” sealing apparatus, the case labeler 7624 may be considered to be a “drive-through” case labeler such that the AMR 5300/5800 moves through the case labeler 7624 entirely under its own motive power. Indeed, the case top sealer 7620 and the case labeler 7624 may be co-located so that an open, erected carton may be closed, sealed and labeled as the AMR 5300/5800 transfers the erected carton through the co-located case top sealer 7620 and case labeler 7624.

[0314] FIG. 56 illustrates, in a plan view, a portion 5600 of an order fulfillment center. The fulfillment center portion 5600 includes a charging station 5602, a shipping container induction station 5604, a plurality of goods loading stations 5606A, 5606B, 5606C (collectively or individually 5606), a dunnage induction station (not shown), an inspection station (not shown), a rework station (not shown), an order verification station (not shown in FIG. 56), a closing station 5616 and a routing staging station 5618.

[0315] FIG. 57 illustrates example steps in a method of fulfilling an order.

[0316] In view of FIG. 56, the control system may control the drive wheels 5306D to move

(step 5702, FIG. 57) the AMR 5300 from the charging station 5602 to the shipping container induction station 5604. Upon arrival of the AMR 5300 at the shipping container induction station 5604, the control system may control the electric actuator 5410 to move the slide plate 5408 into the first position. Minimizing vacuum leakage in the reservoir may be considered to be an important step toward minimizing a number and duration of activations of the vacuum pump 5406. Frequent activations of the on-board vacuum pump 5406 may be shown to reduce a cycle time (time between recharging sessions) of the AMR 5300.

[0317] At the shipping container induction station 5604, a shipping container 5309, which is appropriately sized to fulfill a customer order, may be received (step 5704, FIG. 57) on the top surface 5412 of the outer case 5302 (see FIG. 53A). Under conditions wherein the shipping container 5309 does not completely cover the top surface 5412 of the outer case 5302, it may be shown that a subset of the one-way valves 5502 sense being covered by the shipping container. Responsive to the sensing, the subset of the one-way valves 5502 may autonomously act to open. The remaining one-way valves 5502 may remain closed. The shipping container 5309 may be a flexible (e.g., plastic) type bag, an envelope, a tray, a carton, a case, a box. When the shipping container 5309 is not filled with items, the shipping container 5309 may have a relatively low mass/weight and, so without being secured to top surface 5412 with suction force(s), may be vulnerable to becoming displaced, particularly during movement of the cart 5304 during operation.

[0318] The AMR 5300 may generate (step 5706, FIG. 57) a suction force at each suction cup 5404 of at least some of the suction cups of the plurality of suction cups 5404 to, thereby, hold the shipping container 5309 on the AMR 5300.

[0319] The combination of the slide plate 5408 having been moved into the first position and the subset of the one-way valves 5502 having autonomously opened may be shown to allow the suction cups 5404 to act upon the shipping container 5309 to maintain the shipping container 5309 in place on the top surface 5412 of the outer case 5302. In some embodiments, the footprint of the shipping container 5309, when placed and held on the top surface 5412, will be such that the boundaries of the shipping container 5309 will not extend beyond the perimeter of the top surface 5412.

[0320] Under conditions wherein the shipping container does not completely cover the top surface 5412 of the outer case 5302, only a subset of the plurality of suction cups 5404 corresponding to the subset of autonomously opened one-way valves 5502, act upon the shipping container 5309. The one-way valves 5502 may be configured and operate such that only when a surface area of an object (e.g., a portion of a lower surface of the shipping container 5309) covers a corresponding suction cup 5404, will the corresponding state of the valve change from a substantially non-active mode (which may permit only a very low level of air flow into the suction cup 5404/valve 5502 combination), to an active mode that provides a substantially increased (e.g., full) suction force to be developed by that suction cup created by a substantially increased (e.g., maximum) developed air flow into the suction cup 5404/valve 5502 combination. By only activating the suction cups 5404 that are covered by a portion of a surface of a shipping container, this may result in reduced energy consumption by the AMR 5300 as when compared with an embodiment in which all of the one-way valves 5502 are opened at the same time and all of the suction cup 5404 are activated regardless of whether or not the shipping container 5309 contact surface covers all or only some of contact surfaces of the suction cups 5404. For example, a relatively smaller vacuum pump may be able to be used, resulting in lower pump investment and lower energy consumption.

[0321] It may be shown that the one-way valves 5502 allow the AMR 5300 to adapt to maintain the shipping container in place on the top surface 5412 of the outer case 5302 for a variety of sizes and shapes of shipping container. That is, the AMR 5300 may adapt to maintain the shipping container 5309 in place when the shipping container is a regular slotted bottom- erected case, a paper carton with an open top or side, a cardboard carton with an open top or side, a flexible bag with an open end, or an open top or side envelope, for just four examples. In general, the AMR 5300 may be seen to be able to efficiently adapt to maintain the shipping container in place for a variety of sized shipping containers, such as when the shipping container is any type of shipping container with bottom surface portions that can cover one or more suction cups, and which may have an opening that may be on a top, a side or at an end of the shipping container.

[0322] As the shipping container 5309 is maintained in place on the top surface 5412 of the outer case 5302, the shipping container 5309 is able to remain fixed on the AMR 5300. In other words, the shipping container 5309 may be prevented from moving or falling off while the AMR 5300 transports the shipping container 5309 to and from various stations around the fulfillment center (see FIG. 56), or while actions such as loading goods into the shipping container 5309 or closing and labelling the shipping container 5309, are performed. It will be appreciated that the embodiments disclosed herein may be particularly advantageous where the shipping container 5309 is empty or contains goods that are light in weight such that the shipping container 5309 is, accordingly, associated with a higher likelihood of moving around upon, or falling from, the top surface 5412, especially when the cart 5304 is in motion during operation.

[0323] In some embodiments, while the suction force is being generated at each suction cup 5404 of at least some of the suction cups of the plurality of suction cups 5404 to hold the shipping container 5309 on the AMR 5300, the control system of the cart 5304 may, subsequently, execute instructions to move (step 5708, FIG. 57) the AMR 5300, from the shipping container induction station 5604 to one or more goods loading stations 5606, by directing the transmission to cause the set of drive wheels 5306D to move appropriately. [0324] Accordingly, the AMR 5300 may be shown to move (step 5708, FIG. 57) the shipping container 5309 from the shipping container induction station 5604 to the first goods loading station 5606A, at which the AMR 5300 may maintain (step 5710, FIG. 57) its hold on the shipping container 5309 while the shipping container 5309 receives goods loaded there into. The loading of the goods into the shipping container 5309 may be done autonomously, for example, by a product-loading robot (not shown) that receives instructions, or manually, for example, by a person. The AMR 5300 may transport the shipping container 5309 from the first goods loading station 5606A to a second goods loading station 5606B, at which more goods may be loaded into the shipping container 5309.

[0325] Upon determining (step 5712, FIG. 57) that the AMR 5300 has not yet visited a complete set of goods loading stations 5606 for a particular customer order, the control system may move (step 5714, FIG. 57) the AMR 5300 to transport the shipping container 5309 to a further goods loading station 5606.

[0326] Upon determining (step 5712, FIG. 57) that the AMR 100 has visited a complete set of goods loading stations 5606 for a particular customer order, the control system may move (step 5714, FIG. 57) the AMR 5300 to transport the shipping container 5309 from the last goods loading station 5606 to a top closing and labeling system (not shown) at the closing station 5616.

[0327] The top closing and labeling system may be designed to accept regular slotted cases, envelopes or bags, among other shipping containers. The shipping container 5309 may be closed and labeled, by the top closing and labeling system, without the shipping container 5309 leaving its secured position on the top surface 5412 of the outer case 5302.

[0328] Conveniently, it may be shown that a number of fulfillment operations may be carried out when, as proposed herein, goods are loaded directly into the shipping container 5309 secured to the AMR 5300, is significantly reduced relative to a number of fulfillment operations currently required to be carried out in traditional fulfillment operations.

[0329] Upon having visited the closing station 5616, the control system may move (step 5716, FIG. 57) the AMR 5300 to transport the shipping container 5309 from the closing station 5616 to the appropriate routing staging station 5618. At the routing staging station 5618, the control system of the AMR 5300 may control the electric actuator 5410 to move the slide plate 5408 into the second position. It should be understood that, when the slide plate 5408 is in the second position, the vacuum cups 5404 do not act to maintain their grip on the shipping container 5309 and the shipping container 5309 is released (step 5718, FIG. 57) from the AMR 5300. Accordingly, the shipping container 5309 may be removed from the AMR 5300 and dropped off at the routing staging station 5618, for example, onto an appropriate routing staging conveyor.

[0330] In addition to the goods loading stations 5606, the closing station 5616 and the routing staging station 5618 described above, the AMR 5300 may be shown to transport the shipping container 5309 to and from various other stations or areas, such as a dunnage induction station, an inspection station, a rework station and an order verification station.

[0331] Once the shipping container 5309 has been removed from the AMR 5300, the AMR 5300 may be controlled to return to the shipping container induction station 5604 to obtain a new shipping container, where the new shipping container is appropriate to a next customer order that is to be fulfilled.

[0332] Conveniently, the one-way valves 5502 and their ability to autonomously open in response to sensing that a shipping container 5309 covers them, may be shown to minimize vacuum loss when any portion of the suction cups 5404 are not covered by the shipping container, thereby giving the AMR 5300 a feature of universality.

[0333] Furthermore, the sliding plate 5408 may be shown to act as vacuum cut off, thereby establishing that any size of shipping container that is secured on the AMR 5300 may be released at any time in a fulfillment process without the loss of vacuum in the vacuum reservoir 5402.

[0334] Notably, it is contemplated that the combination of the outer case 5302 and the vacuum pump 5406 may be used, in combination, to retrofit a pre-existing version of the cart 5304. Of course, for proper operation, the control system for the cart would be subjected to an appropriate software update. Additionally, the AMR 5300 may be formed integrally. That is, there may be no discernable distinction between the cart 5304 and the elements that have been described hereinbefore as being contained by the outer case 5302. [0335] Features of the cart 5304 in FIG. 53 may be familiar from known autonomous mobile robots. Indeed, the cart 5304 may be expected to include a rechargeable power source, such as a battery (not explicitly shown), and a transmission (not explicitly shown). The transmission, or a drive motor, may be configured to cause the set of drive wheels 5306D to move the cart 5304. The rechargeable power source, the transmission and drive wheels 5306D may be mounted to the base of the cart 5304. A typical, modern-day AMR can run up to three hours between charges. The AMR 5300 may be configured to return to a designated charging station 5602 as required. At the designated charging station 5602, the AMR 5300 may establish a connection between charging circuitry (not shown) and an external energy source, such as an electrical wall receptacle.

[0336] It should be clear that other mechanisms are available for maintaining a shipping container on an AMR. FIG. 58 illustrates an AMR 5800 as an alternative to the AMR 5300 of FIG. 53, in accordance with aspects of the present application.

[0337] The AMR 5800 may have a base that forms part of a mobile cart 5804. Other components may be attached to the base of the cart 5804 or interconnected with the base of the cart 5804. In common with the AMR 5300 of FIG. 53, the AMR 5800 of FIG. 58 may have an on-board control system (not shown). The AMR 5800 may include a first belt 5802A and a second belt 5802B carried by the cart 5804. The first belt 5802A may be controlled, by, say, the on-board control system (not shown), in a manner that is independent from the manner in which the second belt 5802B is controlled. Attached to the first belt 5802A may be a first lug 5812A. Attached to the second belt 5802B may be a second lug 5812B.

[0338] Through the on-board control system controlling the first belt 5802 A, the first lug 5812A may be urged in a direction towards or away from the second lug 5812B. Similarly, the on-board control system controlling the second belt 5802B, the second lug 5812B may be urged in a direction towards or away from the first lug 5812A. In this manner, by manipulation of the positions of the first lug 5812A and the second lug 5812B in relation to each other, the on-board control system may control the first belt 5802 A and the second belt 5802B to prepare a gap between the first lug 5812A and the second lug 5812B that is suitable for easily loading of an erected shipping containers of a selected dimension (e.g., a selected length and/or width of bottom surface of erected carton). By further manipulation of the positions of the first lug 5812A and the second lug 5812B in relation to each other, the on-board control system may control the first belt 5802A and the second belt 5802B to close the gap between the first lug 5812A and the second lug 5812B to secure the erected carton between the first lug 5812A and the second lug 5812B. The action of the first lug 5812A and the second lug 5812B may be shown to prevent the erected carton from inadvertently falling off of the AMR 5800. For example, in the embodiment illustrated in FIG. 58, the shipping container 5809 is maintained, on the AMR 5800, while acted upon by the first lug 5812A and the second lug 5812B. Upon arrival at a location at which the erected carton, with goods inside, is to be unloaded from the AMR 5800, the on-board control system may control the second belt 5802B to move the second lug 5812B out of engagement with the erected carton. The on-board control system may also control the first belt 5802 A and, consequently, the first lug 5812A, to urge the erected carton, with one or more goods inside, onto an input conveyor associated with further processing the erected carton. For example, the input conveyor may be associated with a carton sealer, as will be discussed hereinafter. In another aspect of the present application, a robotic arm (not shown) may pick the erected carton from the AMR 5800 and place the erected carton onto the input conveyor associated with further processing the erected carton.

[0339] Thus AMR 5800 may be used for transporting a shipping container, and may comprise a mobile cart; a control system for controlling operation of the autonomous mobile robot; a first belt having an upper surface comprising a first lug; a second belt having an upper surface comprising a second lug. The control system may be operable to control and adjust the spacing of the first lug relative to the second lug to move between: a first position in which the spacing between the first lug and the second lug is suitable to allow a shipping container to be positioned between or removed from between the first and second lugs on the upper surfaces the first and second belts; and a second position where the spacing of the second lugs provides for the first and second lugs to engage side surfaces of the shipping container to secure the shipping container between the first and second lugs above the first and second surfaces of the belts. The upper surfaces of first and second belts may be configured to support a shipping container thereon, such that when the shipping container is secured between the first and second lugs, the shipping container is supported on the first and second surfaces of the belts. Movement of the AMR 5800 illustrated in FIG. 58 may be similar to movement (discussed in reference to FIG. 56) of the AMR 5300 illustrated in FIG. 53. [0340] In view of FIG. 57, some of the steps differ when the AMR 5800 illustrated in FIG. 58 is used in place of the AMR 5300 illustrated in FIG. 53. In particular, step 5706 indicates a step of generating a suction force at each suction cup of at least some of the suction cups of the plurality of suction cups 5404 to, thereby, hold the shipping container 5309 on the AMR 5300. In the context of the AMR 5800 illustrated in FIG. 58, step 5704 may be expected to involve holding the shipping container 5809 on the AMR 5800 through the action of the lugs 5812A, 5812B. Step 5718 of FIG. 57 has been discussed as relating to releasing the shipping container 5309 from the AMR 5300 by reducing the suction provided by the plurality of suction cups 5404. In the context of releasing the shipping container 5809 from the AMR 5800, the on-board control system may control the first belt 5802 A and the second belt 5802B to eject the shipping container 5809 from the AMR 5800 into the routing staging station 5618. In the context of both the AMR 5300 of FIG. 53 and the AMR 5800 of FIG. 58, step 5714 of moving the AMR 5300/5800 to the closing station may involve the AMR 5300/5800 driving the shipping container through the case top sealer 7620 and the case labeler 7624 (see FIG. 56A), thereby closing the open flaps, sealing the shipping container and labeling the shipping container.

[0341] In an example cycle through the portion 5600 of the fulfillment center that is illustrated in FIG. 56, the AMR 5800 may move to the shipping container induction station 5604, where an erected and bottom-sealed carton may be transferred onto the AMR 5800. The AMR 5800 may then move to one or more of the goods loading stations 5606, where a human operator or a robot may place one or more products into the erected and bottom-sealed carton. The AMR 5800 may then move to the order verification station 7630 (see FIG. 56A) to verify the contents of the erected and bottom-sealed carton. The AMR 5800 may, further, move to, and through, the closing station 5616. The closing station 5616 may be implemented to include a top sealer and a labeling system. Accordingly, at the closing station 5616, the erected and bottom-sealed carton may be top-sealed and labeled. The AMR 5800 may then move the top-sealed and labeled carton to the routing staging station 5618. The routing staging station 5618 may be implemented to include a finished case discharge conveyor. The AMR 5800 may release the top-sealed and labeled carton at the routing staging station 5618. The AMR 5800 may then move to the charging station 5602. Alternatively, the AMR 5800 may return to the shipping container induction station 5604, where another erected and bottom sealed carton may be transferred onto the AMR 5800 to, thereby, allow the cycle outlined hereinbefore to be repeated. [0342] An order fulfillment system 1000 is illustrated, schematically, in FIG. 64. The order fulfillment system 1000 of FIG. 64 may be understood to operate in the context of the order fulfillment location 5200 of FIG. 52. The order fulfillment system 1000 is illustrated, in FIG. 64, as including several components, including an order fulfillment processor 1300. The order fulfillment system 1000 may include a plurality of carton forming systems 1100 A, 1100B, 1100C, located, for example, in the shipping container induction region 5206.

[0343] The order fulfillment system 1000 may include a plurality of AMRs 1400A, 1400B, 1400C. The order fulfillment system 1000 is illustrated, in FIG. 64, as including a plurality of carton sealers 1500A, 1500B, 1500C. A plurality of customer order devices may also be provided, including a first customer order device 1200A, a second customer order device 1200B and a third customer order device 1200C. The customer order devices 1200A, 1200B and 1200C may be linked with the order fulfillment processor 1300. The first customer order device 1200A may, for example, be a telephone that may be capable of communication with a call center 1250. The call center 1250 may be adapted to receive orders from customers operating the first customer order device 1200 A and then, by virtue of call center software, a call center operator may input an order for one or more products. The order may be communicated, by a communication link, to the order fulfillment processor 1300. The second customer order device 1200B and the third customer order device 1200C may, for example, be personal computing devices including mobile phones, personal computers, etc., that may be capable of direct communication, such as by communication over a wireless and/or land-based communication network with the order fulfillment processor 1300. This communication network may, for example, be an IPv4, IPv6, X.25, IPX-compliant or similar network. Thus, this network may be the public Internet. Through operation of appropriate software on the customer order devices 1200B, 1200C and the order fulfillment processor 1300, the customer order devices 1200B, 1200C may be adapted to input an order for one or more products into the order fulfillment processor 1300. For example, the customer order devices 1200B, 1200C may be adapted to execute a suitable HyperText Transfer Protocol (HTTP)-enabled browser to access data and services provided by an HTTP server application executed by the order fulfillment processor 1300. Through use of the HTTP-enabled browser, the customer order devices 1200B, 1200C may input, into order fulfillment processor 1300, orders for one or more products. [0344] The order fulfillment processor 1300 may be a mainframe computer, a server, or other computing device capable of processing customer orders received directly or indirectly from the customer order devices 1200A, 1200B, 1200C. The order fulfillment processor 1300 may include a database that includes information that may be stored in a suitable memory therein, including information relating to: (a) information/details of all products that may be ordered by a customer through the order fulfillment system 1000, including one or more characteristics of each product, such as the physical volume occupied by the space and/or the actual physical dimensions (e.g., height, width, length and/or diameter) of each product (such as the dimensions of the box in which one or more items is held), optionally, the weight of each product and, further optionally, product codes associated with each product, such as a Universal Product Codes (UPC) or, if the product is a book, an International Standard Book Number (ISBN); (b) information/details of each of a plurality of types/sizes/configurations of carton/carton blanks that can or are being used in the order fulfillment system 1000 to package one or more products ordered by a customer including the dimensions of each type of carton/carton blank; (c) information/details of each carton forming system (e.g., carton forming systems 1100 A, 1100B, 1100C), including information/details of the carton that each carton forming system is capable of forming (such as the type, size and/or configuration) and, optionally, when a carton forming system includes multiple magazines, the type, size and/or configuration of the carton blanks provided in each of those magazines and the corresponding type, size and/or configuration of the erected carton that can be formed from each type of carton blank and, further optionally, the quantity of carton blanks provided in each of those magazines; (d) information/details about each customer, including the name of the entity and shipping address to which an order fulfilled by the order fulfillment system 1000 is to be shipped and (e) information/details about where each product is located in a product storage facility, such as a warehouse building holding products that may be ordered. The database may continually be updated to include new data. For example, new data may include data related to information/details about new inventory items, for example, new items that are inducted into the product storage induction region 5202 of the order fulfillment location 5200, or information/details about a new type/size/configuration of carton/carton blanks that can be used in the order fulfillment system 1000 to package one or more products ordered by a customer. [0345] As noted, the order fulfillment processor 1300 may also include an HTTP server application adapted to provide database information to the customer order devices 1200B, 1200C and to receive orders from the customer order devices 1200B, 1200C. Some or all of the aforementioned information/details may be input into the order fulfillment processor 1300 manually by an operator of the order fulfillment system 1000. Additionally, or alternatively, the information/details of each available carton may be updated periodically or on an ongoing basis. The PLC 132 of each carton forming system 1100 A, 1100B, 1100C may, during operation, be adapted to monitor the status of the carton blanks in its magazine(s) and provide information relating to that status to the order fulfillment processor 1300. In this way, the order fulfillment processor 1300 may be continually provided with up-to-date information on available carton blanks that are in the magazines of each of the carton forming systems.

[0346] The order fulfillment processor 1300 may also include a product packaging utility/product packaging software module that identifies, from among a plurality of available carton types, a suitable type of carton (or types of carton) for packaging the products in an order placed by a customer. An example of such a product packaging utility is disclosed in U.S. Patent No. 6,876,958 to Chowdhury et al., issued to assignee New Breed Corporation on April 5, 2005 (hereinafter, “Chowdhury”), the contents of which is hereby incorporated by reference herein in its entirety. In particular, the product packaging utility in Chowdhury processes each order placed by a customer to automatically identify, from available carton types/sizes/configurations, a type/size/configuration of suitable carton (or cartons) suitable for packaging the products in the order. The product packaging utility in Chowdhury identifies/determines suitable carton(s) according to an algorithm/function that accesses and uses one or more electronically-stored characteristics of each product in the order (e.g., dimensions, weight, efc.) and one or more electronically-stored characteristics of available carton types (e.g., dimensions, size, configuration, type, maximum volume that can be held, maximum weight that can be held, efc.). This algorithm identifies suitable cartons such that a minimum number of cartons and the smallest size cartons suitable for packaging the products in the order may be provided. Thus, identification of suitable carton types/sizes/configurations can be optimized to provide an optimal carton type/size/configuration that optimizes packaging material used and optimizes empty space in cartons and a carton identified as suitable may be referred to as an “optimal” carton. It will be appreciated that identification of suitable carton types/sizes/configurations may also be identified or optimized according other pre-defined criteria. The carton identification algorithm of the product packaging utility in Chowdhury may also take into account other factors and constraints such as, e.g., the availability of each type/size/configuration of carton, the maximum fill ratio of each type/size/configuration of carton, the maximum number of products that can be placed into each type/size/configuration of carton and whether certain products are pre-packaged together and therefore must be placed in the same carton. Thus, when the order fulfillment processor 1300 includes a product packaging utility, such as product packaging utility disclosed by Chowdhury, the order fulfillment processor 1300 may process a customer order for specific products by accessing information in memory and utilizing an algorithm/function to identify, from among a plurality of available cartons, a suitable carton (or cartons) for packaging those products.

[0347] It should be noted that the size of the carton may be the overall internal available volume of the carton in which items may be held. The size may also be the specific dimensions of the carton. Information regarding the type of carton may include a reference to a material (e.g., paperboard or corrugated cardboard) from which the carton blank is made. Information regarding the type of carton may include a reference to a configuration, which may indicate that the carton is a top opening carton that is generally cuboid in shape when closed, or another configuration such as a regular slotted case, etc.

[0348] The product packaging utility disclosed by Chowdhury may generate, for each carton of a particular type/size/configuration identified to fulfil an order, a packing list indicating an order in which each of the products is to be placed into the carton, as well as placement information indicating where each product is to be placed in the carton. For example, the placement information may be expressed using three-dimensional coordinates (e.g., 0, 0, 0) in a coordinates system defined for the carton and/or descriptors of locations in the carton (e.g., front, right hand side, second layer, efc.). It follows that, when the order fulfillment processor 1300 includes a product packaging utility, such as the product packaging utility disclosed by Chowdhury, the order fulfillment processor 1300 may generate a packing list and/or placement information for each identified carton. The order fulfillment processor 1300 may also generate a diagram illustrating a desired optimal physical arrangement of the products in each carton. Such a diagram may be readily generated using placement coordinates for each product, as provided by the product packaging utility disclosed in Chowdhury. [0349] For each carton of a particular type identified to fulfil an order, the order fulfillment processor 1300 may also be configured to select one of the carton forming systems 1100A, 1100B, 1100C (individually or collectively 1100) to form a suitable carton of the type/size/configuration identified by the order fulfillment processor 1300. The order fulfillment processor 1300 may access and use information stored in its memory regarding the suitability of the carton forming systems to handle an identified suitable carton. For example, suitability of a carton forming system may be determined by the order fulfillment processor 1300 based on stored information regarding whether the carton forming system includes magazines designated to hold the types/size/configuration of carton blanks required forming the identified carton. Suitability of a carton forming system may also be determined based on stored information regarding the quantity of the required type/size/configuration of carton blanks in a magazine of the carton forming system. Such quantities may be measured using suitable sensors placed at each carton forming system and updated during operation. Alternatively, the order fulfillment processor 1300 may simply select a carton forming system randomly or according to a predefined sequence.

[0350] Once the order fulfillment processor 1300 has selected a suitable carton forming system (e.g., one of the carton forming systems 1100 of FIG. 64) has been selected, the order fulfillment processor 1300 may generate a fulfillment order data structure (e.g., a file, an object, a message or the like) containing information for, or instructions to, the selected carton forming system 1100 to form a suitable carton blank into an erected carton. A generated fulfillment order data structure may be communicated, by a communication link to the PLC 132 of the selected carton forming system 1100.

[0351] The fulfillment order data structure may include indicators indicating (i) the type/size/configuration of the carton, determined by the product packaging utility, that is to be formed by the selected carton forming system 1100; (ii) the particular magazine of the selected carton forming system 1100 containing carton blanks for forming the suitable carton; (iii) a list of the particular product(s), from the customer order being fulfilled, that are to be loaded into the erected carton once formed, with the list, optionally, identifying the products by associated product codes and, optionally, arranged in an order in which the products are to be loaded into the erected carton once formed; (iv) the stations in the product induction region 5208, of each particular product from the customer order being fulfilled; and (v) customer shipping information for that carton indicating the destination name and address for that carton. In some cases, the fulfillment order data structure may include information for multiple cartons to be handled by the selected carton forming system 1100.

[0352] A fulfillment order data structure may be received and processed by the PLC 132 of the selected carton forming system 1100. In particular, the PLC 132 of the selected carton forming system 1100 processes the fulfillment order data structure to identify a requested type/size/configuration of carton (or cartons) to be formed and the particular magazine of the carton forming system containing carton blanks for forming each required carton. Once a suitable carton and the particular magazine containing carton blanks for forming the suitable carton have been identified, the PLC 132 of the selected carton forming system 1100 may then cause a suitable carton blank to be formed into the requested type/size/configuration of carton.

[0353] Optionally, the data structure may be stored in memory of the PLC 132 of the carton forming system or in memory of the order fulfillment processor 1300 for later retrieval when the order is picked and packed, as described below.

[0354] Once the carton has been erected for a particular customer product order, the erected carton may then be physically transferred to an AMR (collectively or individually, referenced as 1400).

[0355] An erected carton, formed from a carton blank, and having dimensions of width W, height H and length L, can be loaded, as illustrated in FIG. 67, with items (/.< ., products) numbered 1 to 6 arranged in a particular arrangement and may also include some additional dunnage or packing material (e.g., bubble wrap type material) that may be inserted to maintain the stability and integrity of the items in the packaging arrangement during shipping to the customer. In view of the particular arrangement of items specified for an order, an AMR may be controlled to visit stations in a particular order (say, the station holding the largest item may be visited first) so that an erected carton may be loaded in a manner consistent with the specified arrangement. [0356] Turning now to FIGS. 59, 60, 60A, 61, 62 and 63, the carton forming system 1100 may comprise the same or substantially the same components as the carton forming system 100 of FIG. 1 A, described above, except where differences are hereinafter described. Like in the carton forming system 100 of FIG. 1 A, the structural/mechanical components of the carton forming system 1100 may be made from any suitable materials. The carton forming system 1100 is particularly useful as part of a customer order fulfillment order fulfillment system 1000 that may fulfil product orders placed or initiated by customers as described above. However, the carton forming system 1100 may also be used in other applications.

[0357] As an alternate to a magazine like the magazine 110 of the carton forming system 100 of FIG. 1 A, described above, the carton forming system 1100 may include or utilize a plurality of magazines, such as magazines labeled Ml through M16 in FIG. 60. The magazines M1-M16 may each contain one or more stacks of product packaging, such as carton blanks, which each may generally be like the carton blanks 111 processed by the system 100, with at least some of the magazines M1-M16 containing different types/sizes and/or configurations of packaging/carton blanks to other magazines. The size, configurations and types of carton blanks (and the cartons that can be formed therefrom) can vary to provide a range of carton sizes, configurations and types that can be automatically processed by carton forming system 1100 without the need for any manual intervention to modify any components of the carton forming system 1100. The PLC 132 of the carton forming system 1100 may be programmed such that the particular dimensions/overall size/configuration (e.g., such as regular slotted carton or “RSC”)/type of each of the carton blanks held in each one of the magazines M1-M16 is stored in the memory of the PLC 132. Recall that alternatives to the RSC configuration include envelope configurations and tray configurations. When such alternatives are used, some of the carton forming systems 1100 may be replaced with envelope feeders or tray feeders.

[0358] It should also be noted that the carton forming system 1100 may be configured with magazines having a different set/selection of sizes/configurations/types of carton blanks from that of the other magazines, so that each of the carton forming systems 1100 is operable to process different cartons blanks. The carton forming systems 1100 may be configured with magazines such that they collectively process a pre-defined set of carton blank types, thereby providing a range of carton sizes, configurations and types. [0359] Each of the magazines M1-M16 may have its own carton blank transfer apparatus that may include a transversely oriented magazine conveyor 1203(1) to 1203(16) (referred to individually or collectively using reference numeral 1203), respectively. Each of the magazine conveyors 1203 may be controlled by the PLC 132 of the carton forming system 1100, such that a stack of carton blanks in each of the magazines M1-M16 may be moved to a position adjacent a longitudinally oriented, central carton blank in-feed conveyor 1204. Each magazine M1-M16 may have a transfer apparatus under the control of the PLC 132 that is operable to extract and move a carton blank from a stack in the magazine M1-M16 adjacent to the in-feed conveyor 1204 and feed the carton blank onto the central in-feed conveyor 1204 to that the carton blank may be transported in a manner like the manner described above in connection with the system 100.

[0360] With reference now to FIG. 60 A, by way of a representative example of the construction of a magazine, the magazine conveyor 1203 may include a frame 1215 that supports five, generally parallel, and spaced continuous belts 1213 that may be made of any suitable flexible material such as Ropanyl. The continuous belts 1213 may each extend between a plurality of rotatable idler wheels 1221, mounted on a freely rotatable shaft, and a plurality of rotatable drive wheels 1223. The drive wheels 1223 may be mounted for rotation with a common drive shaft 1225 of a magazine conveyor servo motor 1219 that may be interconnected, via and in communication with a servo drive, to the PLC 132 of the carton forming system 1100. The continuous belts 1213 may each have an upper belt portion that together may support one or more stacks of carton blanks 1211 thereon. The PLC 132 may give an instruction (such as by order fulfillment processor 1300) to form a carton and, if required, the PLC 132 may cause the upper belt portion of the in-feed conveyor belt 214 to move towards the in-feed conveyor 1204 by operation of the magazine conveyor servo motor 1219 rotating the drive wheels 1223. In this way, the in-feed conveyor belt 214 can, if necessary, move a stack of carton blanks 1211 to a position adjacent to the in-feed conveyor 1204.

[0361] Positioned proximate the end of each magazine conveyor 1203 adjacent to the in-feed conveyor 1204 may be a vertically and longitudinally oriented plate 1230. Each plate 1230 may be supported by a plurality of plate support members 1235 that may be part of the frame 1215. A lower longitudinally extending edge 1233 of the plate 1230 may be positioned so that only the bottom carton blank 1211 in a stack of carton blanks (/.< ., the blank that is immediately above the upper portions of the belts) can pass through a slot provided beneath the lower edge 1233 of the plate 1230 and the horizontal plane formed by the upper surface of the upper portions of the continuous belts 1213. In this way, a slot 1231 can be provided that can permit a single carton blank 1211 at a time from the bottom of the stack to be pushed transversely through the slot 1231 and onto the in-feed conveyor 1204.

[0362] A pushing mechanism may be provided to respond to signals from the PLC 132 of the carton forming system 1100 to push a carton blank 1211 in a magazine from the bottom of the stack though the slot 1231 and onto the in-feed conveyor 1204. The pushing mechanism may be any suitable type of device and may, for example, include a plurality of lugs 1217 located in the spaces between the continuous belts 1213. The lugs 1217 may be driven, in a cyclical path, by a common type crank mechanism (not shown) that may include a common pneumatic or hydraulic cylinder with a piston controlled, by the PLC 132, by activating appropriate valves to suitably control the flow of pressurized air/hydraulic fluid to the cylinder. The cylinder may have a piston arm attached to a longitudinally oriented bar member that may be mounted for rotation. The crank mechanism may be configured to provide a path for the lugs 1217 that commences in a position behind the bottom carton blank in a stack; then moves transversely between the continuous belts 1213 while engaging the rear side edge of the bottom carton blank thereby pushing the bottom carton blank through the slot 1231. Once the crank mechanism reaches the end of the stroke, the lugs 1271 may be shown to descend downwards beneath the stack of carton blanks and move transversely in an opposite direction back to the starting position, while, at the same time, not engaging the next bottom carton blank on the stack and passing beneath the stack. The path returns the lugs 1217 back to the start position so that, when signaled by the PLC 132, to load another carton blank onto the in-feed conveyor 1204, the operation can be repeated.

[0363] In summary, the PLC 132 can, thus, control the magazine conveyor servo motor 1219 and, thus, the movement of each conveyor 1203 and, consequently, the movement of the lugs 1271. Accordingly, the PLC 132 may selectively move and transfer a single carton blank at a time onto the in-feed conveyor 1204 from any one of the magazines Ml to M16.

[0364] Therefore, unlike in system 100, where a stack of carton blanks may be fed to the alignment conveyor 206 by the in-feed conveyor 204, in the order fulfillment system 1000, separate individual carton blanks may be fed in series and longitudinally by the in-feed conveyor 1204 to the alignment conveyor 1206. The particular sequence/order of carton blanks that are placed onto the in-feed conveyor 1204 of each carton forming system 1100 may be determined and selected by the PLC 132 such that the carton blanks may arrive at the alignment conveyor 1206 in such a manner in which it is desired to process the carton blanks, at least within the carton forming system 1100.

[0365] Further, each PLC 132 may maintain, in its memory, records of the carton blanks that have been placed onto the in-feed conveyor 1204 to be formed. Each record may include information received by the PLC 132 from the order fulfillment processor 1300 (e.g., by way of the fulfillment order data structure) for a particular carton blank to be formed. For example, this information may include the type/size/configuration of the carton blank. A new record can be added each time a request for a new carton is received from the order fulfillment processor 1300 and, optionally, records can be removed once a carton has been formed. Thus, such records may be organized and maintained in sequence in the memory of the PLC 132 using a conventional shift registering technique. In this way, the record for the next carton blank scheduled to arrive at the alignment conveyor 1206 may be provided at the output of the shift registers as the next carton blank arrives. Furthermore, the type/configuration/size of the next carton blank may be determined from the provided output.

[0366] Once a given carton blank has been transferred from the in-feed conveyor 1204 to the alignment conveyor 1206, the alignment conveyor 1206 may then, under control of the PLC 132, move the given carton blank to the pick-up position. The pick-up position may, in part, be determined by the front edge of each carton blank abutting the surfaces of a pair of spaced vertical plates 1218 (see FIG. 63) as they are moved longitudinally downstream by the alignment conveyor 1206.

[0367] The in-feed conveyor 1204 may be constructed, in a manner substantially similar to the construction of the in-feed conveyor 204 of FIG. 7, to include a pair of spaced in-feed conveyor belts 214 that may be driven by a suitable motor, such as a DC motor or a variable frequency drive motor. In a case wherein the motor is a DC motor, the motor may be controlled, by the PLC 132, through a DC motor drive (such as are all sold by Oriental under model AXH- 5100-KC-30). [0368] The in-feed conveyor belts 214 may have an upper belt portion supported on rollers (not shown). The PLC 132 can, as required, cause upper portions of the in-feed conveyor belts 214 to move longitudinally downstream towards the alignment conveyor 1206. In this way, the in-feed conveyor belts 214 can move a series of spaced-apart carton blanks longitudinally downstream. The PLC 132 can control the motor driving the in-feed conveyor 1204 through the motor drive and, thus, the in-feed conveyor 1204 can be operated to move and transfer a series of carton blanks obtained from multiple magazine of magazines Ml to M16 towards, and for transfer to, the alignment conveyor 1206.

[0369] The alignment conveyor 1206, like the alignment conveyor 206 of FIG. 7, may also include a series of transversely oriented rollers 1208 that may be mounted for free rotating movement to a lower portion of the magazine frame 202. An alignment conveyor belt 1216 may be driven by a motor that has a corresponding motor drive. This motor and motor drive for the alignment conveyor 1206 may also be controlled by the PLC 132. The alignment conveyor belt 1216 may be provided with an upper belt portion supported on rollers 1208, upon which one or more carton blanks may be supported. The alignment conveyor belt 1216 may be operated to move each carton blank in turn further longitudinally until the front face of the carton blank abuts with a generally planar, vertically and transversely oriented inward facing surface of upstanding spaced plates 1218, so that each carton blank is, in turn, placed into the pick-up position.

[0370] An in-feed conveyor belt 1214 of the in-feed conveyor 1204 and the alignment conveyor belt 1216 of the alignment conveyor 1206 may be made from any suitable material such as for example Ropanyl.

[0371] A sensor (not shown), such as an electronic eye model 42KL-D1LB-F4 made by Allen-Bradley, may be located within the horizontal gap between the in-feed conveyor belt 1214 and the alignment conveyor belt 1216. The sensor may be positioned and operable to detect the presence of the front edge of a blank as each blank in turn begins to move over the gap between the in-feed conveyor belt 1214 and the alignment conveyor belt 1216. Upon detecting the front edge, sensor may send a digital signal to the PLC 132 signaling that a particular carton blank (the size/configuration/type of which the PLC 132 is aware) has moved to a position where the conveyor 1206 can start to move. The PLC 132 can then cause the motor for the conveyor 1206 to be activated such that the top portion of the alignment conveyor belt 1216 starts to move the carton blank downstream. In this way, there can be a “hand-off’ of each carton blank from the in- feed conveyor 1204 to the alignment conveyor 1206.

[0372] Once the rear edge of each carton blank passes the sensor, a signal may be sent to the PLC 132, which can then respond by sending a signal to shut down the motor driving the in-feed conveyor belt 1214 of the in-feed conveyor 1204. The in-feed conveyor 1204 is then in a condition to await a further signal thereafter to feed the next carton blank in the series of carton blanks on the in-feed conveyor 1204 to the alignment conveyor 1206. Meanwhile, the alignment conveyor 1206 can be operated to move the carton blank placed thereupon to the pick-up position.

[0373] The presence of a carton blank on the alignment conveyor 1206 at the pick-up position may be detected by another sensor that may be the same type of sensor as the presence sensor 240 and the gap sensor 242 of FIG. 7. The sensor may detect the presence of the front edge of a blank at the pick-up position and may send a digital signal to the PLC 132 signaling that a carton blank is at the pick-up position. At the pick-up position, the carton blank may also be centered longitudinally by a pair of moveable longitudinally oriented side wall guides 1201, 1202.

[0374] Each carton blank may be suitably longitudinally and transversely positioned and oriented in a pick-up position for proper engagement by one of the erector heads, like the erector heads 120a, 120b of the system 100. The side guide walls 1201, 1202 may be mounted, on tracks, to a lower portion of a lower frame and both side guide walls 1201, 1202 may be oriented generally vertically and may extend longitudinally for substantially the full length of the alignment conveyor 1206. The side guide walls 1201, 1202 may be mounted in a similar manner as the left hand side guide wall 200 and the right hand side guide wall 201 in the system 100.

[0375] A drive mechanism may be provided to drive each of the side walls 1201, 1202 on respective tracks. For the side walls 1201, 1202, one or more drive mechanisms that are in electronic communication with the PLC 132 can be provided. By way of example, a servo motor 258 (see FIG. IB) with gear head may be provided and be in electronic communication with the PLC 132 through a servo drive. Examples that could be used are servo motor MPL-B1530U- VJ42AA made by Allen-Bradley, in combination with servo drive 2094-BC01-MP5-S also made by Allen-Bradley and gear head AE050-010 FOR MPL-A1520 made by Apex.

[0376] Like in the carton forming system 100, in the carton forming system 1100, lead screw rods may be inter-connected to servo motor/gear heads. The lead screw rods may pass through nuts, which may be fixedly secured to plates. The plates may be interconnected to spaced, generally vertically oriented bar members. The bar members may be interconnected to a support frame (not shown) forming part of the side walls. By activating the servo motor/gear heads, the rotation of the servo motor may rotate the screw rods. As the rods pass through nuts, the nuts can be moved laterally either inwards or outwards, thereby causing the side walls 1201, 1202 to slide on their tracks inwards or outwards depending upon the direction of rotation of the screw rods. Encoders may be provided within, or in association with, the servo drive motors and the encoders may rotate in relation to the rotation of the respective drive shaft of the servo drives. The encoders may be in communication with, and provide signals to, the servo drives, which can then pass the information to the PLC 132. Thus, the PLC 132 may be able to determine the longitudinal position of the screw rods in real time and, thus, determine the transverse position of the side walls 1201, 1202. The PLC 132 may, accordingly, operate the servo drives to adjust the position of the side walls 1201, 1202. The particular type of encoder that may be used is known as an “absolute” encoder. Thus, once the encoders are calibrated so that a position of each the screw rod is “zeroed,” even if power is lost to the order fulfillment system 1000, the encoders can maintain their zero position calibrations. With the transverse alignment mechanism of the side guides walls 1201, 1202 in abutment with the left and right side edges of the carton blank, the guide walls can ensure that the datum line, when the carton blanks are flattened, is properly transversely aligned to be labelled by a labelling device 1281 (only shown in FIG. 63) and to be picked up by the erector head 120 of the carton forming system 1100 and moved through folding and sealing apparatus 130, as described above to achieve proper folding and sealing of the carton blank.

[0377] Optionally, the PLC 132 may verify that the type/size/configuration of the carton blank at the pick-up position matches the expected type/size/configuration of carton blank. For example, the top surface of each carton blank may include a bar code identifying its type/size/configuration and this bar code may be read at the pick-up position by a suitably positioned bar code reader. The type/size/configuration of the carton blank, read from this bar code, may be compared to the expected type/size/configuration of the carton blank, which may be determined from a record of the next scheduled carton blank stored in memory of the PLC 132, as described above. Verification is successful when there is a match. When there is not a match, the PLC 132 may issue a signal requesting manual operator intervention.

[0378] As indicated above, each carton blank in each magazine may be generally initially formed and provided in a flattened tubular configuration, such as, by way of the example that is illustrated in FIGS. 10A-10E. Each carton blank has a height dimension “H”; a length dimension “L”; and a major panel length “Q” (see FIG. 10B). The PLC 132 of each carton forming system 1100 may maintain, in its memory, each of these three dimensions for a carton blank to be processed by the carton forming system 1100 and, using these stored dimensions, the PLC 132 can determine the necessary positions and/or movements of at least some of the components of the carton forming system 1100, including the path of movement of the erector heads 120a, 120b as the erector heads 120a, 120b move and cycle through their processing sequences.

[0379] In this regard, for each carton blank in each of magazines Ml to Ml 6, the PLC 132 may have the information necessary to adequately process each carton blank selected.

[0380] As was indicated above, in relation to a representative carton blank as shown in FIG. 11, each carton blank in each magazine may be designated with a first datum line “Wl” that passes through the mid-point of the fold line between panel D and flap K and through the midpoint of the fold line between panel B and flap J. This first datum line Wl may be determined by the PLC 132 for a carton blank to be processed, based on the dimensions H, L and Q of the blanks stored by the PLC 132 or obtained by the PLC 132. The carton blank may also be designated with a second datum line “W2” that may be determined by the PLC 132 and which passes along, and is generally parallel to, the fold line between panel A and flap F. The first datum line Wl will be parallel to the second datum line W2. The PLC 132 may also determine the relative position of the bottom of the erected carton for the carton blanks in each magazine, as this will be aligned with a vertical datum plane passing through the first datum line Wl and the second datum line W2. Aligning the position of the second datum line W2 and of the datum plane with other components in the carton forming system 1100 may be shown to establish that the carton is properly positioned during processing. Also, the vertical distance R between the first datum line W1 and the second datum line W2 may be calculated by the PLC 132. This can ensure that the PLC 132 knows where it needs to position the erector head so that top panel A and, accordingly, the first datum line W 1 are properly positioned throughout the processing of the carton blank by the carton forming system 1100.

[0381] The carton forming system 1100 may be shown to be able to track and modify the position of each carton blank as the carton blank is being processed and, in particular, the vertical position of the first datum line W1 of the carton blank as the carton blank moves longitudinally through carton forming system 1100 and as various components of the carton forming system 1100 engage the carton blank during its movements. This may be shown to establish that the carton blank being processed is appropriately positioned relative to the system components so that the system components engage the carton blank at the correct position on the carton blank during processing of the carton blank. For carton blanks that may be configured differently than the carton blank 111, suitable adjustments may possibly be required to the dimensions and datums maintained by the PLC 132, in order for the carton forming system 1100 to be able to process a particular size/configuration/type of carton blank.

[0382] Once the carton blank has been formed and sealed to form an erected carton that is partially sealed and may be in a configuration such as shown in FIG. 16, the erected carton may be delivered from the discharge conveyor 117 (see, for example, FIG. 8) and may be placed onto an accumulation conveyor that may be part of the respective carton loader such as a particular one of the AMRs 1400 that may be associated with the particular carton forming system 1100 that formed the erected carton. Indeed, in aspects of the present application, responsive to the particular AMR 1400 arriving at the particular carton forming system 1100, a robotic arm (not shown) may be controlled to pick the erected carton from the discharge conveyor 117 and place the erected carton on the particular AMR 1400.

[0383] An order obtaining process may be considered to be initiated when an empty erected carton is moved from an accumulation conveyor and placed onto an AMR 1400 that can autonomously move around the warehouse, where the products handled by system 1100 are located. The AMR 1400 may be controlled to visit one or more loading stations in the product induction region 5208. [0384] Once the order (or part order for a particular carton) has been obtained within the erected carton carried by the AMR 1400, such that all products have been loaded into the erected carton, the AMR may carry the erected carton to one of the final carton sealing apparatuses 1500. For example, the AMR 1400 may transfer the erected carton, with all products loaded therein, onto a predetermined Random Top Carton Seal (RTCS) in-feed conveyor that may feed the erected carton to a suitable top sealing device. The RTCS may be adapted to receive information provided by the order fulfillment processor 1300 so the RTCS may automatically adjust the sealing components of the device so that the device may close and seal the top of the erected and loaded carton. The sealed carton may then be conveyed into the route distribution accumulation region 5212 for further sorting and processing. An example of the type of suitable RTCS apparatus that could be employed as part of the order fulfillment system 1000 is the random carton sealer made by Marq Packaging Systems.

[0385] In operation of the order fulfillment system 1000, each one of a plurality of customers may use a customer order device, such as the order placement devices 1200, including possibly accessing the call center 1250. Through operation of appropriate software on the order placement devices 1200, the order placement devices 1200 may communicate directly or indirectly with the order placement processor 1300 so that multiple orders may be placed by customers, each order being for one or more products, into the order fulfillment processor 1300.

[0386] The order fulfillment processor 1300 may process the customer orders received directly or indirectly from customer order devices 1200. The order fulfillment processor 1300 may, for each order, utilize its database that includes information that may be stored therein, including information relating to: (a) details of all products that may be ordered by a customer through the order fulfillment system 1000, including the actual physical dimensions of each product (such as the dimensions of the item package in which an item is packaged), optionally, the weight of each product and, further optionally, product codes associated with each product; (b) details of each of a plurality of types/sizes/configurations of carton blanks that can be used in the order fulfillment system 1000 to package one or more products ordered by a customer, including the dimensions of each carton/carton blank; (c) details of each carton forming system (e.g., the carton forming systems 1100 A, 1100B, 1100C), including the types of erected cartons that each carton forming system is capable of forming and, optionally, when a carton forming system includes multiple magazines, the type of carton blank provided in each of those magazines and the corresponding type of erected carton that can be formed from each type of carton blank and, further optionally, the quantity of carton blanks provided in each of those magazines; (d) information about each customer, including the name of the entity and the shipping address to which an order fulfilled by the order fulfillment system 1000 is to be shipped; and (e) information about where each product is located in a warehouse building housing products that may be ordered.

[0387] The order fulfillment processor 1300 may also, for each order, use the product packaging utility to identify a suitable carton and, possibly, an optimum carton (e.g., having a particular type/size/configuration) from the packaging suite of a limited and predetermined number of types/sizes/configurations of cartons. Thus, when each order for specific products is input into the order fulfillment processor 1300, the product packaging utility can determine the optimal carton or carton that can be used to package the products for each order (e.g., determine the least number of cases and/or the smallest size of cases that are required to package all the products in the customer order).

[0388] The order fulfillment processor 1300 may then, for each order, generate a fulfillment order data structure that may be communicated by a communication link to the PLC 132 of one of the carton forming systems 1100. The order fulfillment processor 1300 may have determined to which of the carton forming systems 1100 to send each fulfillment order data structure either randomly or based on availability and/or suitability to handle the carton type/size/configuration determined for a particular customer order. The fulfillment order data structure may include information including: (i) the type/size/configuration of erected carton determined by the product packaging utility that is required to be formed by the carton forming system 1100; (ii) the particular magazine of the carton forming system containing carton blanks for forming the required type/size/configuration of carton; (iii) a list of the particular product(s) from the customer order being fulfilled that are required to be loaded into the required erected carton once formed, optionally arranged in the order in which the products should be loaded into the carton once formed; (iv) optionally, a diagram illustrating a desired optimal physical arrangement of the product(s) in loading the erected carton; (v) optionally, the location in the warehouse building of each particular product from the customer order being fulfilled; and (vi) customer shipping information for that carton, indicating the destination name and address for that carton.

[0389] Each fulfillment order data structure may then be received and processed by the PLC 132 of the carton forming system to which the data structure is sent. In particular, the PLC 132 of the carton forming system processes the fulfillment order data structure to identify the type/size/configuration of the erected carton required, the particular magazine of the carton forming system containing carton blanks for forming each required type/size/configuration of erected carton and the contents of the label (or labels) to be applied. Once a required type/size/configuration of carton blank and the particular magazine containing carton blanks for forming the required type/size/configuration of erected carton have been identified, the PLC 132 of the carton forming system may cause a carton blank from the identified magazine to be formed, generally as outlined above.

[0390] In particular, the PLC 132 activates the appropriate conveyor of magazine conveyors 1203(1) to 1203(16), corresponding to the identified magazine, if required to move a stack of carton blanks of the identified type adjacent to the in-feed conveyor 1204. The transfer apparatus may, under the control of the PLC 132, then transfer the desired carton blank from the identified magazine to the in-feed conveyor 1204. The in-feed conveyor 1204 may be shown to then, under the control of the PLC 132, move that carton blank longitudinally and then, when signaled by the PLC 132, to do so, transfer the carton blank to the alignment conveyor 1206.

[0391] The alignment conveyor 1206, also under the control of the PLC 132, may then move the carton blank to the pick-up position and the PLC 132 may then also cause the side walls 1201, 1202, to transversely align the carton blank so that the carton blank is at the correct pick-up position. The PLC 132 may then cause the carton forming components of the carton forming system, including an erecting head 120, to be moved by the movement sub-system to pick up the carton blank 111 from the pick-up position and erect and partially seal an erected carton from the carton blank 111. The PLC 132 may, on an on-going basis, as each carton blank is being processed, cause any adjustments in components of the folding and sealing apparatus 130 to be made to accommodate each carton blank 111 as a plurality of carton blanks 111 are processed. [0392] Once the erected carton has been formed for a particular customer product order, the erected carton may then be physically transferred to an AMR 1400. The AMR 1400 may then be controlled to visit stations in the product induction region 5208 at which the products may be received within the erected carton.

[0393] As briefly discussed hereinbefore, the stations in the product induction region 5208 may be associated with provision of products that are stored in the tower storage region 5204. Also as briefly discussed hereinbefore, in some embodiments, a plurality of towers, which may be used to store products, may be located in the tower storage region 5204, although towers are not specifically illustrated in the tower storage region 5204 in FIG. 52.

[0394] FIG. 75 illustrates a perspective view of a tower 7510, among the plurality of towers, which may be used to store products, in accordance with an example embodiment of the present application. As shown, the tower 7510 may have compartments 7512 for storage of individual products within the compartments 7512. Some compartments, such as a first compartment 7512A, of the tower 7510 may be filled with individual products corresponding to the same stock keeping unit (SKU). Some other compartments, such as a second compartment 7512B, of the tower 7510 may be filled with individual products corresponding to at least two different SKUs. Each compartment 7512 may have one or more openings, such as first openings 7514 or second openings 7516, through which individual products may be stored in the tower 7510 and taken out of the tower 7510.

[0395] The storing of products in the plurality of towers 7510 may, generally, involve the following steps. When products arrive at the order fulfillment location 5200, often organized on a pallet, any packaging surrounding the products may first be removed, so that individual product items may be accessible. In some embodiments, the individual product items may also be checked for obvious defects. Assuming no defects are found, personnel may pick up the individual product items and store them into the compartments 7512 of the plurality of towers 7510. Once a particular product item has been stored into a particular compartment 7512, the personnel may scan a barcode on the particular product item and/or a barcode located on the tower 7510 (e.g., a barcode associated with the particular compartment 7512 in which the particular product item has been stored), so that the order fulfilment processor 1300 is aware of a location for the particular product item. This process may also be done automatically. For example, there may be one or more robots for removing packaging, one or more robots for picking up individual product items and storing them into the compartments 7512 of the plurality of towers 7510, and one or more robots for ensuring that information regarding the location (e.g., a particular component 7512 of a particular tower 7510) of each stored individual product item is known to the order fulfilment processor 1300.

[0396] Each opening, such as the first opening 7514 or the second opening 7516, of the compartments 7512 may be covered by one or more flexible strips 7520, which may prevent the individual products stored within the compartments 7512 from falling out of the respective compartment 7512, for example, during transportation of the tower 7510 by a towertransportation AMR 7518.

[0397] In operation, the tower-transportation AMR 7518 may engage with the tower 7510 and transport the tower 7510 to the product storage induction region 5202, where, as discussed hereinbefore, personnel and/or robots 5999 may unload products delivered to the order fulfilment system 5200 (such as by transport trailers and which product may be on pallets) store products into the tower 7510. Once the tower 7510 is sufficiently filled with products, the towertransportation AMR 7518 may transport the tower 7510 to an available location within the tower storage region 5204.

[0398] When one or more products stored in the tower 7510 are required for fulfilling an order, the order fulfilment processor 1300 may instruct the tower-transportation AMR 7518 to transport the tower 7510 between a first location in the midst of the tower storage region 5204 and a second location in the product induction region 5208. The tower-transportation AMR 7518 may be a device manufactured by Amazon Robotics, formerly Kiva Systems. The towertransportation AMR 7518 may navigate around the tower storage region 5204. When the towertransportation AMR 7518 reaches the first location, the tower-transportation AMR 7518 may slide underneath the tower 7510 and lift the tower 7510 off the ground through, e.g., a corkscrew action. The tower-transportation AMR 7518 may then carry the tower 7510 to the second location in the product induction region 5208.

[0399] Conventional AMRs are known to navigate in a variety of ways. A conventional AMRs may include an upward facing camera to be used to read a bar code on the underside of the tower 7510. Additionally, a conventional AMRs may include a downward facing camera to be used to read bar codes on the floor of the tower storage region 5204. The bar codes may be understood to allow an AMR to determine its instant location information and navigate accordingly. The location information may be combined with readings from other navigation sensors, such as encoders, accelerometers and rate gyroscopes. Conventional AMRs are also known to include collision detection systems, which may be implemented as infrared sensors and touch-sensitive bumpers, which may act to cause the AMR to stop in response to people or objects getting in the way of AMR navigation.

[0400] In some embodiments, a tower 7510 in the tower storage region 5204 may be identified, for example, by the order fulfillment processor 1300, as storing one or more products for fulfilling an order. The tower 7510 storing the one or more products for fulfilling the order, or simply the one or more products, may be transported from the tower storage region 5204 to a particular station in the product induction region 5208. This transportation may be performed manually or automatically. For example, a plurality of tower-transportation AMRs 7518 (not shown) may generally be designated for transporting towers 7510 between the tower storage region 5204 and the product induction region 5208. A fulfillment order data structure generated by the order fulfillment processor 1300 may include tower-transportation AMR instructions for one of the plurality of tower-transportation AMRs 7518 to engage with the tower 7510 and transport the tower 7510 to the particular station in the product induction region 5208, where the erected carton may receive the one or more products for fulfilling the order. Indeed, loading of the one or more products into the erected carton may be carried out manually or in a robotic manner. A station in the product induction region 5208 at which the loading of the one or more products into the erected carton is carried out manually may be called a “manual product induction station.” A station in the product induction region 5208 at which the loading of the one or more products into the erected carton is carried out in a robotic manner may be called a “robotic product induction station.” For example, a loading robot (not shown) may be positioned near and/or be assigned to a robotic product induction station in the shipping container induction region 5208. When a tower (see, for example, the tower 7510 of FIG. 75) storing one or more products for fulfilling an order is transported to the robotic product induction station, the loading robot may be instructed by the order fulfillment processor 1300 to retrieve the one or more products from one or more compartments of the tower 7510 and load them into the appropriate case or carton. For example, the loading robot may include an extendable arm capable of reaching for a specific product within the one or more compartments of the tower 7510 and loading the specific product into the case. The product induction region 5208 may include one or more loading robots for loading products from towers 7510 into cases, e.g., one loading robot may serve one robotic product induction station, or a plurality of robotic product induction stations, in the product induction region 5208. In this way, the AMR 1400, which supports the erected carton, may travel to one or more stations in the product induction region 5208 and, at each station, receive, from a respective tower 7510, one or more products for fulfilling the order, each tower 7510 having been transported from a first location in the tower storage region 5204 to the respective station by a respective tower-transportation AMR 7518 having received towertransportation AMR instructions by the order fulfillment processor 1300.

[0401] Once the order (or part order for a particular carton) has been obtained by the AMR 1400, such that all products have been loaded into the erected carton, either at a manual product induction station or at a robotic product induction station, the AMR 1400 may carry the loaded carton to one of the final carton sealing apparatuses 1500A, 1500B, 1500C. For example, the AMR 1400 may carry the erected carton, with all products loaded therein, through a predetermined Random Top Carton Seal (RTCS) in-feed conveyor that may feed the erected carton to a suitable top sealing device. The RTCS may be adapted to receive information provided by the order fulfillment processor 1300 so the RTCS may automatically adjust the sealing components of the device so that the device may close and seal the top of the erected and loaded carton. The finished carton may then be conveyed into the central carton distribution system for further sorting and processing.

[0402] The further sorting and processing may include labeling the finished carton. The labelling device 1281, illustrated in FIG. 63, may be considered to be configured for labeling a carton blank 111 before the carton blank 111 is formed by the carton forming system 1100. Alternatively, a labelling device (not shown) may be employed to label the finished carton at the output end of the final carton sealing apparatuses 1500A, 1500B, 1500C.

[0403] In the case of labeling a erected carton while the erected carton remains in control of the carton forming system 1100, the labelling device 1281 may be mounted to the frame of carton forming system 1100 in the vicinity of the alignment conveyor 1206. For example (although not depicted as such in FIG. 63, for simplicity), the labelling device 1281 may be mounted to a frame portion of carton forming system 1100 generally above where a carton blank 111 is located when the carton blank 111 is in the pick-up location. The labelling device 1281 may be operable to print and apply one or more labels to one or more panels, preferably upward facing panels, of the carton blank 111 located at the pick-up location. The labelling device 1281 may be any suitable device, such as the PLS-500 label application system made by Paragon Labeling Systems Inc. of White Bear Lake, MN, in conjunction with an integral print engine, such as a Lt408 print engine or a S84 Series print engine (e.g., model nos. S8408, S8412 or S8424) made by SATO America, Inc. of Charlotte, NC. While, in some embodiments, a labelling device may apply a physically separate label to a finished carton or a carton blank 111, in other embodiments, the labelling device may apply printing to the finished carton or the carton blank 111 without providing the printing on a physically separate label.

[0404] As noted above, the label or labels applied to an upward facing panel of each carton blank 111 by the labelling device 1281 may be specifically configured for that particular carton blank 111 and may contain various types of information relating to an order of products to be fulfilled and placed into the erected carton to be formed from that particular carton blank 111. The label or labels may contain information providing certain order information including types of products to be loaded into the erected carton to be formed from that blank, optionally including product codes of those products, the customer to whom the case is to be shipped and the customer’s address. The label or labels may also contain a unique carton identifier. Some or all of the information may be provided in bar code format.

[0405] The label is, in aspects of the present application, printed and applied to the carton blank 111 while the carton blank 111 is in a flattened configuration at the pick-up location and prior to being erected and bottom sealed. This may make the label application process more reliable and provides the carton blank 111 with a unique identification.

[0406] A first example label 1283a that might be applied by the labeling device 1281 is illustrated in FIG. 65. A second example label 1283b that might be applied by the labeling device 1281 is illustrated in FIG. 66. [0407] Various modifications are also possible in some embodiments. By way of example only, instead of providing for the magazine conveyors 1203(1) to 1203(N) for magazines Ml to M(N), it may be possible to provide for a robotic system which could extract carton blanks as demanded by the PLC 132 from any one of a stack of carton blanks in each of the magazines. The robotic system could place a particular carton blank that may be required on an in-feed conveyor. In other embodiments, the in-feed conveyor could be eliminated and the robotic system may place each carton blanks that is required at the pick-up position.

[0408] Other fulfilment systems are contemplated. For example, FIG. 69 illustrates a schematic plan view of an order fulfilment center 6900. The order fulfilment center 6900 may share similarities with the order fulfilment center 5200 described in detail above. In this example embodiment, the order fulfilment center 6900 includes a product storage induction region 6902, a product storage region 6904, a shipping container induction region 6906, an order verification and sealing region 6910, and a route distribution accumulation region 6912. Depending on the size of the order fulfillment center 6900, the order fulfillment center 6900 may include multiples of one or more of the regions illustrated in FIG. 69 and may, in some cases, omit one or more regions.

[0409] Like shipping container induction region 5206 described above, the shipping container induction region 6906 of FIG. 69 may be populated with a plurality of receptacle forming/delivery systems, perhaps with one or more of such systems following the design of the carton forming system 100 disclosed hereinbefore. In some embodiments one or more of the receptacle forming/delivery systems of a plurality of receptacle forming/delivery systems may only be capable of producing/delivering a single size/configuration/type of receptable to an AMR.

[0410] According to aspects of the present application, a plurality of AMRs (e.g., AMRs 5300 and/or 5800) may be deployed for movement within the warehouse, between the various illustrated regions, as will be explained in greater detail further below. For example, an AMR may be controlled to visit the shipping container induction region 6906 to obtain a shipping case (or other receptacle), and subsequently controlled, with the shipping container secured thereon, to visit the product storage region 6904 to receive one or more products within the shipping container for fulfilment of an order. [0411] At the product storage induction region 6902, various products may be shown to arrive at the order fulfillment center 6900, for example, in a plurality of transport trailers. Multiple units of a single SKU may be grouped into a container, and multiple containers may be grouped into a pallet. The term “pallet” may, in some cases, refer to a stacked structure of containers resting on a pallet base, for handling using machines, such as forklifts 6999. The term “pallet” may, in some other cases, refer to the pallet base. In some embodiments, a plurality of pallets may arrive as one unit and the unit may have to be separated into individual pallets by personnel and/or machinery. For example, the plurality of pallets may be tied or wrapped together and subsequently untied or unwrapped prior to being stored.

[0412] Pallets may be transported to specific corresponding locations in the product storage region 6904. Such transportation may be done using forklifts 6999, which forklifts may be operated manually by an operator or, in other instances, may operate automatically. In a preferred embodiment, the forklifts 6999 may be implemented as automated guided vehicles (AGVs).

[0413] The product storage region 6904 may comprise a plurality of product storage racks 7100. At the product storage region 6904, the pallets may each be placed in a corresponding storage location. For example, for a particular pallet, the forklifts 6999 may receive, e.g., a set of coordinates or directions, pertaining to a particular storage rack located within the product storage region 6904, and a specific area within the particular storage rack, the particular pallet should be stored. In this way, each product storage rack 7100 may be populated with pallets corresponding to the various products.

[0414] FIG. 70 illustrates a perspective view of part of a product unloading system of an order fulfilment center, in accordance with an example embodiment of the present application. The product unloading system part of FIG. 70 is illustrated as including a product storage rack, among the plurality of product storage racks 7100 in FIG. 69, and an AMR elevator 7110. The product storage rack 7100 may include a plurality of storage levels 7102 for storing pallets, such as a first pallet 7120, containing products. As mentioned hereinbefore, each pallet may contain individual products of a particular SKU. In some embodiments, each pallet may contain a structured set of identical containers, such as containers 7122, each container 7122 containing one or more of a particular SKU (e.g., the container may be a box containing one or more sets of a trio of books sold as one unit). In some embodiments, one or more pallets may contain various different products as opposed to one particular SKU.

[0415] The product storage rack 7100 may further include a plurality of raised platforms 7104, each one of the plurality of raised platforms 7104 positioned proximate to a respective one of the plurality of storage levels 7102. Each of the raised platforms 7104 may be configured for travel of an AMR 5800 thereon.

[0416] The product storage rack 7100 may further include one or more product retrieval robots, such as a robotic picker arm 7106. In some embodiments, a robotic picker arm 7106 may be associated with one respective storage level 7102 of the product storage rack 7100, as illustrated. In some embodiments, a robotic picker arm 7106 may serve multiple storage levels 7102 of the product storage rack 7100. Each robotic picker arm 7106 may be configured to retrieve individual products from the pallets, and load the products into appropriate shipping containers carried by the AMRs 5800.

[0417] Specifically, each robotic picker arm 7106 may be equipped with an end effector suitable for selectively retrieving individual articles from containers within the pallets, and releasing the articles into the appropriate shipping containers carried by the AMRs 5800. The configuration of the end effector of a robotic picker arm 7106 may depend on characteristics of articles to be moved. For example, articles with planar surfaces and relatively low weight may be effectively engaged using an end effector with one or more vacuum cups. Other articles, for example, articles having curved or irregular surfaces or relatively high weight, may be grasped with claws or with clamping devices of corresponding size and shape.

[0418] In some embodiments, multiple, interchangeable end effectors may be available. For example, one or more of the robotic picker arms 7106 may be equipped with a releasable linkage, the linkage configured to engage with or disengage with a selected one of a plurality of end effectors. For example, FIG. 77 shows an example robotic picker arm 7106 having connectors 7710, which may be used to engage with the plurality of end effectors. The connectors 7710 may include physical linkages, such as quick connects for electrical connections and pneumatic connections. Available end effectors (not shown) may be placed in one or more rest locations accessible by the robotic picker arms 7106. When needed, a robotic picker arm 7106 may move to engage, via the connectors 7710, with a suitable end effector and employ the end effector to perform a specific task. After the task has been performed, or when a different end effector is needed, the robotic picker arm 7106 may return to a rest location and release the connectors 7710 to return the end effector.

[0419] The robotic picker arm 7106 may be further configured to perform de-palletizing operations. For example, the robotic picker arm 7106 may be configured to remove packing material from a pallet, such as strapping 7702, or to open or dismantle containers within the pallet in order to access individual articles held in the containers. The robotic picker arm 7106 may be further configured to dispose of any removed packaging material. For example, the robotic picker arm 7106 may grasp the packaging material and transfer the packaging material to a disposal site, such as a chute (not shown).

[0420] To achieve the de-palletizing operations, the robotic picker arm 7106 may engage with an end effector configured to be used in de-palletizing operations. In some embodiments, such an end effector may be a destrapper-debander.

[0421] For example, FIGs. 78A and 78B illustrate a destrapper-debander 7800. The destrapper-debander 7800 may include one or more of a motor 7804, a roller (not shown), a scissor 7807, and a clamp including a clamp top part 7806 and a clamp bottom part 7805. In operation, a cycle may begin as the robotic picker arm 7106 positions the destrapper-debander 7800 proximate the strapping 7702. The clamp parts 7805/7806, using a pinching mechanism, may hold the strapping 7702 in place. Once the strapping 7702 is held in place, the scissor 7807 may slice the strapping 7702. Because the clamp parts 7805/7806 are holding the strapping 7702 in place, the strapping 7702 may maintain its position while tension is released, thereby avoiding undesired unpredictable movement. Once the strapping 7702 is cut, the motor 7804 may spin the destrapper-debander 7800 to wind the strapping 7702 about the entire destrapper-debander 7800. The roller (not shown) may be a spring-loaded roller employed to maintain the position of the strapping 7702 on the destrapper-debander 7800 as the strapping 7702 forms a wound reel around the destrapper-debander 7800.

[0422] Once the strapping 7702 is completely wound, the robotic picker arm 7106 may place the strapping 7702 in a dunnage drop zone or chute (not shown). Specifically, the robotic picker

I l l arm 7106 may move the destrapper-debander 7800 to be positioned above the dunnage drop zone or chute. There, the clamp parts 7805/7806 may disengage from holding the strapping 7702, thereby allowing the wound reel of the strapping 7702 to fall down the chute. Alternatively, there may be a mechanism (not shown) to push the wound reel of the strapping 7702 off the destrapper-debander 7800 so that the wound reel of the strapping 7702 may fall down the chute. This cycle may be repeated as necessary to remove any/all straps from a pallet 7120.

[0423] The robotic picker arm 7106 may be mounted on a rail (not shown) above an associated storage level 7102. Such configuration provides effective access to articles through the tops of cases. However, other mounting arrangements are possible. For example, the robotic picker arm 7106 may be mounted below the associated storage level 7102 or suspended on a side frame. Alternatively, the robotic picker arm 7106 may be an element of a free-standing autonomous robot, which can move along the storage levels 7102 and/or the raised platforms 7104, perhaps utilizing the AMR elevator 7110 to travel to other raised platforms 7104 or to the ground level of the order fulfilment center 6900.

[0424] The robotic picker arm 7106, as illustrated in FIG. 70, may be able to move in multiple axes, e.g., in the x-axis, the y-axis, and the z-axis, on rails (not shown) and, therefore, may be able to reach any product stored on the associated storage level 7102.

[0425] The AMR elevator 7110 may be configured to transport an AMR 5800 between the ground and any of the raised platforms 7104 of the product storage rack 7100. The AMR elevator 7110 may include a receiver dock 7112 positioned between vertical rails 7114. The loading dock 7112 may be configured to move vertically along the vertical rails 7114 using actuators 7016. In some embodiments, the AMR elevator 7110 may further include wheels or other means to configure the AMR elevator 7110 to travel along the x-axis and the y-axis. In some embodiments, one AMR elevator 7110 may serve one product storage rack 7100. Alternatively, one AMR elevator 7110 may serve multiple product storage racks 7100.

[0426] In operation, the AMR elevator 7110 may be controlled to receive an AMR having a shipping container, or other receptacle, secured thereon, such as the AMR 5800 illustrated in FIG. 70, at the loading dock 7112, and transport the AMR 5800 from the ground level to one of the raised platforms 7104. Once the AMR 5800 has reached its intended platform 7104, the AMR 5800 may exit the loading dock 7112 onto the raised platform 7104 and move along the raised platform 7104 until the AMR 5800 reaches an instructed spot for receiving a specific product required for fulfilling an order. The robotic picker arm 7106 may engage with and retrieve the required product from a container within a corresponding pallet, such as the container 7122 within the first pallet 7120, and load the required product into the shipping container, after which the AMR 5800 travels back towards the AMR elevator 7110 and onto the loading dock 7112, after which the AMR 5800 is transported to the ground level. If a particular product storage rack 7100 has multiple items required to fulfil the order, the AMR elevator 7110 may be controlled to transport the AMR 5800 to all of the necessary raised platforms 7104 of the product storage rack 7100 to receive the various items. This process may repeat at one or more product storage racks 7100 until the shipping container has received all of the products required to fulfil an order. The AMR 5800 may then be controlled to travel elsewhere for further processing.

[0427] In some embodiments, a product retrieval robot, such as the robotic picker arm 7106, may include a sensor for detecting the product to be retrieved for a shipping case. For example, the sensor may include a camera and the robotic picker arm 7106 may be configured to use computer vision to detect the product to be retrieved. The robotic picker arm 7106 may be configured with one or more grippers, such as suction cups or any other suitable grippers, for retrieving products. In some embodiments, the product unloading system may be organized in such a way that at least a section of a storage level 7102 has pallets or containers containing similarly shaped and/or similarly sized, and/or similarly packaged, positioned close to one another. The corresponding robotic picker arm 7106 serving that section may be equipped with a gripper, which may more easily interact with products of that shape and/or size and/or packing.

[0428] In embodiments where one or more pallets contain a structured set of identical containers, each container containing one or more of a particular SKU, the dimensions of each container, as well as the way in which the containers are organized, may be known to the product retrieval robot. For example, the embodiment illustrated in FIG. 70 shows the first pallet 7120 containing a structured set of identical containers 7122. In such embodiments, instead of, or in addition to, using computer vision, the product retrieval robot may be numerically guided to retrieve one of the containers and load the retrieved container into a shipping case. [0429] In some embodiments, each product retrieval robot may be configured to load products into one type of shipping case (e.g., one robot may be configured to load products into an open-top regular slotted case and another robot may be configured to load products into an open-sided envelope). In some embodiments, one or more product retrieval robots may be configured to load products into more than one type of shipping case, and the robot may be able to determine, e.g., using the camera and computer vision, which type of shipping case into which the product retrieval robot is to load a particular product, so that the product retrieval robot may accurately load the product into the shipping case.

[0430] FIG. 71 illustrates an embodiment of an example concept of the fulfillment center 6900 that utilizes AMR devices such as the AMR 5300 of FIG. 53 and/or the AMR 5800 of FIG. 58, as described herein. In similar fashion to what has been previously described in relation to FIG. 56A, an AMR such as the AMR 5300 or the AMR 5800 in the system can be programmed to move from station to station along an example path 7210 and process orders as follows.

[0431] The AMR 5300/5800 moves to one of several case induction stations 7204, where a receptacle forming/delivery system (e.g., a case erector, as described hereinbefore) has produced a shipping case that is sized appropriately for a particular customer order. The case induction stations 7204 may be part of the shipping container induction region 5206 (FIG. 52), 6906 (FIG. 69). The case erector transfers the shipping case onto the AMR 5300/5800 and the AMR 5300/5800 secures the shipping case onto itself according to one of the methods described previously.

[0432] The AMR 5300/5800 moves to the product storage region 6904, where the shipping case secured onto AMR 5300/5800 receives, from one or more product storage racks 7100, one or more products required to fulfil the customer order according to the methods described above in relation to FIG. 70.

[0433] The AMR 5300/5800 then moves to one of a plurality of order verification stations 7630 so that the contents of the shipping case can be verified as corresponding to the products of the customer order. [0434] The AMR 5300/5800 then moves to a case sealer 7220, among a plurality of case sealers 7220, and to a case labeler 7224 so that the shipping case may, in turn, be sealed and labelled. For example, if the shipping case is a bottom-sealed regular slotted case, the top of the case can then be sealed by the case sealer 7220 and labelled, e.g., with a label containing information helpful for shipping the sealed shipping case to the customer. In some embodiments, order verification, case sealing, and/or case labelling may be achieved at the same station, as described below in relation to FIG. 73.

[0435] The AMR 5300/5800 then moves to a case discharge station 7225, where the sealed shipping case can be unloaded from the AMR 5300/5800 onto a discharge conveyor 7226 to be subsequently loaded, by personnel and/or robots 6998, into a delivery vehicle.

[0436] The AMR 5300/5800 may then move to a charging station 7202 or return to a case induction station 7204 to receive a shipping container that is sized appropriately for a different customer order and repeat the cycle.

[0437] FIGs. 72-74 provide more detail on steps 1, 3, 4, and 5 of the example process 7210.

[0438] FIG. 72 illustrates a perspective view of a plurality of case induction stations 7204 of the order fulfilment center FIG. 69. Each case induction station 7204 is positioned at a tail end of a case erector or a carton forming system, such as the carton forming system 100, located within shipping container induction region 6906. Each case induction station 7204 may include a case discharging system 7240, which may include a discharge conveyor 7226. As shown, a shipping case, such as a case 7250, may be constructed by a case erector and may be loaded onto the discharge conveyor 7226. An AMR may be instructed to travel to the discharge conveyor 7226 to receive the case (AMR 5300 is shown, but it may alternatively be AMR 5800). For example, illustrated is a first AMR 5300-1, which has traveled to a first case induction station 7204 to receive a first case 7250, a second AMR 5300-2, which has traveled to a second case induction station 7204 and received a second case 7252, and a third AMR 5300-3, which is traveling to a third case induction station 7204 to receive a third case.

[0439] In some embodiments, each case erector may be configured to construct and deliver one type of shipping case (e.g., a regular slotted case), and may be configured to construct and deliver only one particular size of case. In some embodiments, one or more of the case erectors may be configured to construct more than one type of shipping case (e.g., a regular slotted case and an open-sided envelope). In such embodiments, one or more of the case erectors may be configured to construct more than one size of case. Regardless of the capabilities of any one particular case erector, the plurality of case erectors within the shipping container induction region 6906 may be able to construct a variety of shipping case types, in a variety of sizes, so that an appropriately sized, appropriate type of container may be constructed for a customer order. For example, as illustrated in FIG. 72, the first case 7250 may be larger than the second case 7252, as the first case 7250 may have been constructed for a customer order having more products, or larger-sized products, than the second case 7252.

[0440] Once the AMR 5300 has received a case, the AMR 5300 may be instructed to travel to the product storage region 6904 so that the case may be filled with one or more products required to fulfil the customer order.

[0441] FIG. 73 illustrates a perspective view of an order verification and case sealing station 7620 located in the order verification and sealing region 6910. Conveniently, each order verification and case sealing station 7620 may be configured such that the first case 7250 containing a customer’s requested products does not have to be unloaded from and re-loaded onto the AMR 5300 it travels on. Instead, the first case 7250 remains secured onto the AMR 5300, and the AMR 5300 and the first case 7250 move through the case sealing station 7620 together. The case sealing station 7620 may be configured with means (not shown) for verifying that the one or more products within the first case 7250 is accurate and complete and means for sealing the container. In some embodiments, each order verification and case sealing station 7620 may be configured to interact with one type of shipping case (e.g., an top-open regular slotted case vs. a side-open envelope). In some embodiments, one or more verification and case sealing stations 7620 may be configured to interact with more than one type of shipping case. Regardless of the capabilities of any one verification and case sealing station 7620, the plurality of stations 7620 within the order verification and sealing region 6910 may be able to perform verification and sealing services for a variety of shipping case types and for a variety of size types.

[0442] In some embodiments, one or more of the order verification and case sealing stations 7620 may further be configured for labelling a case after verification and sealing, with a label (not shown) containing information required for proper delivery to (e.g., sender name and address, recipient name and address, weight, tracking barcode, etc.). In some embodiments, the labelling of a case may occur elsewhere, e.g., at a different station.

[0443] FIG. 74 illustrates a perspective view of a plurality of case discharge stations 7225 of the order fulfilment center of FIG. 69. As shown, each case discharge station 7225 includes a discharge conveyor 7226 with a receiving end, for receiving a verified, sealed and labelled shipping case from an AMR 5300, and a discharge end, at which end the case may be loaded into a delivery container (e.g., a storage space of a delivery transport trailer) for delivery to the respective customer. In a preferred embodiment, the AMR 5300 may have means (e.g., as explained elsewhere with respect to AMR 5800) to automatically unload its shipping case onto the discharge conveyor 7226. In some embodiments, an automated vehicle or person may assist the unloading of a shipping case from its respective AMR 5300. Loading of cases from the discharge end of the discharge conveyor 7226 into delivery vehicles may be achieved by one or more persons or automated robots 7998, as illustrated in FIG. 74. Alternatively, loading of cases from the discharge end of the discharge conveyor 7226 into delivery vehicles may be achieved by automated vehicles.

[0444] FIG. 76 illustrates, in a schematic plan view, an order fulfilment location 7600 that may be viewed as a hybrid of the order fulfilment center 5200 of FIG. 52 and the order fulfilment center 6900 of FIG. 69. The order fulfillment location 7600 may be considered to be physically organized, in a logical manner, into areas or regions associated with various functions. The order fulfillment location 7600 includes a product storage induction region 7603, a tower storage region 7604T, a product rack storage region 7604P, a shipping container induction region 7606, the product induction region 7608, an autonomous mobile robot movement region 7610 in which are located a plurality of AMRs (such as for example AMRs 5300 and/or AMRs 5800), and a route distribution accumulation region 7612. In practice, depending upon the size of the order fulfillment location 7600, the order fulfillment location 7600 may include multiples of the regions illustrated in FIG. 76 and may, in some cases, omit one or more regions.

[0445] The tower storage region 7604T may be populated by a plurality of towers 7510 (see FIG. 75). In some embodiments, the plurality of towers 7510 in the tower storage region 7604T may store higher margin, lower volume products. Examples of such products may include consumer electronics, clothing, toys, and health and beauty items. In some embodiments, the number of different individual products (SKUs) stored by the plurality of towers 7510 may be on the order of several hundred thousand, or one or more millions, of different products (e.g., a vast range of different books or DVDs).

[0446] The product rack storage region 7604P may be populated by a plurality of product storage racks 7100, as well as a plurality of AMR elevators 7110 (see FIG. 70). In some embodiments, the plurality of product storage racks 7100 in the product rack storage region 7604P may store lower margin, higher volume products. For example, the plurality of product storage racks 7100 may store grocery items. In some embodiments, as described in more detail hereinafter, the product rack storage region 7604P may be subdivided into various sub-regions maintained at different conditions, e.g., different temperatures. In this way, the product rack storage region 7604P may be able to simultaneously store refrigerated grocery goods and frozen grocery goods, in addition to grocery goods that can be maintained at ambient / normal room temperature. In some embodiments, the number of different types (SKUs) of products stored by the plurality of product storage racks 7100 in the product rack storage region 7604P may be on the order of several thousand, but may be storing many multiple units of the same SKUs/type of products (e.g., multiple individual oranges, multiple cartons of milk, etc. .

[0447] In operation, at the product storage induction region 7603, various products may be shown to arrive at the order fulfillment center 7600 in, for example, a plurality of transport trailers.

[0448] Some of the products that have arrived, often organized upon a pallet, may be stored into compartments of the plurality of towers, which towers are eventually located at the tower storage region 7604T.

[0449] Personnel and/or robots 7999 may unload products delivered (such as by transport trailers and which products may be delivered on pallets) to the order fulfilment system 7600. Individual products organized upon a pallet may be retrieved through de-palletization and dismantlement processes. Each individual unloaded product may, subsequently, be placed by personnel and/or robots 7999 in a given tower 7510 among the towers 7510, as described hereinbefore. Upon being filled with products, a given tower may then be moved, by a tower- transportation AMR 7518, so that the given tower 7510 is located within the tower storage region 7604T. Information regarding the location in which each individual product is stored (e.g., the specific tower 7510 and the compartment 7512 of the specific tower), may be stored in a suitable memory of the order fulfilment processor 1300.

[0450] Some of the products that have arrived, often organized upon a pallet, may be transported, upon their respective pallets, to specific corresponding locations in the product rack storage region 7604P, where a plurality of product storage racks 7100, at which the pallets may be stored, are located. Such transportation may be done using forklifts 7997. The forklifts 7997 may be operated manually by an operator or may operate autonomously. In a preferred embodiment, the forklifts 7997 may be automated guided vehicles (AGVs).

[0451] In some embodiments, products to be stored at the product rack storage region 7604P, may arrive to the order fulfilment location 7600/7600A or order fulfilment center 6900 in a standardized storage case, palletized on a standardized pallet base. In other words, suppliers may place products, which are to be stored at the product rack storage region 7604P and used in the fulfilment of orders, into a standardized storage case and may palletize a plurality of such cases on a standardized pallet base, as described hereinafter.

[0452] Referring briefly to FIGS. 79 and 80, FIG. 79 illustrates an example standardized storage case 7910. The standardized storage case 7910 may be one type of standardized storage case. The standardized storage case 7910 may be manufactured from plastic and may be designed to be durable and reusable. Each type of standardized storage case, among a plurality of standardized storage cases, may be manufactured to exact standardized dimensions. For example, the standardized storage case 7910 may be manufactured to have a length, /, of 24 inches, a width, w, of 20 inches, and a height of 22 inches. The standardized storage case 7910 may generally conform to the shape of an open top case, with two parallel faces 7912 along the length of the standardized storage case 7910 and two parallel faces 7914 along the width of the standardized storage case 7910. The standardized storage case 7910 may further include a handle 7912 and a plurality of holes 7916 in each of the faces 7912 and 7914. The handles 7912 may enable easier lifting of the standardized storage case 7910 by an individual (such as an employee of a supplier), and the plurality of holes 7916 may enable the individual to more easily see what is contained in the standardized storage case 7910. [0453] The type of standardized storage case that is chosen may be based on product type. For example, the standardized storage case 7910 may be the chosen standardized storage case type for certain or all bakery products because the dimensions, material, and other features of the standardized storage case 7910 may be ideal for such goods. Other types of standardized storage cases may be well suited for other types of grocery goods, such as dairy, meat and poultry, fruits and vegetables, frozen goods, etc. Thus, the dimensions, material, and features of one type of standardized storage case may differ from other types. Regardless of the number of different types, in some embodiments, all standardized storage cases, to be delivered to the order fulfilment location 7600/7600 A or order fulfilment center 6900 and stored at the product rack storage region 7604P, may be known to the order fulfillment system, and therefore to a robot configured to be used in de-palletizing operations, such as the robotic picker arm 7106. The individual suppliers may be responsible for maintaining and refurbishing the standardized storage cases, ensuring that the standardized storage cases, such as standardized storage case 7910, which arrive at the order fulfilment location or center are without defects.

[0454] Some products may not arrive in standardized storage cases like the standardized storage case 7910. These products may be those which are prepackaged into a unit, and sold by the unit, such as cases of consumer beverages. These products may be palletized onto a pallet base without being contained in a standardized storage case, or any other container. In some embodiments, these products may be wrapped with straps which can be removed by an end effector of a robotic picker arm, such as the destrapper-deb ander 7800. Alternatively, these products may also arrive to the order fulfilment location in a standardized storage case, such as the standardized storage case 7910.

[0455] As mentioned above, in some embodiments, many, most or all products to be stored at the product rack storage region 7604P may arrive palletized on a standardized pallet base. FIG. 80 shows a pallet 8010 containing products to be stored at the product rack storage region 7604P. The pallet 8010 includes a plurality of standardized storage cases 7910 palletized on a standardized pallet base 8002. The illustrated embodiment shows eight standardized storage cases 7910 in the pallet 8010, organized into two layers comprising four standardized storage cases 7910 each, but this is only an example. In some embodiments, the number of layers may be increased. In some embodiments, the number of standardized storage cases per layer may be increased, e.g., for standardized storage cases with smaller dimensions that the standardized storage case 7910. Similar to processes described elsewhere, the pallet 8010 may be wrapped with straps which can be removed by an end effector of a robotic picker arm, such as the destrapper-debander 7800 of the robotic picker arm 7106.

[0456] The standardized pallet base 8002 may be manufactured from wood or plastic and may be designed to be durable and reusable. The standardized pallet base 8002 may be manufactured to exact standardized dimensions. In some embodiments, these dimensions include a length, L, of 48 inches (1219.2 mm) and a width, W, of 40 inches (1016 mm). This standard size for the standardized pallet base 8002 ensures compatibility and ease of use across various industries and supply chain networks. The standardized pallet base 8002 may have a “stringer” design, including three parallel wooden or plastic beams running the length of the pallet, with deck boards placed across them. This design may offer good load-bearing capacity and stability. Additionally, the standardized pallet base 8002 may have block support at the corners, which block support may enable forklift tines to easily engage with and move the standardized pallet base 8002, thereby allowing for efficient handling during loading and unloading. The standardized pallet base 8002 may be a “four-way entry” pallet base. As such, forklifts or pallet jacks may be able to engage the pallet from any side. The individual suppliers may be responsible for maintaining and refurbishing the standardized pallet bases 8002 to, thereby, ensure that the standardized pallet bases 8002, which arrive at the order fulfilment location, are without defects.

[0457] Returning to FIG. 76, the product rack storage region 7604P may comprise a plurality of product storage racks 7100. At the product rack storage region 7604P, the pallets, which may include the standardized pallet base 8002 and standardized storage cases like the standardized storage case 7910, may each be placed in a corresponding storage location. For example, for a particular pallet, the forklifts or pallet jacks may receive, e.g., a set of coordinates or directions, pertaining to a particular storage rack located within the product rack storage region 7604P, and a specific area within the particular storage rack 7100, the particular pallet should be stored. In this way, each product storage rack 7100 may be populated with pallets corresponding to the various products.

[0458] In some embodiments, the product rack storage region 7604P may be divided into a plurality of zones, and each of the plurality of zones may be maintained at different conditions. [0459] For example, FIG. 76A shows an order fulfillment location 7600A where the product rack storage region 7604P is divided into three zones 7605-1, 7605-2, and 7605-3. Each of the three zones 7605-1, 7605-2, and 7605-3 may include one or more product storage racks 7100, which may be populated with pallets corresponding to various products.

[0460] The zones 7605-1, 7605-2, and 7605-3 may be maintained at different conditions. For example, a first zone 7605-1 may maintain products at a moderate temperature, e.g., at room temperature or ambient temperature; a second zone 7605-2 may maintain products at a reduced temperature as compared to the temperature of the first zone 7605-1, e.g., at a refrigerated temperature; and a third zone 7605-3 may maintain products at a temperature at or below freezing. In this way, the zones 7605-1, 7605-2, and 7605-3 may provide three different storage conditions for storage of different products. For example, as previously mentioned the product rack storage region 7604P may house grocery items. Items that are safe to be stored at room temperature, such as non-perishable grocery goods, may be kept in the first zone 7605-1; perishable grocery items such as fresh produce and meats may be kept in the second zone 7605-2; and frozen grocery items may be kept in the third zone 7605-3.

[0461] In some embodiments, an air curtain or air door may be provided for the product storage racks 7100 located within the second zone 7605-2 and/or the third zone 7605-3. The air curtain may be a device configured to blow a consistent and controlled high-velocity stream of air to create an air seal and separate two environments from each other. Specifically, the air curtain may separate a portion of a product storage rack 7100 storing products at a refrigerated or freezing temperature, from an average warehouse temperature, which may be an ambient temperature.

[0462] For example, referring to FIG. 70, for a product storage rack 7100 located within the second zone 7605-2 or the third zone 7605-3, an air curtain (not shown) may be positioned above the product storage rack 7100 and configured to blow a high-velocity stream of air, in a substantially vertical direction, between the plurality of storage levels 7102 and the plurality of raised platforms 7104. The air curtain may therefore allow a first environment which includes the plurality of storage levels 7102 and the products stored on the plurality of storage levels 7102, to be maintained at different conditions from a second environment which includes the plurality of raised platforms 7104, the one or more robotic picker arms 7106, the AMR elevator 7110, the AMRs 5800, and any forklifts or automated guided vehicles travelling along the ground level. For example, for a product storage rack 7100 located within the second zone 7605-2, the first environment may be maintained at a refrigerated temperature and the second environment may be maintained at an ambient temperature, while for a product storage rack 7100 located within the third zone 7605-3, the first environment may be maintained at a below freezing temperature and the second environment may be maintained at an ambient temperature. In this way, within the second zone 7605-2 and the third zone 7605-3, the AMR 5800, the AMR elevator 7110, and any other equipment or material located within the second zone 7605-2 and the third zone 7605-3, may be protected from damage that may be caused by refrigerated or freezing temperatures. The one or more robotic picker arms 7106 may be configured to enter and exit the first environment to retrieve products stored on the plurality of storage levels 7102 and release them into one or more shipping containers carried by an AMR 5800. In a rest position, the one or more robotic picker arms 7106 may be located in the second environment to minimize any damage from prolonged exposure to refrigerated or below freezing temperatures. In some embodiments, more than one air curtains may be provided for a product storage rack 7100, to ensure that air seals are created all around the products stored on the plurality of storage levels 7102. In other words, as opposed to creating an air seal at just a front side of the plurality of storage levels 7102, air curtains may be provided to create air seals at the left, right, and rear sides of the plurality of storage levels 7102. In some embodiments, air curtains or other means for maintaining various areas or environments of the second zone 7605-2 and/or the third zone 7605-3 at different temperatures may not be implemented. Instead, the second zone 7605-2, including the entirety of the product storage racks 7100 and AMR elevators 7110 may generally be maintained at a refrigerated temperature such that when any AMRs 5800 and vehicles travelling along the ground level enter the second zone 7605-2, they are exposed to the refrigerated temperature at which the second zone 7605-2 is maintained. Similarly, the third zone 7605-3, including the product storage racks 7100 and AMR elevators 7110, may generally be maintained at a below freezing temperature such that when any AMRs 5800 and vehicles travelling along the ground level enter the third zone 7605-3, they are exposed to the refrigerated temperature at which the third zone 7605-3 is maintained.

[0463] Referring to either FIG. 76 or FIG. 76A, the shipping container induction region 7606 may be populated with a plurality of carton forming systems, perhaps following the design of the carton forming system 100 disclosed hereinbefore. In embodiments where the product rack storage region 7604P is split into the three zones 7605-1, 7605-2, and 7605-3, which maintain products at different temperatures and conditions, one or more of the plurality of carton forming systems may be configured to form shipping containers that can safely transport one or more items stored in the second zone 7605-2 or the third zone 7605-3 to a delivery destination. For example, the one or more of the plurality of carton forming systems may be configured to form a shipping container having an inner insulated lining, or a shipping container made only from insulative material, to prevent melting or spoiling of items during transport to a delivery destination. Alternatively or additionally, one or more of the plurality of carton forming systems may be configured to form shipping containers that include an insulated portion and a noninsulated portion, so that an item from the tower storage region 7604T or the first zone 7605-1, which item does not require particular insulation, may be delivered in a same shipping container as an item from the second zone 7605-2 or the third zone 7605-3, which item does require insulation.

[0464] According to aspects of the present application, a plurality of autonomous mobile robots (AMRs) such as for example AMRs 5300 and/or AMRs 5800, may be deployed for movement within the autonomous mobile robot movement region 7610.

[0465] In some embodiments, the order fulfillment processor 1300 may receive an order requiring one or more products stored in the tower storage region 7604T and one or more products stored in the product rack storage region 7604P.

[0466] Once the order is received, an appropriately sized, appropriate type of container may be constructed for the order, e.g., by a case erector within the shipping container induction region 7606, and an AMR, such as AMR 5300 or AMR 5800, may be controlled to visit the shipping container induction region 7606 to obtain the shipping container.

[0467] The combination of the AMR and the shipping container may then be controlled to visit one or more stations in the product induction region 7608. At a given station or at given stations in the product induction region 7608, the one or more products required to fulfil the order, which are stored in the tower storage region 7604T, may be received within the shipping container carried by the AMR. The stations in the product induction region 7608 may be associated with provision of products that are stored in towers 7510 in the tower storage region 7604T.

[0468] In operation, the tower-transportation AMR 7518 (see FIG. 75) may engage with the tower 7510 and transport the tower 7510 between a first location in the midst of the tower storage region 7604T and a second location in the product induction region 7608. The towertransportation AMR 7518 may be a device manufactured by Amazon Robotics, formerly Kiva Systems. The tower-transportation AMR 7518 may navigate around the tower storage region 7604T. When the tower-transportation AMR 7518 reaches the first location, the towertransportation AMR 7518 may slide underneath the tower 7510 and lift the tower 7510 off the ground through, e.g., a corkscrew action. The tower-transportation AMR 7518 may then carry the tower 7510 to the second location in the product induction region 7608.

[0469] In some embodiments, a tower in the tower storage region 7604T may be identified, for example, by the order fulfillment processor 1300, as storing one or more products for fulfilling an order. The tower storing the one or more products for fulfilling the order, or simply the one or more products, may be transported from the tower storage region 7604T to a particular station in the product induction region 7608. This transportation may be performed manually or automatically. For example, a plurality of AMRs (not shown) may generally be designated for transporting towers between the tower storage region 7604T and the product induction region 7608. A fulfillment order data structure generated by the order fulfillment processor 1300 may include tower-transportation AMR instructions for one of the plurality of tower-transportation AMRs 7518 to engage with the tower and transport the tower to the particular station in the product induction region 7608, where the erected carton may receive the one or more products for fulfilling the order. Indeed, loading of the one or more products into the erected carton may be carried out manually or in a robotic manner. For example, a loading robot (not shown) may be positioned near and/or be assigned to a station in the product induction region 7608. When a tower (see, for example, the tower 7510 of FIG. 75) storing one or more products for fulfilling an order is transported to the station, the loading robot may be instructed by the order fulfillment processor 1300 to retrieve the one or more products from one or more compartments of the tower and load them into the appropriate case or carton. For example, the loading robot may include an extendable arm with vacuum suction cups, capable of reaching for a specific product within the one or more compartments of the tower and loading the specific product into the case. The product induction region 7608 may include one or more loading robots for loading products from towers into cases, e.g., one loading robot may serve one station, or a plurality of stations, in the product induction region 7608. In this way, the AMR (such as AMR 5300/5800), which supports the erected carton, may travel to one or more stations in the product induction region 7608 and, at each station, receive, from a respective tower, one or more products for fulfilling the order, each tower having been transported from a first location in the tower storage region 7604T to the respective station by a tower-transportation AMR 7518 having received tower-transportation AMR instructions by the order fulfillment processor 1300.

[0470] Upon having received the one or more products that have been stored in various locations in the tower storage region 7604T, to fulfil the customer order, the AMR 5300/5800 may be controlled to move to the product rack storage region 7604P to receive the one or more products stored in the product rack storage region 7604P, which are required to fulfil the customer order. In the product rack storage region 7604P, the shipping case secured onto the AMR 5300/5800 may receive, from one or more product storage racks 7100, one or more further products to complete the customer order according to the methods, described hereinbefore, in relation to the product storage rack 7100 illustrated in FIG. 70.

[0471] Upon the receipt of a product that completes an order (or at least a part of the order to be loaded into that case), the AMR may then be controlled to move around the autonomous mobile robot movement region 7610 so that further order fulfillment functions may be carried out. For a few examples, the AMR 5300/5800 may be controlled to move the shipping container to a location within the autonomous mobile robot movement region 7610 at which location the weight of the shipping container may be verified. The shipping container may then be sealed and labelled.

[0472] The weight-verified, sealed and labelled shipping container may then be received at the route distribution accumulation region 7612, where the shipping container may be loaded, by robots and/or personnel 7998, upon a delivery vehicle.

[0473] In embodiments where the product rack storage region 7604P is split into the three zones 7605-1, 7605-2, and 7605-3, the one or more products stored in the product rack storage region 7604P, which are required to fulfil the customer order, may include products from at least two of the three zones 7605-1, 7605-2 and 7605-3 and, therefore, may include products that are stored at least at two different temperatures and conditions. In such embodiments, the shipping container may be one that includes both an insulated and a non-insulated portion, as described elsewhere. When the combination of the AMR 5300/5800 and the shipping container is controlled to visit one or more stations in the product induction region 7608 to receive the one or more products stored in the tower storage region 7604T required to fulfil the order, or to the product rack storage region 7604P to receive the one or more products stored in the first zone 7605-1 of the product rack storage region 7604P required to fulfil the order, the one or more products may be received in the non-insulated portion of the shipping container. When the combination of the AMR and the shipping container is controlled to move to the second zone 7605-2 or to the third zone 7605-3 of the product rack storage region 7604P to receive the one or more products, which are required to fulfil the customer order, the one or more products may be received in the insulated portion of the shipping container. The insulated portion of the shipping container may be sealed from the non-insulated portion of the shipping container. In this way, the insulated portion may prevent the one or more products contained within the insulated portion from melting or spoilage and, simultaneously, protect the one or more products contained within the non-insulated portion from becoming damaged due to a product in the insulated portion, e.g., water damage from being in contact with a frozen product.

[0474] Alternatively, more than one shipping container may be used to fulfil the customer order. For example, assuming a customer order requires one or more products stored in each of the tower storage region 7604T, the first zone 7605-1 of the product rack storage region 7604P, the second zone 7605-2 of the product rack storage region 7604P, and the third zone 7605-3 of the product rack storage region 7604P, a first AMR may be controlled to visit the shipping container induction region 7606 to receive a first shipping container. The first shipping container may not include any material for insulation and the combination of the first AMR 5300/5800 and the first shipping container may be controlled to move to the product induction region 7608 to receive the one or more products required to fulfil the order, which are stored in the tower storage region 7604T. The combination of the first AMR 5300/5800 and the first shipping container may further be controlled to move to the product rack storage region 7604P to receive the one or more products required to fulfil the order, which are stored in the first zone 7605-1. A second AMR 5300/5800 may be controlled to visit the shipping container induction region 7606 to receive a second shipping container. The second shipping container may include material for insulation and the combination of the second AMR 5300/5800 and the second shipping container may be controlled to move to the product rack storage region 7604P to receive the one or more products required to fulfil the order which are stored in the second zone 7605-2. A third AMR 5300/5800 may be controlled to visit the shipping container induction region 7606 to receive a third shipping container. The third shipping container may also include material for insulation and the combination of the third AMR 5300/5800 and the third shipping container may be controlled to move to the product rack storage region 7604P to receive the one or more products required to fulfil the order, which are stored in the third zone 7605-3. The employment of the first, second and third shipping containers is only an example. In some embodiments, the second shipping container may be used to receive the products stored in both the second zone 7605-2 and the third zone 7605-3. In some embodiments, a shipping container may be used to receive items stored in the tower storage region 7604T and a different shipping container may be used to receive items stored in the first zone 7605-1. In some embodiments, more than one shipping container may be used to receive items from the first zone 7605-1, more than one shipping container may be used to receive items from the second zone 7605-2, and more than one shipping container may be used to receive items from the second zone 7605-2.

[0475] The combination of the first AMR 5300/5800 and the first shipping container, the second AMR 5300/5800 and the second shipping container, and the third AMR 5300/5800 and the third shipping container, may subsequently be controlled to move to the order verification and sealing region 6910 and move through any one case sealing station 7620, which verifies that the one or more products within the first shipping container, the second shipping container, and the third shipping container are accurate and complete, and seals the first shipping container, the second shipping container, and the third shipping container. The combination of the first AMR 5300/5800 and the first shipping container, the second AMR 5300/5800 and the second shipping container, and the third AMR 5300/5800 and the third shipping container, may subsequently be controlled to move to a particular order discharge station 7225 to be loaded into a delivery container (e.g., a storage space of a delivery vehicle) for delivery to the respective customer. [0476] Over the normal course of order fulfilment, the products contained within a particular pallet stored on a product storage rack 7100 may be continuously removed from the pallet and provided to shipping containers held by AMRs 5300 or 5800, in order to fulfil orders requesting the products. As discussed previously, a pallet stored on product storage racks 7100 may include a plurality of standardized storage cases, such as the standardized storage cases 7910, palletized on a standardized pallet base 8002, where each of the standardized storage cases 7910 store products that can be used for a customer order. A robotic picker arm 7106 may retrieve the individual products from the standardized storage cases 7910 and load the retrieved individual products into shipping containers carried by the AMR 5300 or 5800. The robotic picker arm 7106 may retrieve individual products from a particular one of the standardized storage case 7910 until there are no more products inside of the particular standardized storage case 7910. Responsive to there being no more products inside of the particular standardized storage case 7910, an “empty” AMR (z.e., an AMR that is not carrying a case/shipment container or a standardized storage case 7910), such as AMR 5300 or 5800, may be controlled to visit the product storage rack 7100 where the particular standardized storage case 7910 is located. An empty AMR 5300/5800 may be defined as an AMR that is not carrying a shipping container or a standardized storage case 7910 but can accept at least one of the foregoing . For example, the empty AMR 5300/5800 may be one that previously carried thereon a shipping container, which it received from a shipping container induction region (e.g., the shipping container induction region 7606 of FIG. 76), and subsequently was controlled to travel to various locations for fulfilment of an order, until the shipping container was released at a route distribution accumulation region (e.g., the route distribution accumulation region 7612 of FIG. 76) to be loaded upon a delivery vehicle. The empty AMR 5300/5800 may be controlled to travel to the location of the particular standardized storage case 7910 (e.g., the storage level 7102 where the particular standardized storage case 7910 is stored). The robotic picker arm 7106 may then retrieve the (now empty) particular standardized storage case 7910, and load the particular standardized storage case 7910 onto the empty AMR 5300/5800. The combination of the formerly empty AMR 5300/5800 and the particular standardized storage case 7910 may travel to an exit station (not shown) where the particular standardized storage case 7910 may be unloaded. The once-again empty AMR 5300/5800 may subsequently be controlled to visit another product storage rack 7100 to receive another empty standardized storage case 7910 and unload it at the exit station or, alternatively, may be controlled to visit the shipping container induction region 7606 to receive a shipping container to start off an order fulfilment process, as discussed in detail hereinbefore. Therefore, the AMR 5300/5800 may be dually purposed to, on the one hand, receive a shipping container and participate in an order fulfilment process and, on the other hand, receive an empty standardized storage case 7910 and transport it to an exit station to be added to a pallet of empty standardized storage cases 7910, as described hereinafter. Therefore at least some, and possibly all, of the plurality of AMRs 5300/5800 which operate as such dual purpose AMRs, will be configured and operable so that they are capable of carrying both: (i) one or more sizes of cases/ shipment containers; and (ii) a standardized storage case 7910.

[0477] The process of removing products and/or empty standardized storage cases 7910 stored atop a particular standardized pallet base 8002 may continue until the particular standardized pallet base 8002 is empty (i.e., has no products stored thereon). Responsive to the particular standardized pallet base 8002 being empty, an AGV may be controlled to visit the product storage rack 7100 where the particular standardized pallet base 8002 is located. The AGV may be controlled to retrieve the particular standardized pallet base 8002 and may be controlled to travel to the exit station, where the AGV may unload the particular standardized pallet base 8002.

[0478] In some embodiments, various autonomous machines, such as AGVs or AMRs 5300/5800, may be controlled to repalletize a plurality of the same type of empty standardized storage cases onto an empty standardized pallet base 8002 located at the exit station to form an empty repalletized pallet. The empty repalletized pallet may then be returned to a supplier, producer, or manufacturer, who may then reuse the plurality of empty standardized storage cases and the empty standardized pallet base 8002 for storing products and, then once again, send the palletized products to the order fulfilment location 7600/7600A or the order fulfilment location 6900 to be used for the fulfilment of orders. The use of standardized storage cases and standardized pallet bases may, therefore, allow a closed loop system to be formed, as regards to the standardized storage cases and the standardized pallet base 8002.

[0479] Aspects of the present application may be implemented in a transformation of an existing fulfilment center. It may be expected that the existing fulfilment center has a layout similar to the order fulfillment location 5200 illustrated in FIG. 52 and that the layout is defined, for example, over 1,000,000 square feet. In an example transformation, it is proposed to transform a fulfilment center having a layout similar to the order fulfillment location 5200 illustrated in FIG. 52 to a fulfilment center having a layout similar to the order fulfillment location 7600 illustrated in FIG. 76. Notably, a layout similar to the order fulfillment location 5200 illustrated in FIG. 52 has an area designated as the tower storage region 5204. In an example transformation, it is proposed to convert part of an area designated as the tower storage region 5204 to an area designated as the product rack storage region 7604P. The remainder of the area may remain as the tower storage region 7604T.

[0480] Notably, the configuration illustrated in FIG. 76 is just one of many possible configurations. In FIG. 76, the area designated as the product rack storage region 7604P is approximately equal to the area designated as the tower storage region 7604T. In another configuration, the area designated as the product rack storage region 7604P may be approximately one ninth of the area designated as the tower storage region 7604T. That is, 100,000 square feet of the original 1,000,000 square feet may be given over to the product rack storage region 7604P. The product rack storage region 7604P may, alternatively, be described as a “High Bay” warehouse area capable of handling product storage racks 7100 (see FIG. 70) having 10-15 levels. Post conversion, the product rack storage region 7604P may be capable of storing in excess of 100,000 pallets with in the order of 3,000,000 grocery products. The product rack storage region 7604P may, as described in conjunction with FIG. 76A, be divided into three temperature zones 7605-1, 7605-2, and 7605-3 for storing grocery products at ambient temperatures, refrigerated temperatures and frozen temperatures.

[0481] The product rack storage region 7604P may contain 4,000 to 5,000 individual SKU pallet storage positions. Each SKU pallet storage position may be capable of storing up to 20 full SKU pallets on two levels of roller-driven conveyor. Each SKU pallet position may support, at a discharge end, a dedicated SKU robotic picker arm 7106 (see FIG. 77). The dedicated SKU robotic picker arm 7106 may be programmed exclusively for the SKU that it handled by the dedicated SKU robotic picker arm 7106.

[0482] As part of modification performed at an existing fulfilment center, approximately 15 miles of so-called “tote and case conveyor” may be replaced by 100,000 square feet of AMR track. The AMR track may allow for a connection among all of the functions of the fulfillment process. The AMR track may allow individually programmed AMRs 5300/5800 to complete individual order fulfillment processes.

[0483] It may be expected that the AMR track will allow AMRs 5300/5800 to visit the existing manual product induction stations, perhaps in the order of 300-500 manual product induction stations in the product induction region 7608, and the 4,000-5,000 individual SKU pallet storage positions in the product rack storage region 7604P. It may be expected that the AMR track will allow AMRs 5300/5800 to visit: shipping container induction stations in the shipping container induction region 7606 (see FIG. 76); order verification stations 7630 (see FIG. 56A); rework stations; case sealing stations 7620 (see FIGS. 56A, 73); order discharge stations 7225 (see FIG 71); and discharge conveyors 7226 (see FIG. 71).

[0484] Post conversion, it may be found that aspects of the product and pallet intake process of the existing fulfilment center remains unchanged. Trailers may be manually unloaded of their product loads. The products may be depalletized, if necessary, and the products may be processed at the product storage induction region 5202 for storage in the tower storage region 7604T.

[0485] Other aspects of the product and pallet intake process may be shown to differ from the intake process of the existing fulfilment center. For example, an inbound, single SKU pallet, arriving on a trailer, may be implemented as a plurality of standardized storage cases 7910 (see FIG. 79) upon a standardized pallet base 8002 (see FIG. 80). It is contemplated that full, standardized pallet bases 8002 may be received on trailers on a just-in-time basis, in lots of, say, 20 full, standardized pallet bases 8002 at a time. Such trailers-full may be unloaded by AGVs. The AGVs may deliver each full, standardized pallet base 8002 to an appropriate individual SKU pallet storage position in the product rack storage region 7604P.

[0486] As noted hereinbefore, a given inbound single SKU pallet (a plurality of standardized storage cases 7910 resting on a standardized pallet base 8002) may be subjected to robotic depalletization by a robotic picker arm 7106 (see FIG. 77) while the given inbound single SKU pallet is positioned on a storage level 7102 of a product storage rack 7100 (see FIG. 70). Indeed, the given inbound single SKU pallet may be specifically configured to facilitate robotic depalletization. For example, the given inbound single SKU pallet may be configured with strapping instead of stretch wrap. It may be shown that using strapping facilitates robotic depalletizing. The plurality of standardized storage cases 7910 resting on the standardized pallet base 8002 may be isolated from the strapping by a pallet top sheet, which may be formed of corrugated cardboard. As is known, the single SKU pallet may include other non-product material, such as slip sheets, which may also be formed of corrugated cardboard. Additionally, rather than a plurality of standardized storage cases 7910, the products may be found in shipping cases, which may also be formed of corrugated cardboard.

[0487] As the robotic picker arm 7106 loads products into the AMRs 5300/5800, corrugated shipping cases may be emptied. Empty corrugated shipping cases may be picked by the robotic picker arm 7106 and dropped into a corrugated material recycling chute (not shown) as part of the product storage rack 7100. The shipping case, pallet top sheets and slip sheets, upon reaching a bottom of the corrugated material recycling chute, may drop onto a dunnage accumulation conveyor (not shown) located in the center of the product storage rack 7100. Material carried on the dunnage accumulation conveyor may be accumulated and loaded automatically into an automatic compactor and strapping machine for recycling. Thereafter, an AGV may pick strapped bundles and position the strapped bundles into a recycling trailer for delivery to a recycling station.

[0488] Conveniently, each standardized storage case 7910 among the plurality of standardized storage cases 7910 that rests on the standardized pallet base 8002 may be configured with an open top. The open top may be shown to allow for the robotic picker arm 7106 to pick products out of the standardized storage case 7910 and place the products into a shipping container carried on an AMR 5300/5800. Many grocery products, like fruits and vegetables, are known to be shipped in cases with an open top configuration.

[0489] When a standardized pallet base 8002 has been emptied of all of the standardized storage cases 7910 that originally rested thereon, the robotic picker arm 7106 may load the empty standardized pallet base 8002 onto an AMR 5300/5800. The AMR 5300/5800 may then transfer the empty standardized pallet base 8002 to empty standardized pallet base staging area (not shown). In the empty standardized pallet base staging area, a pallet base stacking robot may stack the empty standardized pallet bases 8002 in stacks of a manageable height, say, ten empty standardized pallet bases high. [0490] A customer order may be placed on a web site and processed by the order fulfillment processor 1300. The order fulfillment processor 1300 may determine various customer order- related parameters, such as: number of items in the customer order; shipping container size; shipping container style; shipping locations; number of shipping containers; and shipping destination address. It is contemplated that artificial intelligence innovations will enhance future order processing.

[0491] The fulfillment process may begin with the order fulfillment processor 1300 directing an AMR 5300/5800 to a shipping container induction region 7606 (see FIG. 76). It may be shown that there is virtually no limit to the number of shipping containers to be used to complete the customer order.

[0492] A right-sized shipping container may be affixed to the AMR 5300/5800 and used as a collating and accumulating device for the customer order. The shipping container induction region 7606 may be provisioned with over 150 shipping container forming machines, with each shipping container forming machine capable of forming a unique size and style of shipping container.

[0493] The AMR 5300/5800 carrying the right-sized shipping container for the customer order may be directed to receive products at any combination of the 300-500 manual product induction stations in the product induction region 7608 and/or the 4,000 individual SKU pallet storage positions in the product rack storage region 7604P. The receipt of products may be expected to continue until all of the items in the customer order (or part of a customer order for a particular shipping container) have been placed into the right-sized shipping container.

[0494] Once the right-sized shipping container has received all the items in the customer order, the AMR 5300/5800 may be directed to one of 200 order verification stations 7630 (see FIG. 56A) to confirm the contents of the right-sized shipping container matches the customer order using check weight systems. Using vision systems, the order verification stations 7630 may also check the item distribution in the shipping container. All data associated with the dimensional and weight information for each component in the customer order may be verified at the order verification stations 7630. With the customer order verified, the AMR 5300/5800 may be instructed to pass through an appropriate case closing and order identification system (see the case top sealer 7620 and the case labeler 7624 of FIG. 56A). Dunnage may or may not be added at the case closing aspect of the system, in dependence upon the extent to which the shipping container has been selected to have a “right” size. Barcodes and shipping labels may be automatically applied to the erected case at the order identification aspects of the system.

[0495] Occasionally, shipping containers may be rejected at the order verification station 7630. A rejected shipping container may cause the AMR 5300/5800 to be directed to an rework station, at which the rejected shipping container may be reworked manually. Subsequent to reworking, the AMR 5300/5800 may be directed back to a designated order verification station 7630.

[0496] Responsive to successful verification at the order verification station 7630, the AMR 5300/5800 may be directed to a combination dunnage insertion and case sealing station (see, for example, the case sealing stations 7620 in FIG. 56A and FIG. 73), at which, if necessary, dunnage may be added into the shipping container to stabilize the contents of the customer order and the top of the shipping container may be sealed.

[0497] It should be well understood that misplaced dunnage insertion or shipping container sealing faults may cause the AMR 5300/5800 to be instructed to visit a rework station, at which the shipping container may be reworked manually. Subsequent to reworking, the AMR 5300/5800 may be directed back to a designated combination dunnage insertion and case sealing station.

[0498] The AMR 5300/5800, with a verified and sealed shipping container, may be directed to a labelling station (see the case labeler 7624 of FIG. 56A). The labelling station may be expected to label the shipping container to in accordance with routing and delivery instructions specific to the customer order. Order information data may be used to determine whether a “heavy” label and/or a “fragile” label are to be automatically applied at the labelling station.

[0499] The AMR 5300/5800, with a verified, sealed and labelled shipping container, may be directed to a route distribution accumulation region 7612, at which the AMR 5300/5800 may offload the shipping container onto a discharge routing conveyor 7626 (FIG. 56A) for loading into delivery vehicle. All of the shipping containers for a specific route may be accumulated and loaded into a delivery vehicle that has been assigned to the specific route.

[0500] The AMR 5300/5800, while carrying the verified shipping container, may act on instructions to proceed to a particular one of, say, 150 stations in the route distribution accumulation regions 7612. The instructions may be based on a destination of the shipping container being on a delivery route assigned to a delivery vehicle associated with a particular station in the route distribution accumulation region 7612. As shipping containers accumulate for a given delivery route, a driver of the delivery vehicle assigned to the given delivery route may move shipping containers from the discharge routing conveyor 7626 into the delivery vehicle. The stations in the route distribution accumulation regions 7612 may be configured to be located directly adjacent to delivery vehicle loading positions. A delivery vehicle driver may commence a shift by packing a plurality of shipping containers for a delivery route into a delivery vehicle designated to that delivery route. On average, between 75 and 150 shipping containers, representing customer orders may be expected to be loaded into a delivery vehicle by a delivery vehicle driver carrying out a loading operation. Once the loading operation is completed, the delivery vehicle driver may be expected to distribute the shipping containers to respective customers using traditional delivery methods.

[0501] FIG. 81 illustrates a 1x4 stack 8100 of crates 7910 (FIG. 79) carried on top of an AMR 5300 (FIG. 53).

[0502] FIG. 82A illustrates, in a schematic plan view, an order fulfilment location 8200A that may be viewed as an alternative to the order fulfilment center 7600 of FIG. 76. The order fulfillment location 8200A may be considered to be physically organized, in a logical manner, into areas or regions associated with various functions. The order fulfillment location 8200A includes a product storage induction region 8203, a tower storage region 8204T, a product rack storage region 8204P, a shipping container induction region 8206, a product induction region 8208, an autonomous mobile robot movement region 8210, in which are located a plurality of AMRs (such as for example AMRs 5300 and/or AMRs 5800), and a route distribution accumulation region 8212. In practice, depending upon the size of the order fulfillment location 8200A, the order fulfillment location 8200A may, in some cases, include multiples of the regions illustrated in FIG. 82 and may, in some other cases, omit one or more regions. [0503] The tower storage region 8204T may be populated by a plurality of towers 7510 (see FIG. 75). In some embodiments, the plurality of towers 7510 in the tower storage region 7604T may store higher margin, lower volume products. Examples of such products may include consumer electronics, clothing, toys, and health and beauty items. In some embodiments, the number of different individual products (SKUs) stored by the plurality of towers 7510 may be on the order of several hundred thousand, or one or more millions, of different products (e.g., a vast range of different books or DVDs).

[0504] In contrast to the tower storage region 7604T of FIG. 76, in addition to the plurality of towers 7510, the tower storage region 8204T of FIG. 82 A may also be populated by a plurality of stacks 8100 of crates 7910 (see FIG. 81). That is, the tower storage region 8204T of FIG. 82A may be populated by a plurality of towers 7510 mixed together with a plurality of stacks 8100.

[0505] The product rack storage region 8204P may be populated by a plurality of product storage racks 7100, as well as a plurality of AMR elevators 7110 (see FIG. 70). In some embodiments, the plurality of product storage racks 7100 in the product rack storage region 8204P may store lower margin, higher volume products. For example, the plurality of product storage racks 7100 may store grocery items.

[0506] The product rack storage region 8204P is illustrated as divided into three zones 8205- 1, 8205-2 and 8205-3. Each of the three zones 8205-1, 8205-2 and 8205-3 may include one or more product storage racks 7100, which may be populated with pallets corresponding to various products.

[0507] The zones 8205-1, 8205-2 and 8205-3 may be maintained at different conditions. For example, a first zone 8205-1 may maintain products at a moderate temperature, e.g., at room temperature or ambient temperature. A second zone 8205-2 may maintain products at a reduced temperature as compared to the temperature of the first zone 8205-1, e.g., at a refrigerated temperature. A third zone 8205-3 may maintain products at a temperature at or below freezing. In this way, the zones 8205-1, 8205-2 and 8205-3 may provide three different storage conditions for storage of different products. For example, as previously mentioned the product rack storage region 8204P may house grocery items. Items that are safe to be stored at room temperature, such as non-perishable grocery goods, may be kept in the first zone 8205-1; perishable grocery items such as fresh produce and meats may be kept in the second zone 8205-2; and frozen grocery items may be kept in the third zone 8205-3.

[0508] In some embodiments, an air curtain or air door may be provided for the product storage racks 7100 located within the second zone 8205-2 and/or the third zone 8205-3. The air curtain may be understood to be a device configured to blow a consistent and controlled high- velocity stream of air to create an air seal and separate two environments from each other. Specifically, the air curtain may separate a portion of a product storage rack 7100 storing products at a refrigerated or freezing temperature, from an average warehouse temperature, which may be an ambient temperature.

[0509] For example, referring to FIG. 70, for a product storage rack 7100 located within the second zone 8205-2 or the third zone 8205-3, an air curtain (not shown) may be positioned above the product storage rack 7100 and configured to blow a high-velocity stream of air, in a substantially vertical direction, between the plurality of storage levels 7102 and the plurality of raised platforms 7104. The air curtain may therefore allow a first environment which includes the plurality of storage levels 7102 and the products stored on the plurality of storage levels 7102, to be maintained at different conditions from a second environment which includes the plurality of raised platforms 7104, the one or more robotic picker arms 7106, the AMR elevator 7110, the AMRs 5800, and any forklifts or automated guided vehicles travelling along the ground level. For example, for a product storage rack 7100 located within the second zone 8205-2, the first environment may be maintained at a refrigerated temperature and the second environment may be maintained at an ambient temperature, while for a product storage rack 7100 located within the third zone 8205-3, the first environment may be maintained at a below freezing temperature and the second environment may be maintained at an ambient temperature. In this way, within the second zone 8205-2 and the third zone 8205-3, the AMR 5800, the AMR elevator 7110, and any other equipment or material located within the second zone 8205-2 and the third zone 8205-3, may be protected from damage that may be caused by refrigerated or freezing temperatures. The one or more robotic picker arms 7106 may be configured to enter and exit the first environment to retrieve products stored on the plurality of storage levels 7102 and release them into one or more shipping containers carried by an AMR 5800. In a rest position, the one or more robotic picker arms 7106 may be located in the second environment to minimize any damage from prolonged exposure to refrigerated or below freezing temperatures. In some embodiments, more than one air curtains may be provided for a product storage rack 7100, to ensure that air seals are created all around the products stored on the plurality of storage levels 7102. In other words, as opposed to creating an air seal at just a front side of the plurality of storage levels 7102, air curtains may be provided to create air seals at the left, right, and rear sides of the plurality of storage levels 7102. In some embodiments, air curtains or other means for maintaining various areas or environments of the second zone 8205-2 and/or the third zone 8205-3 at different temperatures may not be implemented. Instead, the second zone 8205-2, including the entirety of the product storage racks 7100 and AMR elevators 7110 may generally be maintained at a refrigerated temperature such that when any AMRs 5800 and vehicles travelling along the ground level enter the second zone 8205-2, they are exposed to the refrigerated temperature at which the second zone 8205-2 is maintained. Similarly, the third zone 8205-3, including the product storage racks 7100 and AMR elevators 7110, may generally be maintained at a below freezing temperature such that when any AMRs 5800 and vehicles travelling along the ground level enter the third zone 8205-3, they are exposed to the refrigerated temperature at which the third zone 8205-3 is maintained.

[0510] In operation, at the product storage induction region 8203, various products may be shown to arrive at the order fulfillment center 8200A in, for example, a plurality of transport trailers.

[0511] Some of the products that have arrived, often organized upon a pallet, may be stored into compartments of the plurality of towers, which towers are located at the tower storage region 8204T. Individual products organized upon a pallet may be retrieved through de-palletization and dismantlement processes and each individual product may subsequently be placed in one of the towers 7510, as described hereinbefore. Information regarding the location in which each individual product is stored (e.g., the specific tower 7510 and the compartment 7512 of the specific tower), may be stored in a suitable memory of the order fulfilment processor 1300.

[0512] Some of the products that have arrived, often organized in crates upon a pallet, may be removed from the pallet, by personnel and/or robots 7999, and remain in their respective crates. Crates (say, as few as one and as many as six) may be stacked upon an AMR 5300 (see FIG. 81) to form a stack 8100. In some embodiments, each respective crate may store a product of a distinct SKU. For example, each respective crate in a stack 8100 may store a different type of one product (e.g., different flavors of a candy item). Alternatively, each crate in a stack 8100 may store a different product to one or more the other crates in the stack 8100 (e.g., one crate in the stack 8100 may store a candy item, a separate crate in the same stack 8100 may store a gum product, etc. . Various stacks 8100 may be transported, upon the AMRs 5300, into the tower storage region 8204T.

[0513] Some of the products that have arrived, often organized upon a pallet, may be transported, upon their respective pallets, to specific corresponding locations in the product rack storage region 8204P, where a plurality of product storage racks 7100, at which the pallets may be stored, are located. Such transportation may be done using forklifts 7997. The forklifts 7997 may be operated manually by an operator or may operate autonomously. In a preferred embodiment, the forklifts 7997 may be AGVs.

[0514] In some embodiments, products to be stored at the product rack storage region 8204P, may arrive to the order fulfilment location 8200A in a standardized storage case, palletized on a standardized pallet base. In other words, suppliers may place products, which are to be stored at the product rack storage region 8204P and used in the fulfilment of orders, into a standardized storage case and may palletize a plurality of such cases on a standardized pallet base, as described hereinbefore.

[0515] The order fulfilment location 8200A of FIG. 82 A includes a product induction region 8208. The product induction region 8208 may include both manual product induction stations and robotic product induction stations. Furthermore, due to the mix of towers 7510 and stacks 8100 in the tower storage region 8204T, there may also be a mix of robotic product induction stations. Indeed, some of the robotic product induction stations may be suited to obtaining a product from a tower 7510 and placing the product into an erected carton on an AMR 5300. Others of the robotic product induction stations may be suited to obtaining a product from a crate 7910 in a stack 8100 and placing the product into an erected carton on an AMR 5300. For those instances wherein the product to be obtained is in a crate 7910 that is not the top crate 7910 in the stack 8100, the robotic product induction station that is suited to obtaining a product from a crate 7910 may be expected to include robotic arms suited for a task of lifting one or more crates 7910 off the stack 8100 to, thereby, allow access to the crate 7910 storing the product to be obtained. [0516] FIG. 82B illustrates, in a schematic plan view, an order fulfilment location 8200B that may be viewed as an alternative to the order fulfilment center 8200 A of FIG. 82 A.

[0517] Rather than mixing, in the tower storage region 8204T, a plurality of towers 7510 and a plurality of stacks 8100, as illustrated in the order fulfilment center 8200 A of FIG. 82 A, the order fulfilment center 8200B of FIG. 82B features a stack storage region 8204R that is separate from, and a level above, the tower storage region 8204T. Access to the stack storage region 8204R is illustrated, in FIG. 82B, as being provided by a ramp 8220. One alternative to the ramp 8220 is an elevator (not shown).

[0518] The order fulfilment location 8200B of FIG. 82B is illustrated as including a product induction region 8228 in the stack storage region 8204R. The product induction region 8228 may include robotic product induction stations suited to obtaining a product from a crate 7910 in a stack 8100 and placing the product into an erected carton on an AMR 5300. For those instances wherein the product to be obtained is in a crate 7910 that is not the top crate 7910 in the stack 8100, the robotic product induction station that is suited to obtaining a product from a crate 7910 may be expected to include robotic arms (not shown) suited for a task of lifting one or more crates 7910 off the stack 8100 to, thereby, allow access to the crate 7910 storing the product to be obtained.

[0519] FIG. 83 illustrates an arrangement of crates 7910 (FIG. 79) within a crate retention structure 8300. The structure 8300 is illustrated as being carried on top of an AMR 5300 (FIG. 53). The structure 8300 provides an alternative to the stack 8100 of FIG. 81. Conveniently, for those instances wherein the product to be obtained is in a crate 7910 that is not the top crate 7910, the robotic product induction station that is suited to obtaining a product from a crate 7910 may be expected to withdraw the crate 7910 from the structure 8300 to, thereby, allow access to the crate 7910 storing the product to be obtained. On one hand, a robotic arm (not shown), at the robotic product induction station, may entirely withdraw the crate 7910 from the structure 8300, thereby separating the crate 7910 from the structure 8300. On the other hand, the robotic arm (not shown), at the robotic product induction station, may partially withdraw the crate 7910 from the structure 8300, thereby maintaining a spatial location of the crate 7910 within the structure 8300, as though the crate 7910 is a drawer. [0520] In the context of FIG. 82B, a plurality of crate retention structures 8300 may populate the stack storage region 8204R. The product induction region 8228 may include robotic product induction stations suited to obtaining a product from a crate 7910 in a crate retention structure 8300 and placing the product into an erected carton on an AMR 5300.

[0521] FIG. 84 illustrates a further crate retention structure 8400. Like the structure 8300 of FIG. 83, the further crate retention structure 8400 of FIG. 84 is illustrated as being carried on top of a crate retention AMR 8402. In contrast to the structure 8300 of FIG. 83, the further crate retention structure 8400 of FIG. 84 is illustrated as having legs 8404. Conveniently, the legs 8404 allow the further crate retention structure 8400 to be stored in a manner that is separate from the crate retention AMR 8402.

[0522] As discussed hereinbefore, in the context of the tower 7510 (see FIG. 75), the crate retention AMR 8402 may slide underneath the further crate retention structure 8400 and lift the further crate retention structure 8400 off the ground through, e.g., a corkscrew action. The crate retention AMR 8402 may then carry the further crate retention structure 8400 to an indicated location.

[0523] In the context of FIG. 82B, a plurality of further crate retention structures 8400 may populate the stack storage region 8204R. The product induction region 8228 may include robotic product induction stations suited to obtaining a product from a crate 7910 in a further crate retention structure 8400 and placing the product into a shipping container carried on an AMR 5300.

[0524] It is contemplated that either the crate retention structure 8300 (see FIG. 83) or the further crate retention structures 8400 (see FIG. 84) may be provisioned with a robot arm (not shown) on top of the structure. By provisioning a crate retention structure with a robot arm, an AMR with an erected shipping container may simply approach the location of the crate retention structure to receive a product from a crate 7910 carried by the crate retention structure. Accordingly, traffic at the product induction region 8228 may be reduced or eliminated.

[0525] The further crate retention structure 8400 has been discussed as an alternative to the crate retention structure 8300 of FIG. 83, which, in turn, is an alternative to the stack 8100 of FIG. 81. The crate retention structure 8300 of FIG. 83 and the stack 8100 of FIG. 81 have been presented, up to this point, as storage for multiple crates 7910, where each crate 7910 stores a product of a distinct SKU. Notably, however, it is contemplated that, for a scenario in which each crate 7910 stores a product of the same SKU, the further crate retention structure 8400 of FIG. 84 may be considered to be an alternative to the pallet 8010 of FIG. 80. Then, rather than moving, by forklifts 7997 or other AGVs, pallets 8010 of products onto the product storage racks 7100 in the product rack storage region 8204P (see FIG. 82), a plurality of crate retention AMRs 8402 may move a plurality of further crate retention structures 8400 onto the product storage racks 7100 in the product rack storage region 8204P. Conveniently, a product induction system based on the further crate retention structures 8400 may reduce any need for human operators for the forklifts 7997, which, as described hereinbefore, may be used to move pallets 8010 of products onto the product storage racks 7100 in the product rack storage region 8204P.

[0526] It is known that the forklifts 7997 may be the default vehicle for unloading pallets 8010 of products from transport trailers at the product storage induction region 8203 (see FIG. 82). It may be considered convenient to employ the further crate retention structures 8400 instead of the pallets 8010. It may be arranged, then, for a selected crate retention AMRs 8402 to board a selected transport trailer, pick up a selected one of the further crate retention structures 8400 and carry the selected further crate retention structure 8400 to a particular destination. Accordingly, for a product induction system that is based on the further crate retention structures 8400, reliance upon human operators for the forklifts 7997 may be reduced.

[0527] Of course, the further crate retention structures 8400 are not currently in common use. However, it is considered feasible to configure a typical transport trailer for use to carry a plurality of the further crate retention structures 8400. FIG. 85 illustrates, in a cut-away plan view, a transport trailer 8500 configured to carry a plurality of the further crate retention structures 8400. It has been discussed, hereinbefore, that AMRs may navigate, at least in part, on the basis of tracks defined by barcodes on the floor of a generic order fulfilment location in which the AMRs are being used. It follows, then, that configuring the transport trailer 8500 for use with the further crate retention structures 8400 may further include implementing, in the transport trailer 8500, an adaptation allowing use with AMRs. Such adaptation may, for example, include installing tracks defined by barcodes on the floor of the transport trailer 8500 to, thereby, facilitate navigation by AMRs in the transport trailer 8500.

[0528] FIG. 86 illustrates a customer order processing matrix 8600. The customer order processing matrix 8600 may be understood to be a result of the order fulfillment processor 1300 (see FIG. 64) having processed a customer order.

[0529] According to the customer order processing matrix 8600, six AMRs 5300/5800 are to be used in the fulfillment of the customer order. It may be understood that the order fulfillment processor 1300 has determined that six AMRs 5300/5800 are to be used in the fulfillment of the customer order based on characteristics of individual items in the customer order. The order fulfillment processor 1300 may designate and schedule six specific AMRs 5300/5800 according to the customer order processing matrix 8600.

[0530] In view of the customer order processing matrix 8600, it may be understood that four shipping containers, each associated with a distinct one of four shipping container codes (RC301, IR246, IF715, RC254) are to be used to package the order. The selection, by the order fulfillment processor 1300, of these four specific shipping containers may be based on individual item characteristics of the items in the customer order. Notably, item 4 and item 5 have been determined to not be packaged in a shipping container. However, this is simply an example, and, in some embodiments, each item to be used in the fulfilment of a customer order may be packaged in a shipping container to, e.g., prevent the items from being damaged.

[0531] Based on the characteristics of non-refrigerated items 1, 7, 8, 9, 10, 11 and 16, the order fulfillment processor 1300 may establish a shipping container size and style. For this portion of the customer order, the shipping container style is RSC and the size is 14”xl0”xl0”, which is implemented using shipping container code RC301. According to the customer order processing matrix 8600, the order fulfillment processor 1300 has designated AMR Al 168 to carry the shipping container for this portion of the customer order.

[0532] Although not illustrated in the customer order processing matrix 8600, the order fulfillment processor 1300 may have determined that a picking and packing process, for this portion of the customer order, will consume between 70 and 80 minutes of AMR travel and wait time. The order fulfillment processor 1300 may also have determined that the processes related to verifying the contents of the shipping container, sealing the shipping container and labeling the shipping container are estimated to consume 10 minutes to complete.

[0533] Based on the characteristics of refrigerated items 2, 3 and 21, the order fulfillment processor 1300 has established a shipping container size and style. For this portion of the customer order, the shipping container style is “insulated refrigerated” and the size is 10”x8”x8”, which is implemented using shipping container code IR246. According to the customer order processing matrix 8600, the order fulfillment processor 1300 has designated AMR A4530 to carry the shipping container for this portion of the customer order.

[0534] Although not illustrated in the customer order processing matrix 8600, the order fulfillment processor 1300 may have determined that a picking and packing process, for this portion of the customer order, will consume between 40 and 50 minutes of AMR travel and wait time. The order fulfillment processor 1300 may also have determined that the processes related to verifying the contents of the shipping container, sealing the shipping container and labeling the shipping container are estimated to consume 10 minutes to complete.

[0535] Based on the characteristics of frozen items 6, 12, 19 and 20, the order fulfillment processor 1300 has established a shipping container size and style. For this portion of the customer order, the shipping container style is “insulated frozen” and the size is 12”x8”xl0”, which is implemented using shipping container code IF715. According to the customer order processing matrix 8600, the order fulfillment processor 1300 has designated AMR A5546 to carry the shipping container for this portion of the customer order.

[0536] Although not illustrated in the customer order processing matrix 8600, the order fulfillment processor 1300 may have determined that a picking and packing process, for this portion of the customer order, will consume between 30 and 40 minutes of AMR travel and wait time. The order fulfillment processor 1300 may also have determined that the processes related to verifying the contents of the shipping container, sealing the shipping container and labeling the shipping container are estimated to consume 10 minutes to complete. [0537] Based on the characteristics of items 4 and 5, the order fulfillment processor 1300 has established that a shipping container is not required. According to the customer order processing matrix 8600, the order fulfillment processor 1300 has designated AMR A9436 to carry item 4 and has designated AMR Al 3462 to carry item 5.

[0538] Although not illustrated in the customer order processing matrix 8600, the order fulfillment processor 1300 may have determined that a picking and packing process, for this portion of the customer order, will consume between 30 and 40 minutes of AMR travel and wait time. The order fulfillment processor 1300 may also have determined that the processes related to verifying the contents of item 4 and item 5, and labeling the shipping container are estimated to consume 10 minutes to complete.

[0539] Based on the characteristics of non-refrigerated items 13, 14, 15, 17 and 18, the order fulfillment processor 1300 may establish a shipping container size and style. For this portion of the customer order, the shipping container style is RSC and the size is 14”xl4”x8”, which is implemented using shipping container code RC254. According to the customer order processing matrix 8600, the order fulfillment processor 1300 has designated AMR A10258 to carry the shipping container for this portion of the customer order.

[0540] For order items 1, 7, 8, 9, 10, 11 and 16, the order fulfillment processor 1300 may instruct AMR Al 168 to proceed to a specific shipping container forming machine in the shipping container induction region 8206. In a manner described in more detail hereinbefore, the specific shipping container forming machine may pick, from the case magazine, a case blank for shipping container code RC301. The specific shipping container forming machine may then erect and bottom seal the shipping container and provide the shipping container to AMR Al 168.

[0541] The order fulfillment processor 1300 may instruct AMR Al 168 to proceed, with the shipping container, to a manual product induction station in the product induction region 8208 to receive item 1.

[0542] The order fulfillment processor 1300 may instruct AMR Al 168 to proceed, with the shipping container, to a manual product induction station in the product induction region 8208 to receive item 7. [0543] The order fulfillment processor 1300 may instruct AMR Al 168 to proceed, with the shipping container, to a robotic product induction station in the stack storage region 8204R to receive item 8.

[0544] The order fulfillment processor 1300 may instruct AMR Al 168 to proceed, with the shipping container, to a robotic product induction station in the stack storage region 8204R to receive item 9.

[0545] The order fulfillment processor 1300 may instruct AMR Al 168 to proceed, with the shipping container, to a manual product induction station in the product induction region 8208 to receive item 16.

[0546] The order fulfillment processor 1300 may instruct AMR Al 168 to proceed, with the shipping container, to a robotic product induction station in the stack storage region 8204R to receive item 11.

[0547] The order fulfillment processor 1300 may instruct AMR Al 168 to proceed, with the shipping container, to a robotic product induction station in the stack storage region 8204R to receive item 10.

[0548] Responsive to the last item (item 10, in this case) having been loaded into the shipping container, the order fulfillment processor 1300 may instruct AMR Al 168 to visit an order verification, case sealing and labelling station, such as the case sealing station 7620 of FIG. 73, to verify the contents of the shipping container, seal the shipping container and label the shipping container.

[0549] For order items 2, 3 and 21, the order fulfillment processor 1300 may instruct AMR A4530 to proceed to a specific shipping container forming machine in the shipping container induction region 8206. In a manner described in more detail hereinbefore, the specific shipping container forming machine may pick, from the case magazine, a case blank for shipping container code IR246. The shipping container code IR246 may, for example, be an insulated container designed for being loaded with refrigerated products. The specific shipping container forming machine may then erect and bottom seal the shipping container and provide the shipping container to AMR A4530. [0550] The order fulfillment processor 1300 may instruct AMR A4530 to proceed, with the shipping container, to a robotic product induction station in the refrigerated temperature second zone 8205-2 within the product rack storage region 8204P. At the robotic product induction station, a robotic product induction robot will depalletize item 2 from a stored pallet and place item 2 into the shipping container on AMR A4530.

[0551] The order fulfillment processor 1300 may instruct AMR A4530 to proceed, with the shipping container, to a further robotic product induction station in the refrigerated temperature second zone 8205-2 within the product rack storage region 8204P. At the robotic product induction station, a robotic product induction robot will depalletize item 3 from a stored pallet and place item 3 into the shipping container on AMR A4530.

[0552] The order fulfillment processor 1300 may instruct AMR A4530 to proceed, with the shipping container, to a further robotic product induction station in the refrigerated temperature second zone 8205-2 within the product rack storage region 8204P. At the robotic product induction station, a robotic product induction robot will depalletize item 21 from a stored pallet and place item 21 into the shipping container on AMR A4530.

[0553] Responsive to the last item (item 21, in this case) having been loaded into the shipping container, the order fulfillment processor 1300 may instruct AMR A4530 to visit an order verification, case sealing and labelling station, such as the case sealing station 7620 of FIG. 73, to verify the contents of the shipping container, seal the shipping container and label the shipping container.

[0554] For frozen items 6, 12, 19 and 20, the order fulfillment processor 1300 may instruct AMR A5546 to proceed to a specific shipping container forming machine in the shipping container induction region 8206. In a manner described in more detail hereinbefore, the specific shipping container forming machine may pick, from the case magazine, a case blank for shipping container code IF715. The shipping container code IF715 may, for example, be an insulated container designed for being loaded with frozen products. The specific shipping container forming machine may then erect and bottom seal the shipping container and provide the shipping container to AMR A5546. [0555] The order fulfillment processor 1300 may instruct AMR A5546 to proceed, with the shipping container, to a robotic product induction station in the frozen temperature third zone 8205-3 within the product rack storage region 8204P. At the robotic product induction station, a robotic product induction robot will depalletize item 6 from a stored pallet and place item 6 into the shipping container on AMR A5546.

[0556] The order fulfillment processor 1300 may instruct AMR A5546 to proceed, with the shipping container, to a robotic product induction station in the frozen temperature third zone 8205-3 within the product rack storage region 8204P. At the robotic product induction station, a robotic product induction robot will depalletize item 12 from a stored pallet and place item 12 into the shipping container on AMR A5546.

[0557] The order fulfillment processor 1300 may instruct AMR A5546 to proceed, with the shipping container, to a robotic product induction station in the frozen temperature third zone 8205-3 within the product rack storage region 8204P. At the robotic product induction station, a robotic product induction robot will depalletize item 19 from a stored pallet and place item 19 into the shipping container on AMR A5546.

[0558] The order fulfillment processor 1300 may instruct AMR A5546 to proceed, with the shipping container, to a robotic product induction station in the frozen temperature third zone 8205-3 within the product rack storage region 8204P. At the robotic product induction station, a robotic product induction robot will depalletize item 20 from a stored pallet and place item 20 into the shipping container on AMR A5546.

[0559] Responsive to the last item (item 20, in this case) having been loaded into the shipping container, the order fulfillment processor 1300 may instruct AMR A5546 to visit an order verification, case sealing and labelling station, such as the case sealing station 7620 of FIG. 73, to verify the contents of the shipping container, seal the shipping container and label the shipping container.

[0560] As discussed hereinbefore, for item 4 and item 5 there is to be no shipping container.

[0561] For item 4, the order fulfillment processor 1300 may instruct AMR A9436 to proceed to a robotic product induction station in the ambient temperature first zone 8205-1 within the product rack storage region 8204P. At the robotic product induction station, a robotic product induction robot will depalletize item 4 from a stored pallet and place item 4 onto AMR A9436.

[0562] For item 5, the order fulfillment processor 1300 may instruct AMR A13462 to proceed to a robotic product induction station in the ambient temperature first zone 8205-1 within the product rack storage region 8204P. At the robotic product induction station, a robotic product induction robot will depalletize item 5 from a stored pallet and place item 5 onto AMR Al 3462.

[0563] For order items 13, 14, 15, 17 and 18, the order fulfillment processor 1300 may instruct AMR A10258 to proceed to a specific shipping container forming machine in the shipping container induction region 8206. In a manner described in more detail hereinbefore, the specific shipping container forming machine may pick, from the case magazine, a case blank for shipping container code RC254. The specific shipping container forming machine may then erect and bottom seal the shipping container and provide the shipping container to AMR A10258.

[0564] The order fulfillment processor 1300 may instruct AMR A10258 to proceed, with the shipping container, to a robotic product induction station in the ambient temperature first zone 8205-1 within the product rack storage region 8204P. At the robotic product induction station, a robotic product induction robot will depalletize item 15 from a stored pallet and place item 15 onto AMR A10258.

[0565] The order fulfillment processor 1300 may instruct AMR A10258 to proceed, with the shipping container, to a robotic product induction station in the ambient temperature first zone 8205-1 within the product rack storage region 8204P. At the robotic product induction station, a robotic product induction robot will depalletize item 14 from a stored pallet and place item 14 onto AMR A10258.

[0566] The order fulfillment processor 1300 may instruct AMR A10258 to proceed, with the shipping container, to a robotic product induction station in the ambient temperature first zone 8205-1 within the product rack storage region 8204P. At the robotic product induction station, a robotic product induction robot will depalletize item 18 from a stored pallet and place item 18 onto AMR A10258. [0567] The order fulfillment processor 1300 may instruct AMR A10258 to proceed, with the shipping container, to a robotic product induction station in the ambient temperature first zone 8205-1 within the product rack storage region 8204P. At the robotic product induction station, a robotic product induction robot will depalletize item 17 from a stored pallet and place item 17 onto AMR A10258.

[0568] The order fulfillment processor 1300 may instruct AMR A10258 to proceed, with the shipping container, to a robotic product induction station in the ambient temperature first zone 8205-1 within the product rack storage region 8204P. At the robotic product induction station, a robotic product induction robot will depalletize item 13 from a stored pallet and place item 13 onto AMR A10258.

[0569] Responsive to the last item (item 13, in this case) having been loaded into the shipping container, the order fulfillment processor 1300 may instruct AMR A10258 to visit an order verification, case sealing and labelling station, such as the case sealing station 7620 of FIG. 73, to verify the contents of the shipping container, seal the shipping container and label the shipping container.

[0570] At each customer order verification station, the AMR may allow for the contents of a shipping container to be subjected to an inspection. An inspection may include weighing the shipping container to verify the contents of the shipping container. According to the inspection, the shipping container may be accepted or rejected.

[0571] A shipping container that is rejected at the customer order verification station may be directed, by the order fulfillment processor 1300, to a manual rework station. At the manual rework station, an associate may attempt to rectify whatever issue caused the shipping container to be rejected. Subsequent to rectifying the issue, the associate may cause the order fulfillment processor 1300 to instruct the AMR carrying the shipping container to proceed to a designated dunnage loading station, a designated top sealing and a designated labeling station.

[0572] A shipping container that is accepted at the customer order verification station may be directed, by the order fulfillment processor 1300, to a designated dunnage loading station, a designated top sealing and a designated labeling station. [0573] At the dunnage loading station, each individual AMR may move a respective shipping container through a dunnage placer. At the dunnage placer, it should be clear that dunnage may only be added if deemed helpful. The AMR may then continue to the top sealing station, at which the shipping container may be sealed. The sealed shipping container may be further inspected. An AMR, carrying a rejected sealed shipping container, may be directed, by the order fulfillment processor 1300, to a manual rework station. At the rework station, an associate may attempt to rectify whatever issue caused the sealed shipping container to be rejected. Subsequent to rectifying the issue, the associate may cause the order fulfillment processor 1300 to instruct the AMR carrying the shipping container to proceed to the designated labeling station. The AMR carrying the sealed shipping container that passes further inspection may be directed, by the order fulfillment processor 1300, to the designated labeling station.

[0574] Each individual AMR may move the respective sealed shipping container through the designated labeling station. At the designated labeling station, a shipping label may be printed and applied to the sealed shipping container, thereby forming a labeled shipping container. Other labels, designating the package as Fragile or Heavy, may also be applied to the labeled shipping container, if deemed necessary. The labeled shipping container may, again, be inspected and may pass inspection or be rejected. An AMR, carrying a labeled shipping container that has been rejected for an issue, may be directed, by the order fulfillment processor 1300, to a manual rework station. At the rework station, an associate may attempt to rectify whatever issue caused the labeled shipping container to be rejected. Subsequent to rectifying the issue, the associate may cause the order fulfillment processor 1300 to instruct the AMR carrying the labeled shipping container to proceed to a designated shipping container delivery route accumulation station. The AMR carrying the labeled shipping container that passes inspection may be directed, by the order fulfillment processor 1300, to the designated shipping container delivery route accumulation station.

[0575] In total, it may be recognized that there are six AMRs (Al 168, A4530, A9436, A13462, A5546 and A10258) involved in fulfilling the customer order represented by the customer order processing matrix 8600 of FIG. 86. It is proposed herein that instructions to the six AMRs involve staggered AMR dispatch times. The staggered AMR dispatch times may, for example, take into account the estimated time for each AMR to fulfill part of the customer order. [0576] As noted above, for example, the order fulfillment processor 1300 may have determined that a picking and packing process, for the items 1, 7, 8, 9, 10, 11 and 16 portion of the customer order, will consume between 70 and 80 minutes of AMR travel and wait time. As also noted above, for example, the order fulfillment processor 1300 may have determined that a picking and packing process, for the frozen items 6, 12, 19 and 20 portion of the customer order, will consume between 30 and 40 minutes of travel and wait time for AMR A5546. Accordingly, the order fulfillment processor 1300 may stagger the dispatch time for AMR A5546 to occur 40 minutes after the dispatch time for AMR Al 168 so that AMR A5546 and AMR Al 168 complete their respective travels around the order fulfillment location 8200 at roughly the same time.

[0577] Indeed, the order fulfillment processor 1300 may stagger the respective dispatch times for all six AMR so that all six AMRs complete their respective travels around the order fulfillment location 8200 at roughly the same time. It follows that all six portions of the customer order arrive at the delivery route accumulation station at approximately the same time.

[0578] To facilitate an effective in-delivery-vehicle sorting process, the order fulfillment processor 1300 may maintain a First-In-Last-Out (FILO) staging strategy for a designated last mile delivery vehicle. As such, the order fulfillment processor 1300 may generate instructions such that all six AMRs accumulate at the delivery route accumulation station at roughly the same time. Upon determining that all six AMRs, making up the customer order, have been accumulated, the order fulfillment processor 1300 may release the AMRs to travel to the discharge conveyor 7226 (see FIGS. 71, 72, 74).

[0579] At an unload position, the six AMRs carrying portions of the customer order may transfer their respective shipping container, or item without shipping container, onto the discharge conveyor 7226. The AMRs may be directed to the unload position in a particular sequence. The customer order may be understood to be conveyed, on the discharge conveyor 7226, to a delivery vehicle loading position. The customer order may be loaded into and stored on the delivery vehicle as a group. All customer orders on a preprogrammed delivery route to be followed by the delivery vehicle may be arranged, by the order fulfillment processor 1300, to arrive at the delivery vehicle loading position on a FILO basis that takes into account the preprogrammed delivery route. All shipping containers that have been designated to the preprogrammed delivery route may be loaded, by the delivery vehicle driver, into the delivery vehicle in a sequence. Preferably, the sequence is a prescribed FILO sequence configured to optimize the delivery process. That is, the unload position in the route distribution accumulation region corresponds to a delivery route representative of an ordered sequence of destinations. The generating, by the order fulfillment processor 1300, of instructions to the six AMRs may be understood to include determining a position, in the ordered sequence of destinations, for the destination for the customer order and arranging a timing of an arrival, of the six AMRs, at the unload position in the route distribution accumulation region, such that the timing of the arrival corresponds to the position in the ordered sequence of destinations.

[0580] Using the preprogrammed delivery route, the delivery vehicle driver proceeds to carry out deliveries. As the driver completes each delivery, the driver may mark the delivery as completed, thereby providing feedback to a delivery monitoring system. Beneficially, users may receive real time data on delivery status.

[0581] As a matter of course, the delivery driver may be expected to arrive at the address of the customer associated with the customer order processing matrix 8600. The driver may unload the shipping containers, and the items that are not in a shipping container, that make up the customer order and place the customer order at the door of the customer. The customer may then be notified of the delivery, thereby completing the order process.

[0582] FIG. 87 schematically illustrates an order fulfilment center 8700 at the center of a network of suppliers of products to be stored at the order fulfilment center 8700. The order fulfilment center 8700 is illustrated as being split into three distinct product storage and customer order induction zones 8702 including: a first zone 8702-1; a second zone 8702-2; and a third zone 8702-3. Each zone may be associated with zone-specific schemes for receiving products, storing products and inducting products into order shipping containers.

[0583] In view of the previously discussed order fulfilment center 8200B of FIG. 82B, the first zone 8702-1 may be understood to map to the product rack storage region 8204P. It follows that the first zone 8702-1 may be understood to be used in the context of relatively fast-moving consumer SKUs with a relatively small (say, 5,000) number of SKUs. The SKUs may be robotically inducted, by AMRs, and stored in the first zone 8702-2 in product storage racks similar to the product storage racks 7100 discussed hereinbefore (see FIGS. 70, 76, 76A, 82A, 82B).

[0584] In view of the previously discussed order fulfilment center 8200B of FIG. 82B, the second zone 8702-2 may be understood to map to the stack storage region 8204R. It follows that the second zone 8702-2 may be understood to be used in the context of relatively mediummoving consumer SKUs with a relatively middling (say, 25,000) number of SKUs. The SKUs may be robotically inducted, by AMRs (like the AMR 8402 of FIG. 84), and stored in the second zone 8702-2 in crate retention structures (like the further crate retention structure 8400 of FIG. 84).

[0585] In view of the previously discussed order fulfilment center 8200B of FIG. 82B, the third zone 8702-3 may be understood to map to the tower storage region 8204T. It follows that the third zone 8702-3 may be understood to be used in the context of relatively slow-moving consumer SKUs with a relatively large (say, 1,000,000) number of SKUs. The SKUs may be manually inducted, by personnel, and stored in the third zone 8702-3 in towers (like the tower 7510 of FIG. 75).

[0586] With partnerships established with the suppliers illustrated in FIG. 87, an order fulfillment processor (e.g., the order fulfillment processor 1300 of FIG. 64) may determine an inventory process to be followed for each of the SKUs arriving at the order fulfilment center 8700. Inbound SKUs may be allocated to a designated receiving dock associated with an appropriate product storage and customer order induction zone 8702. The receiving dock may be part of the product storage induction region 8203 (see FIG. 82). SKUs designated to the first zone 8702-1 and the second zone 8702-2 may be received on further crate retention structures 8400. SKUs designated to the third zone 8702-3 may be received in traditional packaging.

[0587] A first stage of processing products may be related to inbound product receiving and trailer unloading.

[0588] SKUs that are inbound and destined for the first zone 8702-1 of the order fulfilment center 8700 may be expected to arrive, in inbound transport trailers, on crate retention structures (e.g., the further crate retention structure 8400 of FIG. 84) with a single SKU per crate retention structure. The inbound transport trailers may be configured to transport crate retention structures (like, e.g., the transport trailer 8500 of FIG. 85). The inbound transport trailer may, for example, be configured to transport 28 crate retention structures. The inbound transport trailer may, for example, be configured with an AMR track defined by barcodes on the floor of the inbound transport trailer. Each crate retention structure may be removed from the inbound transport trailers by an AMR (e.g., AMR 8402 in FIG. 84).

[0589] A second stage of processing products may be related to removing empty crates (e.g., crates 7910) from the order fulfilment center 8700.

[0590] In one aspect of the present application, empty crates in the first zone 8702-1 may be installed into designated crate retention structures (e.g., the further crate retention structure 8400 of FIG. 84). Upon determining that a particular designated crate retention structure qualifies as an empty designated crate retention structure, that is, the particular designated crate retention structure is full of empty crates, an order fulfillment processor may instruct an AMR (e.g., AMR 8402 in FIG. 84) to transport the particular designated crate retention structure into a transport trailer specifically designated to receive empty crate retention structures. The AMR may release the particular designated crate in a designated location in the transport trailer. The AMR may then depart the transport trailer and await further instructions.

[0591] A third stage of processing products may be related to storing inbound crate retention structures.

[0592] The AMR carrying an inbound crate retention structure associated with a single SKU may be directed from the transport trailer to a designated position in a designated product storage rack (see the product storage racks 7100 discussed in relation to FIGS. 70, 76, 76A, 82A, 82B) in the first zone 8702-1. It is contemplated herein that movement of crate retention structures will be carried out by AMRs. Accordingly, it may be noted that use of roller conveyors, which are conventionally used for movement of conventional pallets of products, may be obviated.

[0593] The first zone 8702-1, in a routine implementation, may be capable of storing approximately products representative of 5,000 SKUs on conventional pallets in combination with, say, 130,000 crate retention structures. [0594] Responsive to determining that a crate on a particular crate retention structure at a particular order induction station in the first zone 8702-1 has been emptied, a given AMR may be instructed to visit the particular order induction station. At the particular order induction station, an order induction robot (see the robotic picker arm 7106 of FIG. 70) may place the empty crate onto the given AMR.

[0595] Upon determining that the last crate has been removed from the particular crate retention structure, a further AMR may be instructed to visit the particular order induction station. The further AMR may engage the particular crate retention structure, for example, by slipping under the particular crate retention structure and lifting the particular crate retention structure and transport the particular crate retention structure to a re-palletizing station. At the repalletizing station, the particular crate retention structure may await the arrival of empty crates. A robotic arm may be responsible for populating the particular crate retention structure with empty crates.

[0596] Once all of the available crate locations in the particular crate retention structure have been filled with empty crates, an available AMR may be instructed to transport the particular crate retention structure to a designated location in a transport trailer that has been specifically designated to receive empty crate retention structures. Upon determining that a transport trailer has a complete load of empty crate retention structures, a transport truck associated with the transport trailer may transport the load of crate retention structures full of empty crates to a location of one of the suppliers of products to the order fulfilment center 8700. This last act of returning a load of crate retention structures full of empty crates may be considered to close a loop of activity between the supplier of products and the order fulfilment center 8700.

[0597] There may be in the order of 200 carton forming systems in a shipping container induction region (see, for example, the shipping container induction region 8206 of FIG. 82 A). Each carton forming system may be configured to produce a unique size and style of shipping container formed or erected from blank corrugated recyclable materials. Alternatively, in some embodiments, one or more of the carton forming system may be configured to produce more than one size and/or more than one style of shipping container formed or erected from blank corrugated recyclable materials. The variety of sizes and styles of shipping container may be shown to allow products to be packed in order-specific shipping containers. For example, refrigerated and frozen products may be packed into insulated shipping containers. As discussed briefly hereinbefore, the size and number of shipping containers employed for a given customer order may be determined on the basis of the sizes, types and quantities of items in the given customer order.

[0598] Upon initiation of a specific customer order, the order fulfillment processor (e.g., the order fulfillment processor 1300 of FIG. 64) may direct an available AMR to the appropriate carton forming system. The carton forming system may form a shipping container and place the formed shipping container on the AMR. The order fulfillment processor may then route the AMR to the first of a series of product induction stations. There may be in the order of 5,000 product induction stations in the first zone 8702-1, in the order of 500 product induction stations in the second zone 8702-2 and in the order of 500 product induction stations in the third zone 8702-3.

[0599] As discussed hereinbefore, the AMR may be designed to hold and carry any shipping container among a wide variety of styles and sizes of shipping containers. The AMR may accept shipping containers from any one of the over 200 carton forming systems. As part of fulfilling an order, a given AMR may move a shipping container to one or more designated product induction stations, order verification stations, container sealing stations, labeling stations, rework stations, delivery route accumulation stations and discharge conveyors.

[0600] AMRs that have been routed to one of the roughly 5,000 product induction stations in the first zone 8702-1 may be, more particularly, directed to a robotic product loading position. At the robotic product loading position, a robot may pick a product from a crate carried by a crate retention structure and place the product into the shipping container carried by the AMR. The robot may be expected to pick multiple products to fulfill a customer order. The AMR may then be directed to a next product induction station on an order induction route. AMRs that have been routed to the refrigerated and frozen food sections of the first zone 8702-1 may be expected to carry insulated shipping containers.

[0601] The first zone 8702-1 may be expected to be capable of handling products that do not require a shipping container, for example, bundled cases of beverages. These types of products may be picked directly from a crate retention structure and placed onto an available AMR. The AMR may be expected to then carry the product directly to a verification station. [0602] SKUs that are inbound, into the second zone 8702-2, on crate retention structures with one or more SKUs per crate retention structure, may arrive in transport trailers that are equipped to carry crate retention structures. As illustrated in FIG. 85, the transport trailer may be configured to hold 28 crate retention structures and feature AMR track embedded in the floor of the transport trailer. Each SKU on a crate retention structure destined for the second zone 8702-2 may be carried in a single crate. As discussed hereinbefore, each crate retention structure may be removed from the transport trailer by an AMR.

[0603] As discussed hereinbefore in relation to the first zone 8702-1, to close the loop with a consumer product provider of SKUs for the second zone 8702-2, an outbound transport trailer may be reloaded with crate retention structures full of empty crates.

[0604] An AMR assigned to a multiple SKU crate retention structure may be directed to travel from the transport trailer to a designated storage position in the second zone 8702-2.

[0605] A single-level implementation of the second zone 8702-2 (see FIG. 82B) may be expected to be employed in a manner very similar to the manner in which the third zone 8702-3 is employed.

[0606] It may be noted that use of AMRs for unloading crate retention structures from a transport trailer and moving the crate retention structures to respective designated storage positions in the second zone 8702-2 may obviate use of roller conveyors, which are conventionally used for movement of conventional pallets of products.

[0607] The second zone 8702-2, in a routine implementation, may be capable of storing products representative of approximately 25,000 SKUs in crates stored within approximately 5,000 crate retention structures.

[0608] Responsive to determining that the last crate on the crate retention structure at a product induction station in the second zone 8702-2 has been emptied, an AMR may be directed to transport the crate retention structure full of empty crates to a re-palletizing station.

[0609] At the re-palletizing station, once it has been determined that all of the available crate locations in the particular crate retention structure are filled with empty crates, the crate retention structure full of empty crates may be wrapped at a pallet strapping stations. An available AMR may be instructed to transport the particular (wrapped) crate retention structure to a designated location in a transport trailer that has been specifically designated to receive empty crate retention structures. Upon determining that a transport trailer has a complete load of empty crate retention structures, a transport truck associated with the transport trailer may transport the load of crate retention structures full of empty crates to a location of one of the suppliers of products to the order fulfilment center 8700. This last act of returning a load of crate retention structures full of empty crates may be considered to close a loop of activity between the supplier of products and the order fulfilment center 8700.

[0610] There may be in the order of 200 carton forming systems in a shipping container induction region (see, for example, the shipping container induction region 8206 of FIG. 82 A). Each carton forming system may be configured to produce a unique size and style of shipping container formed or erected from blank corrugated recyclable materials. Alternatively, in some embodiments, one or more of the carton forming systems may be configured to produce more than one size and/or more than one style of shipping container formed or erected from blank corrugated recyclable materials. The variety of sizes and styles of shipping container may be shown to allow product to be packed in order-specific shipping containers. As discussed briefly hereinbefore, the size and number of shipping containers employed for a given customer order may be determined on the basis of the sizes, types and quantities of items in the given customer order.

[0611] Upon initiation of a specific customer order, the order fulfillment processor (e.g., the order fulfillment processor 1300 of FIG. 64) may direct an available AMR to the appropriate carton forming system. The carton forming system may form a shipping container and place the formed shipping container on the AMR. The order fulfillment processor may then route the AMR to the first of a series of product induction stations.

[0612] As discussed hereinbefore, the AMR may be designed to hold and carry any shipping container among a wide variety of styles and sizes of shipping containers. The AMR may accept shipping containers from any one of the over 200 carton forming systems. As part of fulfilling an order, a given AMR may move a shipping container to one or more designated product induction stations, order verification stations, container sealing stations, labeling stations, rework stations, delivery route accumulation stations and discharge conveyors.

[0613] As described hereinbefore, products are stored in the second zone 8702-2 in crates in crate retention structures. Each of the crate retention structures may be considered to be fully accessible by AMRs. When a customer order includes a product stored in the second zone 8702- 2, the order fulfillment processor (e.g., the order fulfillment processor 1300 of FIG. 64) may direct one AMR to retrieve the appropriate crate retention structure from a location within the second zone 8702-2 and move the appropriate crate retention structure to a particular product induction station in a product induction region (see, for example, the product induction region 8228 in FIG. 82B) to meet another AMR carrying an appropriate shipping container.

[0614] AMRs that have been routed to one of the roughly 500 product induction stations in the second zone 8702-2 may be, more particularly, directed to a robotic product loading position. At the robotic product loading position, a robot may pick a product from a crate carried by a crate retention structure and place the product into the shipping container carried by the AMR.

[0615] At the robotic product loading position the crate retention structure may be processed to make a particular product available, from an appropriate crate, for picking by an order induction robot. At the robotic product loading position, a robot may pick a product from a crate carried by a crate retention structure and place the product into the shipping container carried by the AMR. The robot may be expected to pick multiple products to fulfill a customer order. The AMR may then be directed to a next product induction station on an order induction route.

[0616] SKUs that are inbound, into the third zone 8702-3, may, typically, arrive packed in corrugated boxboard cases. The corrugated boxboard cases may be unloaded manually from the transport trailer. The received cases may be inspected and scanned. The received cases may also be unpacked to allow individual products, unpacked from the cases, to be scanned and placed into totes. The totes may then be conveyed to a storage induction station.

[0617] In the context of the third zone 8702-3, when transport trailers are returned to the consumer products supplier, it is expected that the transport trailer will be returned in an empty state. [0618] Upon arriving at a storage induction station, a given tote may be directed to one storage induction station among, say, hundreds of storage induction stations. An associate may be expected to manually pick the product from the tote, scan the product and place the product into an available space in a tower (like the tower 7510 of FIG. 75) carried by an AMR. Responsive to the remaining products contained in the tote having been picked and placed in other spaces in the tower (or in other towers) the AMR may move the tower out of the storage induction stations and into a tower storage region (like the tower storage region 8204T of FIG. 82B). Empty totes may be stacked and returned to the product receiving area to be recycled.

[0619] The third zone 8702-3, in a routine implementation, may be capable of storing products representative of approximately 1,000,000 SKUs in over 10,000 towers.

[0620] As discussed, it is expected that products in the third zone 8702-3 are received packed in corrugated inbound shipping containers. After the inbound shipping containers have been unpacked, the inbound shipping containers may be subjected to a process that involves collecting and compacting the inbound shipping containers. The collected and compacted shipping containers may then be shipped out of the order fulfilment center 8700 to be recycled. This is process may be considered to be consistent with known order fulfilment center processes.

[0621] There may be in the order of 200 carton forming systems in a shipping container induction region (see, for example, the shipping container induction region 8206 of FIG. 82 A). Each carton forming system may be configured to produce a unique size and style of shipping container formed or erected from blank corrugated recyclable materials. Alternatively, in some embodiments, one or more of the carton forming systems may be configured to produce more than one size and/or more than one style of shipping container formed or erected from blank corrugated recyclable materials. The variety of sizes and styles of shipping container may be shown to allow product to be packed in order-specific shipping containers. As discussed briefly hereinbefore, the size and number of shipping containers employed for a given customer order may be determined on the basis of the sizes, types and quantities of items in the given customer order.

[0622] Upon initiation of a specific customer order, the order fulfillment processor (e.g., the order fulfillment processor 1300 of FIG. 64) may direct an available AMR to the appropriate carton forming system. The carton forming system may form a shipping container and place the formed shipping container on the AMR. The order fulfillment processor may then route the AMR to the first of a series of product induction stations.

[0623] As discussed hereinbefore, the AMR may be designed to hold and carry any shipping container among a wide variety of styles and sizes of shipping containers. The AMR may accept shipping containers from any one of the over 200 carton forming systems. As part of fulfilling an order, a given AMR may move a shipping container to one or more designated product induction stations, order verification stations, container sealing stations, labeling stations, rework stations, delivery route accumulation stations and discharge conveyors.

[0624] Products in the third zone 8702-3 may be understood to be stored in towers in a tower storage region, with each of the towers being fully accessible by AMRs. When a given customer order specifies a product that may be found in the third zone 8702-3, the order fulfillment processor (e.g., the order fulfillment processor 1300 of FIG. 64) may direct an available AMR to the appropriate carton forming system. The carton forming system may form a shipping container and place the formed shipping container on the AMR. The order fulfillment processor may then route the AMR to the first of a series of product induction stations.

[0625] When a customer order includes a product stored in the third zone 8702-3, the order fulfillment processor (e.g., the order fulfillment processor 1300 of FIG. 64) may direct one AMR to retrieve the appropriate tower from a location within the third zone 8702-3 and move the appropriate tower to a particular product induction station in a product induction region (see, for example, the product induction region 8208 in FIG. 82A) to meet another AMR carrying an appropriate shipping container.

[0626] AMRs that have been routed to one of the roughly 500 product induction stations in the third zone 8702-3 may be, more particularly, directed to a manual product loading position. At the manual product loading position, an associate may pick a product from a location in a tower and place the product into the shipping container carried by an AMR. The associate may be expected to pick multiple products to fulfill a customer order. The AMR may then be directed to a next product induction station on an order induction route. [0627] While various stages of order fulfilment are described hereinbefore as being distinct for the three distinct zones 8702-1, 8702-3 and 8702-3, the remaining stages are common for all three distinct zones 8702-1, 8702-3 and 8702-3.

[0628] Shipping containers or unpackaged products, on respective AMRs, that have completed respective product induction routes are directed to a shipping container verification station among, say, 100 shipping container verification stations. Using tests that involve, for example, vision and check weighing technology, the shipping container verification station may be expected to perform a variety of checks on the shipping container while the shipping container is on the AMR. Shipping containers that fail the tests may be directed, on the AMR, to a manual rework station, at which an associate may act to correct an issue with the order and reroute AMR carrying the shipping container back through the verification station. Shipping containers that pass all of the tests may be directed to a dunnage inserting station (if necessary) or to a shipping container top closing system.

[0629] Due to a mismatch between dimensions of a given product and dimensions of a shipping container, the shipping container may benefit from the addition of dunnage. Dunnage may be seen to protect the given product during so-called last mile deliveries. Unpackaged products, for example, bundles of water bottles may be understood to not require dunnage. Verified shipping containers identified as potentially benefitting from dunnage may be directed to a shipping container dunnage insertion station among, say, 20 shipping container dunnage insertion stations. The shipping container dunnage insertion stations may insert an amount of dunnage directly into the shipping container while the shipping container is carried upon the AMR. The dunnage in the shipping container may be verified in a manner that allows any shipping container with dunnage that cannot be verified to be directed, on the AMR, to a manual rework station. At the manual rework station, an associate may correct the issue and reroute the shipping container to a shipping container top closing and sealing station among, say, 200 shipping container top closing and sealing stations.

[0630] At the top closing and sealing station, it may be expected that the open top of the shipping container is subjected to a process involving closing and sealing, while the shipping container is on the AMR. The shipping container is, generally, not disengaged from the AMR through the entire closing and sealing process. A closure on the shipping container may be inspected with a vision system. Successfully verified shipping containers may then be directed to a shipping container labeling station. A shipping container associated with a failed inspection may be directed, on the AMR, to a manual rework station, at which an associate may attempt to correct the issue that caused the failure and direct an AMR with verified shipping container to a labeling station.

[0631] It may be expected that a majority, for example, 95%, of customer orders will involve more than one shipping container and, accordingly, more than one shipping label and/or radio frequency identification (RFID) tag. It may further be expected that use of a so-called “print and apply” type of label will provide a given shipping container with all information involved in routing, accumulating, expediting, tracking and tracing the given shipping container throughout the last mile delivery process. The labels may be verified for accuracy. An AMR carrying a shipping container with a label that has failed verification may be directed to a manual rework station. At the manual rework station, an associate may take steps to correct the failed verification.

[0632] To ensure that the delivery vehicles are loaded in a “First-in-Last-ouf ’ (“FILO”), the order fulfillment processor may cause shipping containers on AMRs, associated with a single customer order, to accumulate in an accumulation area. Ideally, all of the shipping containers associated with the single customer order may be grouped prior to the entire grouped customer order being sent, in an ordered sequence, to a discharge conveyor.

[0633] At the discharge conveyor, 100-300 shipping containers may accumulate with a designated route in common. The AMRs may be directed to the discharge conveyors in a FILO sequence. As a delivery vehicle is being loaded, shipping containers may accumulate in a FILO sequence that matches delivery vehicle route sequence.

[0634] Discharge conveyors may be expected to move shipping containers to a vehicle loading position in the FILO Sequence. The last mile delivery associate (see robots and/or personnel 7998 in FIG. 82B) may be expected to load the shipping containers into the delivery vehicle in the FILO sequence that is closely related to a pre-planned route sequence. This may be seen to reduce sorting of the shipping containers during the product deliveries. The shipping containers may be scanned as the shipping containers are loaded onto the delivery vehicle to establish accurate and sequential delivery. Upon completion of the loading, the delivery vehicle driver may commence delivering the products that have been loaded onto the delivery vehicle.

[0635] The driver of the delivery vehicle may guide the delivery vehicle to follow directions to various customer drop-off locations along a delivery route. The driver of the delivery vehicle may unload the shipping containers at each customer drop-off location. Conveniently, due to well-planned loading of shipping containers onto the delivery vehicle, sorting of the shipping containers during unloading is obviated.

[0636] Of course, the above described embodiments are intended to be illustrative only and in no way limiting. The described embodiments of carrying out the aspects of the present application are susceptible to many modifications of form, arrangement of parts, details and order of operation. The present application, rather, is intended to encompass all such modifications within its scope, as defined by the claims.

[0637] When introducing elements of aspects of the present application or the embodiments thereof, the articles “a,” “an,” “the” and “said” are intended to mean that there are one or more of the elements. The terms “comprising,” “including” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements.