Automated order filling method and system

A method of automatically picking items to fill a purchase order, comprising the steps of

• providing an automated filling system having a plurality of receptacles for receiving ordered items, a high volume dispenser for rapidly dispensing frequently requested items from a high volume storage area, a low volume pick and place dispenser for dispensing items from a low volume storage area, and a controller for controlling whether the receptacles are conveyed to the high volume dispenser, the low volume dispenser or both,
• receiving a purchase order,
• extracting from the purchase order information about the identity and quantity of items ordered in the purchase order,
• creating from the extracted information a pick list, associating the pick list with a receptacle for receiving picked items,
• determining whether ordered items are located in the high volume storage area or the low volume storage area,
• if no item in the low volume storage area is ordered,
• i. directing the receptacle to the high volume storage area, and
• ii. automatically dispensing ordered items stored at the high volume storage area into the receptacle,
• if at least one item in the low volume storage area is ordered,
• i. first directing the receptacle to the low volume storage area,
• ii. automatically picking items on the pick list from the items stored in the low volume storage area and placing them in the receptacle, and
• if at least one item in the high volume area is also ordered,
• i. next directing the receptacle to the high volume area,
• ii. automatically dispensing ordered items stored at the high volume area into the receptacle, and
• iii. directing the receptacle to a location for further processing,
• if at least one item in the low volume storage area is ordered and no item in the high volume area is also ordered, directing the receptacle to a location for further processing after items from the low volume area have been picked and placed in the receptacle;
• providing a pickup head at the low storage area which includes a vacuum pickup for picking up individual items to be placed in a receptacle, and a plurality of rotatable fingers for grasping a plurality of items in a single stack;
• determining when an item in a storage area is at or below a threshold;
• providing additional inventory of the item that is at or below the threshold;
• translating a pickup head in the pick and place dispenser to the location of the additional inventory;
• rotating the fingers for grasping the additional inventory;
• transferring the additional inventory with the pickup head to a location in the storage area where additional inventory is needed;
• and
• releasing the additional inventory from the fingers.

A system for automatically picking items to fill a purchase order, comprising

• at least one receptacle for receiving items ordered in the purchase order, the receptacle having associated with it unique identifying information;
• a conveyor for moving the receptacle along a preselected path;
• a detector along the path for detecting the unique identifying information associated with the receptacle and generating an output signal representative of that information;
• a system controller which
• i. receives the detector output signal and information about the identity and quantity of items ordered in the purchase order,
• ii. correlates the unique identifying information with the information about the identity and quantity of items ordered in the purchase order, and
• iii. generates commands;
• a high volume storage area located along a first portion of the path of the conveyor for storing items which are frequently ordered;
• a low volume storage area located along a second portion of the path of the conveyor for storing items which are less frequently ordered than the items in the high storage area;
• a director responsive to a command from the controller to direct a receptacle onto the second portion of the path when items located in the low volume storage area are ordered in the purchase order;
• at least one picking robot at the low volume storage area responsive to a command from the controller to pick items located in the low volume storage area that are ordered in the purchase order and place the items in the receptacle;
• at least one dispenser at the high volume storage area responsive to a command from the controller to dispense items located in the high volume storage area that are ordered in the purchase order into the receptacle;
• and
• wherein the at least one picking robot includes a manipulator a vacuum pickup for picking up individual items to be placed in a receptacle, the vacuum pickup including a contact member for sealingly engaging an item, and a vacuum line for supplying negative pressure to the contact member, and a plurality of rotatable fingers for grasping a plurality of items in a single stack, each finger being extendable for extending downward past the contact member and having feet which, when the fingers are rotated, rotate toward and away from the contact member.