Product handling and packaging system

The method of claim:

• further comprising:
• accessing a representation of the first internal volume within the first container;
• selecting a second unoccupied subvolume, within the first internal volume, for a second product unit of a second product type based on the representation;
• and
• at the first dispensing unit:
• elevating the first conveyor through a second lane of the first tray to lift a second row of product units, stored in the second lane, above the first tray;
• and
• advancing the first conveyor to dispense the second product unit, in the second row of product units, toward the second unoccupied subvolume within the first container;
• and
• wherein accessing the first image depicting the first internal volume within the first container comprises accessing the first image depicting the first internal volume comprising unoccupied regions of the first container excluding the second unoccupied subvolume.

The method of claim, further comprising:

• accessing a first signal output by a first weight sensor, arranged at the first dispensing unit, while advancing the first conveyor to dispense the first product unit;
• detecting dispensation of the first product unit and a second product unit from the first tray based on a decrease in weight indicated in the first signal;
• and
• in response to detecting erroneous dispensation of the second product unit from the first tray:
• generating an alert prompting removal of the second product unit from the first container;
• and
• serving the alert to an operator.

The method of claim, further comprising:

• accessing a first signal output by a first weight sensor, arranged at the first dispensing unit, at a first time while advancing the first conveyor to dispense the first product unit;
• detecting failure to dispense the first product unit from the first tray based on absence of a first decrease in weight indicated in the first signal;
• in response to failure to dispense the first product unit from the first tray, maintaining advancement of the first conveyor to dispense the first product unit;
• accessing a second signal output by the first weight sensor at a second time, succeeding the first time, while advancing the first conveyor to dispense the first product unit;
• detecting dispensation of the first product unit from the first tray based on presence of the first decrease in weight indicated in the second signal;
• and
• in response to dispensation of the first product unit from the first tray, triggering the mobile robotic system to navigate to a second dispensing unit, in the set of dispensing units, assigned to dispense a second product unit of a second product type specified in the order.

The method of claim:

• wherein accessing the first image captured by the first optical sensor comprises accessing the first image further depicting features of an extant product unit occupying the first container;
• and
• wherein selecting the first unoccupied subvolume for the first product unit comprises selecting the first unoccupied subvolume, predicted to reduce risk of damage to the first product unit during dispensation into the first container, based on:
• features of the extant product unit occupying the first container;
• and
• a first set of characteristics of the first product type.

The method of claim:

• further comprising:
• generating a first virtual container representing a first virtual volume within the first container based on features represented in the first image;
• simulating a population of virtual product poses, within the first virtual container, for a first virtual product unit of the first product type;
• for each virtual product pose, calculating a packing density of a first virtual container loaded with a first virtual product unit in a virtual product pose;
• and
• converging on a first virtual product pose corresponding to a first virtual container exhibiting a maximum virtual packing density;
• and
• wherein selecting the first unoccupied subvolume for the first product unit comprises selecting the first unoccupied subvolume for the first product unit based on the first virtual product pose.

The method of claim:

• further comprising:
• generating a first virtual container representing a first virtual volume within the first container based on features represented in the first image;
• simulating a population of virtual product dispense configurations, each virtual product dispense configuration representing dispense of a first virtual product unit of the first product type according to a set of dispense parameters;
• and
• converging on a first virtual product dispense configuration:
• corresponding to a first set of dispense parameters;
• and
• characterized by a lowest risk of damage to the first virtual product unit during dispensation into the first virtual container;
• and
• wherein advancing the first conveyor to dispense the first product unit comprises advancing the first conveyor according to the first set of dispense parameters.

The method of claim:

• wherein assigning the first dispensing unit to dispense product units transiently stored in the first tray comprises assigning the first dispensing unit to dispense the first product unit from the first lane of the first tray, the first lane arranged at a first horizontal location within the first tray;
• further comprising triggering the mobile robotic system to align the first container to the first dispensing unit to receive the first product unit in the first unoccupied subvolume based on the first horizontal location of the first lane;
• and
• wherein advancing the first conveyor to dispense the first product unit comprises, in response to alignment between the first container and the first dispensing unit, advancing the first conveyor to dispense the first product unit according to the first set of dispense parameters.

The method of claim:

• further comprising, prior to elevating the first conveyor through the first lane of the first tray, horizontally maneuvering the first conveyor below the first tray to align the first conveyor to the first lane;
• wherein elevating the first conveyor through the first lane of the first tray comprises vertically maneuvering the first conveyor through a first opening, formed in a bottom of the first tray below the first lane, to lift the first row of product units above the first tray;
• and
• further comprising, prior to advancing the first conveyor, laterally extending the first conveyor forward to locate distal ends of the first conveyor over the first container.

The method of claim:

• wherein receiving the order comprises receiving the order further specifying a second product type;
• wherein identifying the first tray transiently storing product units of the first product type comprises identifying the first tray transiently storing:
• product units of the first product type in the first lane;
• and
• product units of the second product type in a second lane, adjacent the first lane, in the first tray;
• further comprising:
• following dispensation of the first product unit into the first container, horizontally maneuvering the first conveyor below the first tray to align the first conveyor to the second lane;
• vertically maneuvering the first conveyor through a second opening, formed in the bottom of the first tray below the second lane, to lift a second row of product units of the second product type above the first tray;
• and
• advancing the first conveyor to dispense a second product unit, in the second row of product units, into the first container.

The method of claim, further comprising:

• triggering the mobile robotic system to navigate to a second dispensing unit assigned to dispense product units from a second tray in the population of trays;
• accessing a second image:
• captured by a second optical sensor proximal the second dispensing unit;
• and
• depicting the first product unit occupying the first container and a second volume within the first container;
• selecting a second unoccupied subvolume, within the second volume, for a second product unit based on the second image;
• and
• at the second dispensing unit:
• elevating a second conveyor, within the second dispensing unit, through a second lane of the second tray to lift a second row of product units, stored in the second lane, above the second tray;
• and
• advancing the second conveyor to dispense the second product unit, in the second row of product units, toward the second unoccupied subvolume within the first container.

The method of claim:

• further comprising:
• accessing a third image:
• captured by the first optical sensor;
• and
• depicting the first product unit occupying the first container at a third pose and a third volume within the first container;
• and
• predicting a third unoccupied subvolume, within the third volume, for the second product unit based on the third image;
• wherein accessing the second image comprises accessing the second image depicting the first product unit occupying the first container at a second pose different from the third pose;
• and
• wherein selecting the second unoccupied subvolume for the second product unit comprises:
• in response to the first product unit occupying the first container at the second pose, different from the third pose, selecting the second unoccupied subvolume, different from the third unoccupied subvolume, based on the second image.

The method of claim, further comprising:

• prior to elevating the first conveyor through the first lane of the first tray:
• aligning the first conveyor to the first lane transiently storing product units of the first product type exhibiting a first width compatible with the first lane;
• and
• expanding the first conveyor to a first separation distance corresponding to the first width of the first product type;
• following dispensation of the first product unit into the first container, aligning the first conveyor to a second lane, adjacent the first lane, transiently storing product units of a second product type specified in the order;
• retracting the first conveyor to a second separation distance, less than the first separation distance, corresponding to a second width of the second product type;
• elevating the first conveyor through the second lane of the first tray to lift a second row of product units, stored in the second lane, above the first tray;
• and
• advancing the first conveyor to dispense a second product unit, in the second row of product units, into the first container.

The method of claim:

• wherein receiving the order comprises receiving the order further specifying a second product identifier of a second product unit of a second product type;
• and
• further comprising:
• identifying a second tray, in the population of trays, transiently storing the second product unit in a second lane of the second tray between adjacent product units;
• triggering the mobile robotic system to navigate to a second dispensing unit assigned to dispense the second product unit from the second tray;
• elevating a second conveyor in the second dispensing unit through a second lane of the second tray to contact the second product unit and lift the second product unit above the second tray;
• and
• advancing the second conveyor to dispense the second product unit into the first container.

A method comprising:

• receiving an order specifying a product type;
• assigning a dispensing unit, in a set of dispensing units, to dispense product units transiently stored in a tray in a population of trays;
• triggering a mobile robotic system, loaded with a container, to navigate to the dispensing unit;
• accessing a first image:
• captured by an optical sensor proximal the dispensing unit;
• and
• depicting a first internal volume within the container;
• and
• selecting an unoccupied subvolume, within the first internal volume, for a product unit of the product type based on the first image;
• and
• via a conveyor of the dispensing unit, dispensing the product unit into the container toward the unoccupied subvolume.

The method of claim, wherein dispensing the product unit into the container via the conveyor comprises:

• maneuvering the conveyor through an opening, formed in a bottom of the tray, to lift a row of product units above the tray;
• maneuvering the conveyor to locate distal ends of the conveyor over the container;
• and
• advancing the conveyor to dispense the product unit, in the row of product units, toward the unoccupied subvolume.

The method of claim, further comprising:

• accessing a signal output by a weight sensor, arranged in the mobile robotic system, while dispensing the product unit into the container;
• accessing a second image captured by the optical sensor and depicting the product unit occupying the container;
• detecting dispensation of the product unit into the container based on:
• presence of an increase in weight indicated in the signal;
• and
• presence of the product unit, within the container, depicted in the second image;
• in response to dispensation of the product unit into the container, triggering the mobile robotic system to navigate to an unloading zone for removal of the container from the mobile robotic system.

The method of claim:

• further comprising identifying the tray transiently storing product units of the product type, the product type exhibiting a set of product characteristics;
• wherein selecting the unoccupied subvolume for the product unit comprises selecting the unoccupied subvolume for the product unit based on the first image and the set of product characteristics of the product type;
• and
• wherein dispensing the product unit into the container via the conveyor comprises:
• selecting a set of dispense parameters for dispensing the product unit into the container based on the set of product characteristics;
• and
• advancing the conveyor according to the set of dispense parameters.

A system comprising:

• a dispensing unit configured to:
• transiently receive a tray storing product units;
• lift a product unit, stored in a lane of the tray, above the tray;
• maneuver the product unit toward a dispensing zone adjacent the dispensing unit;
• and
• dispense the product unit over the dispensing zone;
• and
• a mobile robotic system configured to:
• navigate to the dispensing zone proximal the dispensing unit;
• align a container, transiently loaded in the mobile robotic system, to the dispensing unit to receive the product unit within the container;
• and
• in response to detecting dispensation of the product unit into the container, triggering the mobile robotic system to navigate to an unloading zone for removal of the container from the mobile robotic system.