US 12,600,568 B1 · Integrated autonomous warehouse robot

Abstract

An autonomous warehouse robotics system integrates a multi-sensor platform, adaptive payload handling, dynamic task reallocation, advanced navigation, energy management, and comprehensive safety features into one mobile robot chassis. The system utilizes LiDAR, stereo vision, ultrasonic sensors, mmWave radar, thermal cameras, and event cameras to perform complete environmental sensing and obstacle detection. Sensor fusion combines adaptive weighting, multi-modal data integration, and statistical filtering to create high-confidence maps for reactive path planning and collision avoidance. The robot's payload system features machine vision for item recognition, telescopic lifts, variable-width grippers, and real-time toolhead verification to handle a variety of goods. Fleet management is achieved through dynamic task reallocation that considers robot location, battery level, and operational delays, all coordinated by a cross-platform middleware architecture that ensures standardized communication, remote monitoring, and over-the-air updates among diverse robot brands. Energy management optimizes power usage via predictive routing, autonomous return-to-charge, and auction-based scheduling. Safety is maintained through proximity detection, behavior-based intervention, and human-robot cohabitation protocols while advanced localization is enhanced by fusing ultra-wideband positioning with visual landmark alignment, inertial sensing, and machine learning to deliver high accuracy in non-line-of-sight conditions. An onboard edge AI module further refines navigation and task prioritization through neural network inference, ensuring robust, adaptive operation in dynamic, unstructured warehouse environments.

Claims21

Dependent claims

A mobile robot for warehouse automation, comprising:

a drive system configured for autonomous movement along warehouse floors;
a vertical mobility mechanism configured to enable the robot to travel vertically along shelving structures or rails within a warehouse;
a sensor suite comprising at least at least one camera, and at least one inertial measurement unit (IMU), the sensor suite configured to detect environmental features and obstacles for navigation;
an ultra-wideband (UWB) positioning module configured to determine the position of the robot within the warehouse by communicating with a plurality of fixed UWB anchors;
a digital map storage module containing a digital representation of the warehouse layout including shelving locations and vertical travel paths;
a navigation controller operatively coupled to the sensor suite, the UWB positioning module, and the digital map storage module, the navigation controller configured to:
fuse data from the sensor suite and the UWB positioning module to determine a real-time position and orientation of the robot within the warehouse;
reference the digital map to plan and execute three-dimensional navigation routes, including both horizontal and vertical movements, to target locations in the warehouse;
autonomously control the drive system and the vertical mobility mechanism to transport the robot to selected positions on the floor or at different elevations along shelving structure;
and
an energy management system, comprising:
a battery module;
a plurality of onboard sensors configured to monitor energy consumption by subsystems including drive motors, sensors, and payload handlers;
an energy optimization controller configured to dynamically adjust robot operating parameters in real time based on current battery level, predicted task energy requirements, and charging station availability.

11 more elements

A mobile robot for warehouse automation, comprising:

a drive system configured for autonomous movement along warehouse floors;
a vertical mobility mechanism configured to enable the robot to travel vertically along shelving structures or rails within a warehouse;
a sensor suite comprising at least at least one camera, and at least one inertial measurement unit (IMU), the sensor suite configured to detect environmental features and obstacles for navigation;
a digital map storage module containing a digital representation of the warehouse layout including shelving locations and vertical travel paths;
a navigation controller operatively coupled to the sensor suite and the digital map storage module, the navigation controller configured to determine a real-time position and orientation of the robot within the warehouse, reference the digital map to plan and execute three-dimensional navigation routes, including both horizontal and vertical movements, to target locations in the warehouse;
autonomously control the drive system and the vertical mobility mechanism to transport the robot to selected positions on the floor or at different elevations along shelving structure;
a warehouse mapping and navigation system including:
a plurality of mobile robots, each robot comprising a camera configured to capture visual data of the warehouse environment and an ultra-wideband (UWB) positioning module configured to determine a position of the robot within the warehouse by communicating with a plurality of fixed UWB anchors;
a central processing node operatively coupled to the plurality of mobile robots, the central processing node configured to:
receive, in real time, UWB position data and visual data from each of the plurality of mobile robots as the robots traverse the warehouse;
compare overlapping UWB position data and visual data from multiple robots to identify and filter out inconsistent or erroneous data using a statistical consensus algorithm;
update a digital map of the warehouse based on high-confidence data, wherein the digital map reflects recent changes in warehouse configuration or obstacles detected by the robots;
and
transmit the updated digital map to the plurality of mobile robots to enable autonomous navigation that accounts for recent changes in the warehouse environment.

11 more elements

A system for warehouse automation, comprising:

a drive system configured for autonomous movement along warehouse floors;
a vertical mobility mechanism configured to enable a robot to travel vertically along shelving structures or rails within a warehouse;
a sensor suite comprising at least at least one camera, and at least one inertial measurement unit (IMU), the sensor suite configured to detect environmental features and obstacles for navigation;
a digital map storage module containing a digital representation of the warehouse layout including shelving locations and vertical travel paths;
a navigation controller operatively coupled to the sensor suite and the digital map storage module, the navigation controller configured to determine a real-time position and orientation of the robot within the warehouse, reference the digital map to plan and execute three-dimensional navigation routes, including both horizontal and vertical movements, to target locations in the warehouse;
autonomously control the drive system and the vertical mobility mechanism to transport the robot to selected positions on the floor or at different elevations along shelving structure;
a warehouse mapping and navigation system including:
a plurality of mobile robots, each robot comprising a camera configured to capture visual data of the warehouse environment and an ultra-wideband (UWB) positioning module configured to determine a position of the robot within the warehouse by communicating with a plurality of fixed UWB anchors;
a central processing node operatively coupled to the plurality of mobile robots, the central processing node configured to:
receive, in real time, UWB position data and visual data from each of the plurality of mobile robots as the robots traverse the warehouse;
compare overlapping UWB position data and visual data from multiple robots to identify and filter out inconsistent or erroneous data using a statistical consensus algorithm;
update a digital map of the warehouse based on high-confidence data, wherein the digital map reflects recent changes in warehouse configuration or obstacles detected by the robots;
and
transmit the updated digital map to the plurality of mobile robots to enable autonomous navigation that accounts for recent changes in the warehouse environment.

11 more elements

A method for warehouse automation with a drive system configured for autonomous movement along warehouse floors;

a vertical mobility mechanism configured to enable a robot to travel vertically along shelving structures or rails within a warehouse;
a sensor suite comprising at least at least one camera, and at least one inertial measurement unit (IMU), the sensor suite configured to detect environmental features and obstacles for navigation;
a digital map storage module containing a digital representation of the warehouse layout including shelving locations and vertical travel paths;
and a navigation controller operatively coupled to the sensor suite and the digital map storage module, the method comprising:
determining a real-time position and orientation of the robot within the warehouse, reference the digital map to plan and execute three-dimensional navigation routes, including both horizontal and vertical movements, to target locations in the warehouse;
autonomously controlling the drive system and the vertical mobility mechanism to transport the robot to selected positions on the floor or at different elevations along shelving structure;
performing warehouse mapping and navigation with a system including:
a plurality of mobile robots, each robot comprising a camera configured to capture visual data of the warehouse environment and an ultra-wideband (UWB) positioning module configured to determine a position of the robot within the warehouse by communicating with a plurality of fixed UWB anchors, further including:
receiving, in real time, UWB position data and visual data from each of the plurality of mobile robots as the robots traverse the warehouse;
comparing overlapping UWB position data and visual data from multiple robots to identify and filter out inconsistent or erroneous data using a statistical consensus algorithm;
updating a digital map of the warehouse based on high-confidence data, wherein the digital map reflects recent changes in warehouse configuration or obstacles detected by the robots;
and
transmitting the updated digital map to the plurality of mobile robots to enable autonomous navigation that accounts for recent changes in the warehouse environment.

10 more elements

Dependencies are inferred from the claim text.

Integrated autonomous warehouse robot

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Integrated autonomous warehouse robot

Life of this patent

Abstract

Claims21