CROSS-REFERENCE TO RELATED APPLICATION [0001] This application claims the benefit of provisional patent application No. 62/942,473 filed December 02 ^nd , 2019, titled "MODULAR FULFILLMENT SOLUTION", which is hereby incorporated by reference in its entirety without giving rise to disavowment.

TECHNICAL FIELD

[0002] The present disclosure relates to the field of storage of goods and distribution to end consumers.

BACKGROUND

[0003] In the effort for shortening the delivery time of online placed orders to ordering customers, retailers tend to squeezing micro-fulfillment centers into warehouses closer as possible to the locations of ordering customers, most of which may live in dense urban areas, where availability of real estate, and particularly of warehouses in reasonable prices, is often in a shortage.

[0004] Depending on the type of ordered goods, customers may sometimes expect to have their orders delivered within hours, as a condition for placing an order.

BRIEF SUMMARY

[0005] A first broad aspect of the presently disclosed subject matter, is a mobile truck, comprising at least one storage container, each storage container comprising a plurality of inventory units extending parallel to a longitudinal axis of the storage container each facing an aisle, wherein a plurality of totes are stored in each of the inventory units, arranged in columns and rows, wherein each inventory unit is configured to allow a robotic carrier moving through the aisle to move adjacently to a face of the inventory unit and to pull a tote of interest out of the inventory unit or to insert a tote into an empty storage space in the inventory unit, whereby robotic carriers can transfer totes of interest from the inventory unit to a picking station located near a rear end of the storage container and to transfer totes from the picking station to storage spaces in the inventory units, wherein the robotic carriers are tethered to immovable infrastructure within the storage container for preventing removal of the robotic carriers out of predetermined routes they are intended to follow for transfer of totes, and despite of travel related forces exerted on the robotic carriers due to motion of the mobile truck.

[0006] A second broad aspect of the presently disclosed subject matter, is a storage container, comprising a plurality of inventory units extending parallel to a longitudinal axis of the storage container each facing an aisle, wherein a plurality of totes are stored in each of the inventory units, arranged in columns and rows, wherein each inventory unit is configured to allow a robotic carrier moving through the aisle to move adjacently to a face of the inventory unit and to pull a tote of interest out of the inventory unit or to return a tote into an empty storage space in the inventory unit, whereby robotic carriers can bring totes of interest from the inventory unit to a picking station located near a rear end of the storage container and to return totes from the picking station to storage spaces in the inventory units, wherein the robotic carriers are tethered to immovable infrastructure within the storage container for preventing removal of the robotic carriers out of predetermined routes they are intended to follow for retrieval and return of totes, and despite of travel related forces exerted on the robotic carriers due to motion of a truck by which the storage container may travel.

[0007] A third broad aspect of the presently disclosed subject matter, is a Fulfillment Center, comprising a first plurality of storage containers according to said second broad aspect, arranged on a leveled platform one adjacently to another, with longitudinal axes of their inventory units in parallel, wherein a plurality of picking stations are arranged at a first end of each of the first plurality of storage containers, within a picking container extending adjacently to said first end of each of the storage containers, wherein a longitudinal axis of the picking container is perpendicular to the longitudinal axes of the inventory units.

[0008] In various embodiments, the Fulfillment Center is further comprising a plurality of Inventory Receiving Stations arranged at a second end of each of the first plurality of storage containers opposite the first end, within an Inventory Receiving Container extending adjacently to said second end of each of the storage containers, wherein a longitudinal axis of the Inventory Receiving Container is perpendicular to the longitudinal axes of the inventory units.

[0009] In various embodiments of the Fulfillment Center, at least some of the storage containers comprise each two pairs of Inventory Units, one of the two pairs is arranged back to back with a longitudinal axis of the storage container in between, wherein each of the pairs comprises two facing Inventory Units with an aisle in between. In case the storage containers comprise more than two pairs of Inventory Units, a plurality of pairs may be arranged back to back corresponding aisles in between.

[0010] In various embodiments of the Fulfillment Center, at least some of the plurality of Picking Stations comprise each a left tote conveyor and a right tote conveyor, each of said left and right tote conveyors is arranged with a longitudinal axis thereof in alignment with an aisle extending in between a respective pair of inventory units.

[0011] In various embodiments of the Fulfillment Center, at least some of the plurality of Inventory Receiving Stations comprise each a left tote conveyor and a right tote conveyor, each of said left and right tote conveyors is arranged with a longitudinal axis thereof in alignment with an aisle extending in between a respective pair of inventory units.

[0012] In various embodiments of the Fulfillment Center, each of the left and right tote conveyors, either in the Picking Stations or in the Inventory Receiving Stations, comprises an upper conveyor configured to convey totes in a first direction between an end of a respective aisle and a respective picking or receiving station, and a lower conveyor configured to convey totes in a second direction opposite said first direction, whereby totes conveyed from an aisle to a station by one of the upper and lower conveyors, is conveyed back towards the respective aisle by the other.

[0013] In various embodiments of the Fulfillment Center, the storage container comprises an opening in first end wall thereof, per each of the left and right tote conveyors, in alignment with a respective opening in a side wall of the Picking Container.

[0014] In various embodiments of the Fulfillment Center, the storage container comprises an opening in second end wall thereof, per each of the left and right tote conveyors, in alignment with a respective opening in a side wall of the Inventory Receiving Container.

[0015] In various embodiments, the Fulfillment Center further comprises a second plurality of storage containers leveled on top of the first plurality of storage containers.

[0016] In various embodiments of the Fulfillment Center, at least some of the robotic carriers are configured to move vertically into and from the storage containers of the second plurality of storage containers, through respective openings communicating between the aisles of differently leveled storage containers.

[0017] In various embodiments of the Fulfillment Center, the robotic carrier is enabled to move vertically and horizontally through the aisle.

[0018] A fourth broad aspect of the presently disclosed subject matter is a method, comprising (i) leveling a plurality of storage containers adjacently one to a next with longitudinal axes thereof in parallel ;(ii) adhering at least a first container to an end of the plurality of containers with a longitudinal axis of the first container perpendicularly to said longitudinal axes; (iii) providing openings (e.g. an array of openings configured to allow robotic transfer of totes) between the plurality of storage containers and the first container; (iv) providing the plurality of storage containers with inventory units along the lengths of the storage containers; and (v) providing conveyors in the first container in alignment with said openings. [0019] Iv various embodiments of said method, the method may further comprise (vi) adhering a second container to another end of the plurality of containers with a longitudinal axis of the first container perpendicularly to said longitudinal axes; and (vii) providing openings (e.g. an array of openings configured to allow robotic transfer of totes) between the second container and the plurality of storage containers;

[0020] Iv various embodiments of said method, the method may additionally comprise (viii) providing conveyors in the second container in alignment with said openings between the second container and the plurality of storage containers.

DETAILED DESCRIPTION

[0021] The amount and variety of goods to be delivered from suppliers to end customers have tended to increase over time. This trend is strengthening with the improvements in delivery services (e.g. in terms of reduction in the average of time lapse between placing an on-line order and getting the requested delivery at the destination).

[0022] One technical problem dealt with by the disclosed subject matter is the need to shorten the delivery time of goods from a merchant's warehouse to an ordering customer. Retail businesses, such as food retail, deal with increasing demands for delivery services up to the customer door, which requires solutions for the challenges involved with maintaining the ordered goods in conditions adequate for the quality and freshness of food products, throughout the entire delivery chain, until the very last mile up to a customer's door. It may be desired to allow a retailer to supply orders to mass numbers of customers located within urban areas, as fast as possible from the time an order has been placed.

[0023] Another technical problem dealt with by the disclosed subject matter is the need to reduce the volume needed for storing given amounts of inventory, for both reducing the expenses involved is storage of goods, and allowing more goods to be stored as close as possible to the location of most of the end customers of these goods.

[0024] A first broad aspect the presently disclosed subject matter concerns a mobile fulfillment truck (also referred to herein using the abbreviation MFT). In a first broad aspect the MFT is a mobile machine configured to allow storing, picking and dispatching orders (which may be placed by customers either in advance or online in real time), while moving around in a city, or between urban regions and the like.

[0025] The MFT may begin a round by loading inventory into its storage means, at a designated site. In various embodiments of the presently disclosed subject matter, a plurality of MFTs may cooperate, in logistically covering a predetermined country region, e.g. a city. Such cooperation may be in terms of availability of the MFT service to customers of that service at the country region, regardless of the location of each customer within the region of coverage.

[0026] In various embodiments of the presently disclosed subject matter, the general external construction of an MFT, is based on a conventional truck associated with a conventional trailer, wherein the storage means are housed within a shipping container constituting a Modular Fulfillment Container, and located on the trailer.

[0027] In various embodiments of the presently disclosed subject matter, the shipping container (referred to is of standard dimensions in width, height, and length. Common standard dimensions of shipping containers to be considered in examples herein, are 8 feet (2.4 meters) for width, either 8 feet 6 inches or 9 feet 6 inches (2.6 or 2.9 meters) for height, and either 20 or 40 feet (6 or 12 meters) for length.

[0028] In various embodiments of the presently disclosed subject matter, a trailer carrying a shipping container preloaded with inventory, may be attached to the truck at a designated site from which a delivery round starts. The truck can then head off for the delivery route. In various embodiments of the presently disclosed subject matter, the designated site may be used for loading inventory into shipping containers and/or for performing inbound sorting operations on an inventory existing within the shipping container, as a preparation step for the intended delivery.

[0029] Once prepared for heading, the MFT drives from the loading site to a temporal operation location, at which operator will park the truck and begin the outbound of orders to customers.

[0030] Customers can either come directly to the MFT to pick up their order, or a short distance delivery method (e.g. bicycle or scooter based) can be used to transfer the goods to the customers addresses.

[0031] When the MFT’s inventory is low, it can drive back to the loading site to replace its trailer, i.e. return the trailer for reloading and attach to another trailer having an already loaded shipping container, then heading for another round.

[0032] The shipping container may comprise a plurality of lengthwise disposed tote supporting constructions, constituting inventory units. Each inventory unit extends a predetermined extent along most of the predetermined length of the shipping container, and comprises at least a first vertical face facing an aisle. The inventory unit may be configured to store totes in columns and rows, in a manner that allows pulling each tote out from a space in the construction constituting a tote location, into a space of the aisle, and to transfer totes from the aisle into vacant tote location inside the tote supporting construction. [0033] Each tote location in the tote supporting construction may be uniquely identified by numbering its row and column according to their respective distance from a predetermined reference point. Likewise, the aisle facing face of each tote supporting construction in the container may be uniquely identified by numbering it according to its respective distance from a predetermined vertical reference plane parallel to the faces of the plurality of lengthwise disposed tote supporting constructions.

[0034] The shipping container may further comprise robotic tote carriers configured to move along said columns and rows for reaching a desired tote location and picking a tote stored in the desired tote location or placing a tote to be stored in the desired tote location. The robotic tote carriers may further be configured to exchange totes with (i.e. give totes to, or receive totes from) other tote carriers. For example, a first type of robotic tote carrier, e.g., lift robots, may be configured to travel through a gap and reach products that are placed along columns and rows at both faces of the gap, and a second type of robotic tote carrier, e.g., floor robots, may be configured to travel on the floor and transfer products between different lift robots, between different containers, between a lift robot and a picking station, or the like.

[0035] The shipping container may further comprise, or be in communication with, a computerized control system configured to direct the robotic tote carriers to and from desired locations for picking, exchanging, carrying and storing totes.

[0036] The shipping container further comprises an interface area at which picked totes arrive by tote carriers and from which totes are directed for storage; the interface area is located between an outdoor of the shipping container and between a first end of the plurality of longitudinally disposed tote supporting constructions; whereby orders of goods stored in the shipping container may be prepared while the mobile fulfillment truck is on the move, wherein the control system is configured to direct totes to the interface area based on a route to be followed by the truck such that orders by customers are being prepared in the interface area for delivery to each customer according to customers' queue order determined based on the proximity of customers' addresses to a queue of intended stop spots along the route to be followed, at which the truck can stop for outputting prepared orders for delivering to their ordering customers, respectively, from a stop spot as close as may be cost-effectively afforded per each customer. In various embodiments of the presently disclosed subject matter, the control system is configured to cooperate with a human in consolidation of inventory items to be picked by the human from totes, which automatically arrive at the interface area, carried by robotic tote carriers.

[0037] In the context of the presently disclosed subject matter, robotic tote carriers include autonomous robots capable of moving and changing locations with respect to the shipping container independently of one another, as well as conveyors and/or conveyor belts which do not change location, i.e. stationary, with respect to the shipping container. In various embodiments of the presently disclosed subject matter, the shipping container comprises tracks or rails constituting an infrastructural system to which autonomous robotic tote carriers may be tethered for maintaining their planned locations and routes within the shipping container, regardless of external forces acting on them due to irregularities (e.g. accelerations, decelerations, shakes, bumps) in the motion of the truck and trailer which carry the shipping container. The robotic tote carriers may comprise lift robots and floor robots, similarly to the robots and infrastructure described by US patent application No. 16/596,029 filed October 8, 2019, entitles “Robotic Inventory Handling”, and by US patent application No. 15/310,799 filed November 14, 2016, entitles “Robotic Inventory Handling”, which are hereby incorporated by reference in their entirety without giving rise to disavowment.

[0038] In various embodiments of the presently disclosed subject matter, at least one tote supporting construction may cooperate with lateral shifting means, e.g. rails of tracks, by which it is configured to move sideways into the area of an aisle, when more space is needed at another side of the tote supporting construction or at a next aisle, e.g. for maintenance and technical service purposes.

[0039] In various embodiments of the presently disclosed subject matter, the inventory units may be arranged to form two aisles, thereby enabling the robotic tote carriers to travel vertically and horizontally between the aisles. Each inventory unit may comprise a plurality of rows, e.g., four rows, together forming one side of an aisle. In various embodiments of the presently disclosed subject matter, robotic tote carriers may be enabled to travel vertically and horizontally in the gap of the aisle while being elevated or extended above a floor of the container. Double sided robotic tote carriers may be provided for traveling between the inventory units. The robotic tote carriers may comprise mini-load tote managing machines that enable to approach totes from both sides of the aisle.

[0040] In the context of this disclosure, double sided robotic tote carrier, is a title for a robot having movable or telescoping gripping means configured to approach a storage space on either of opposite sides of an aisle (for either pulling out a tote from, or return a tote into, a storage space), while a main body of the robot remains stationary among storage spaces arranged from both opposite sides of the aisle.

[0041] In various embodiments of the presently disclosed subject matter, the MFT includes power supply equipment for supplying the energy requirements of the electrically operated systems of the MFT. The power supply equipment may be installed at a front end of the shipping container, next to a wall thereof which faces the backside of the truck, or in any other location on the trailer, either within or outside the space walled by the shipping container.

[0042] In various embodiments of the presently disclosed subject matter, the MFT includes a picking unit, which will be referred to herein also a picking station. The picking station may be configured to receive totes of interest from the inventory units, and to allow retrieval of items from totes arriving at the picking station, in amount or number of items according to an order filed by a customer. The picking station may further be configured to allow consolidating items retrieved from the arriving totes, into a delivery tote. The picking station is further configured to allow outputting the delivery tote to a courier vehicle, which may then be heading with the delivery tote to the residential address indicated by the ordering customer as the address for the respective delivery. Once items for a current order are retrieved from a tote at the picking station, the tote may be returned from the picking station back to storage, at the inventory units.

[0043] In various embodiments of the presently disclosed subject matter, the picking station may include two buffer units - one for each aisle, for inventory totes arriving at the picking station. The picking station may additionally include a buffer unit for delivery totes. In various embodiments of the presently disclosed subject matter, the buffer unit for delivery totes is located equidistantly from the buffer units for inventory totes. In the context of the present disclosure a buffer unit is an equipment, such as one or more of a table, a conveyor configured to convey totes in a first direction, e.g., left, a conveyor configured to convey in a second direction different than said first direction, e.g., right, opposite, or orthogonal to the first, and any related equipment, configured to allow transferring totes to and from a picking station or an inventory receiving station, and to allow handling a queue of totes arriving at or exiting from said stations.

[0044] In various embodiments of the presently disclosed subject matter, the delivery tote differs in its structure and/or in its outer dimensions from the inventory totes.

[0045] In various embodiments of the presently disclosed subject matter, the picking activity can be performed by, or under supervision, of a human. Picking and or supervision activity by a human may be performed most effectively at time durations when the MFT is stationary.

[0046] In various embodiments of the presently disclosed subject matter, the picking activity may be performed effectively by robots, during MFT travel time durations as well.

[0047] In various embodiments of the presently disclosed subject matter, the dimensions of an inventory tote are about 350X350X170mm, with the 170mm being the height. In various embodiments of the presently disclosed subject matter, four inventory units, or any other desired number of inventory units, may extend lengthwise along a shipping container of standard dimensions. Given the width of a standard shipping container is about 2.4 meters, four inventory units may allow for two aisles to be formed, one aisle in between two inventory units, each of these aisles having a width about 360mm.

[0048] For maintenance of the inventory units, the adjacent inventory units that are located back to back along the center, each facing a different aisle, may be provided with means for moving sideways, e.g. lateral rails on which the inventory units may slide, once released from being locked in their normal location.

[0049] In various embodiments of the disclosed subject matter such means for moving sideways may allow for moving both said aisles together in the same direction for an extent of about 350mm. Such movement can bring a first of the comoving inventory units into one of the aisles, and the second inventory units into the region normally occupied by the first. This may result with the other of the aisle becoming widened by said 350mm, finally having a width of about 700mm (being its original width plus the width of the region normally being occupied by the second inventory unit). For another example, such means for moving sideways may allow for moving the central adjacent inventory units sideways in opposite directions, bringing each inventory unit into the area of its neighboring aisle. This may result with the formation of a corridor of 700mm width on the regions normally being occupied by the central adjacent inventory units.

A small portion of around lfeet of the container space may be utilized for electrical components such as an air conditioner.

BRIEF DESCRIPTION OF THE FIGURES

The presently disclosed subject matter will be understood and appreciated more fully from the following detailed description taken in conjunction with the drawings in which corresponding or like numerals or characters indicate corresponding or like components. Unless indicated otherwise, the drawings provide exemplary embodiments or aspects of the disclosure and do not limit the scope of the disclosure. In the drawings:

[0050] Fig. 1 illustrates in isometric view the structure of a Modular Fulfillment Container according to an exemplary embodiment of the presently disclosed subject matter, mounted on a semitrailer, as seen to a viewer located from its back side.

[0051] Fig. 1A illustrates in isometric view the Modular Fulfillment Container of Figure 1, as seen to a viewer located from its head side.

[0052] Fig. IB illustrates an isometric enlarged view of a Picking Station region of the Modular Fulfillment Container of Figure 1.

[0053] Fig. 2 illustrates an aerial isometric view of an exemplifying embodiment of a Fast Deployment Fulfillment Center according to the presently disclosed subject matter.

[0054] Fig. 2A illustrates a top view of an exemplifying embodiment of a Fast Deployment Fulfillment Center similar to the embodiment illustrated by Figure 2.

[0055] Fig. 2B illustrates a top view of the Fast Deployment Fulfillment Center illustrated by Figure 2, with workflow marking.

[0056] Fig. 2C illustrates a top view of the Fast Deployment Fulfillment Center illustrated by Figure 2, as seen from under its ceiling.

[0057] Fig. 2D illustrates in isometric enlarged view a portion of the Fast Deployment Fulfillment Center illustrated by Figure 2, as seen to a viewer located from its back side with a rear portion thereof removed to allow viewing inside.

[0058] Fig. 2E illustrates in isometric enlarged view an Inventory Receiving Station of the Fast Deployment Fulfillment Center illustrated by Figure 2.

[0059] Fig. 2F illustrates in isometric view the structure of a Modular Fulfillment Container according to another exemplary embodiment of the presently disclosed subject matter, differing from the embodiment of Figure 1 in the length of the container.

[0060] Fig. 2G illustrates a top view of the Modular Fulfillment Container illustrated by Figure 2F, as seen from under its ceiling.

[0061] Fig. 2H illustrates in isometric enlarged view a portion of the Fast Deployment Fulfillment Center illustrated by Figure 2, as seen to a viewer located from its front side with a front portion thereof removed to allow viewing inside.

[0062] Fig. 21 illustrates in isometric enlarged view a Picking Station of the Fast Deployment Fulfillment Center illustrated by Figure 2.

[0063] Fig. 2J illustrates schematics of the arrangement of totes and dimensions thereof in some exemplifying embodiments of the presently disclosed subject matter.

DETAILED DESCRIPTION OF THE FIGURES

[0064] Referring now to Figure 1 illustrating an isometric view of an exemplary embodiment of a Modular Fulfillment Container 100, according to the presently disclosed subject matter. The Modular Fulfillment Container 100 comprises a shipping container 102 as an envelope. For facilitating visualization, the wall of the shipping container in the figure are illustrated as being semitransparent, and certain wall portions are removed to expose the inner structure of the Modular Fulfillment Container. A plurality of totes 111 are stored within the shipping container 102, in two pairs of Inventory Units. A first pair comprising the two facing Inventory Units 103 and 105, with first respective aisle in between. A second pair comprising the two facing Inventory Units 104 and 106, with second respective aisle in between. The two pairs of Inventory Units are arranged back to back, i.e. with a backside of the Inventory Unit 105 arranged adjacently to a backside of the Inventory Unit 105, in a mirroring configuration with respect to a longitudinal middle of the shipping container. |The shipping container is carried by a semitrailer 101, which can lean on front hydraulic supporters 10 IS when the semitrailer is not attached to a truck.

[0065] A backside space of the shipping container is free of the Inventory Units 103- 106, serving as a Picking Station. Totes of interest are carried from the Inventory Units by robotic carriers (not shown) such as the lift robots described by international patent application No. PCT/IL2018/050200 filed February 21, 2018, which is hereby incorporated by reference in its entirety without giving rise to disavowment. Each inventory unit is configured to allow a robotic carrier moving vertically and horizontally through the aisle to move adjacently to a face of the inventory unit and to pull a tote of interest out of the inventory unit or to insert a tote into an empty storage space in the inventory unit, e.g., during a mobile period of the truck in which the truck is moving. Totes of interest may be positioned on the upper conveyor 108 which convey the totes to a picking position in the picking station. A picking worker 107, can then pick items from the tote of interest and place the items, in amounts and/or numbers according to an order placed by a customer, into a delivery tote 121 intended for the respective ordering customer. The tote of interest can then be lowered (e.g. by the picking worker 107) onto a return conveyor 109, then conveyed by conveyor 109 toward the aisle to be carried back by a robotic carrier into an empty space relevant for storing the returned tote within the Inventory Unit. [0066] A space at front end of the shipping container, i.e. between a front end of the Inventory Units and a front wall of the shipping container, may be utilized as a compartment 171 for auxiliary systems required for proper operation of the MFC. Such auxiliary systems may include one or more of a battery, electrical generator, control units, air conditioning and/or cooling system and the like.

[0067] Once an order has been consolidated from totes of interest into a respective delivery tote 121, the tote 121 may be advanced on an outputting conveyor 118, to be transferred to ordering customer, e.g. by a courier vehicle.

[0068] Referring now to Fig. 1A showing in isometric view the Modular Fulfillment Container 100 of Fig. 1, as seen to a viewer located from its head side. A compartment 171 for auxiliary systems required for proper operation of the MFC is seen in a front space of the shipping container 102.

[0069] Referring to Fig. IB, an isometric enlarged view of a Picking Station region of the Modular Fulfillment Container of Figure 1 is shown. Totes of interest 111 are brought from the inventory units 103 - 106 by robotic carriers and are placed on the conveyors 108 and 128, respective to the aisle from which they arrive. The totes are advanced by the conveyors away from the aisles as indicated by arrows R1 and R2. Once arrived to a picking position where a picking worker 107 can reach their content, the picking worker can pick items from the totes according to an order placed by a customer, and prepare the order by consolidating the items ordered, from inventory totes 111 into a delivery tote 121 dedicated for a respective ordering customer. The totes of interest 111 may then be lowered by either the picking worker 107 or by a robotic means onto the return conveyor 109, as indicated by arrow R4, for moving back towards the respective aisle in the direction indicated by arrow R5.

[0070] Once an order has been consolidated into the respective delivery tote 121, it can be advanced by outputting conveyor 118 toward the back end of the Modular Fulfillment Container in the direction indicated by arrow R6, from which it may be collected for delivery to the intended destination, e.g. by a courier vehicle.

[0071] Referring now to Fig. 2, an aerial isometric view of an exemplifying embodiment of a Fast Deployment Fulfillment Center 200 according to the presently disclosed subject matter is shown. The Fast Deployment Fulfillment Center is comprised of a first plurality of storage containers comprising the five shipping containers 231-235 arranged on a leveled platform one adjacently to another.

[0072] The leveled platform may include, for example, an evenly leveled concrete basis and/or steel rails evenly leveled on a firm basis.

[0073] A plurality of picking stations is arranged within the picking container 240, which, as can be appreciated, is positioned next to a first end of each of the plurality of storage containers 231-235. The picking container 240 extends adjacently to the first end of each of the storage containers, wherein a longitudinal axis of the picking container 240 is perpendicular to the longitudinal axes (marked A1 - A4 in Fig. 2G) of the inventory units within the shipping containers.

[0074] The Fast Deployment Fulfillment Center may further comprise a plurality of Inventory Receiving Stations arranged within an Inventory Receiving Container 220. As can be appreciated, the Inventory Receiving Container 220 is positioned next to a second end of each of the plurality of storage containers 231-235, opposite said first end thereof. The longitudinal axis of the Inventory Receiving Container is perpendicular to the longitudinal axes of the inventory units within the shipping containers.

[0075] A compartment for auxiliary systems, such as a battery, electrical generator, control units, air conditioning and/or cooling system and the like may be constituted by an auxiliary container 271. The auxiliary container 271 may be located away from openings and related logistic activities associated with the operation of the Fast Deployment Fulfillment Center, e.g. near a closed far end of the Inventory Receiving Container 220.

[0076] A truck 251 loaded with a shipping container 202, can park with doors of the shipping container almost next to the open end 220e of the Inventory Receiving Container 220, for fast transfer of inventory from the shipping container 202 into the Inventory Receiving Container 220. The transfer may include using forklifts for unloading pallets 255 from trucks, and for distributing pallets 255 along the Inventory Receiving Container 220 in front of Inventory Receiving Stations thereof. The pallets may then be unpacked for loading goods into totes.

[0077] Fig. 2A illustrates a top view of an exemplifying embodiment of a Fast Deployment Fulfillment Center similar to the embodiment illustrated by Figure 2, with titles printed on some of the containers constituting the Fast Deployment Fulfillment Center 200. The titles intend to indicate that containers 231 and 232 of the embodiment of Fig. 2 may be dedicated for general storage thus simply marked "Storage", and that the container 234 may be dedicated for chilling requiring goods, such as food, thus titled as "Chiller". Container 271 is an auxiliary compartment titled "Control & power". The Picking Container 240 is marked "Picking", and the Inventory Receiving Container 220 is marked "Decant".

[0078] As may be appreciated, the auxiliary container 271 is located away from the entrance opening 220e of the Decant container, and away from the exit opening 240e of the Picking Container and from the activity of courier vehicles 280.

[0079] Fig. 2B illustrates a top view of the Fast Deployment Fulfillment Center illustrated by Figure 2, with workflow marking which include the arrow 202a which indicates that the logistic activity in the Fast Deployment Fulfillment Center may start with unloading the truck 202 toward the entrance 220e of the Inventory Receiving Container 220. The inventory is then distributed within the Inventory Receiving Container 220 in the direction indicated by arrow 220a.

[0080] Next, the Inventory Receiving Stations within the Inventory Receiving Container 220 are used for sorting the goods into inventory totes 211 and distributing each tote to a respective predetermined storage space within the storage containers 231 - 235, as indicated by the respective arrows 231a - 235a.

[0081] The sorted goods then further flow by tote carriers in the direction indicated by the respective arrows 231a - 235a, into the Picking Container 240, according to demands placed by ordering customers.

[0082] The process is finalized when orders are consolidated in Picking Stations into delivery totes. The delivery totes move toward the exit 240e of the Picking Container 240, collected by couriers and delivered by courier vehicles 280 toward their destinations as indicated by arrow 280a.

[0083] Fig. 2C illustrates a top view of the Fast Deployment Fulfillment Center illustrated by Figure 2, as seen from under its ceiling. Inventory Totes 211 are arranged within each storage container in pairs of Inventory Units. A first pair includes the Inventory Units 203 and 205, separated by the aisle 233, on the right of each illustrated storage container, and the second pair includes the Inventory Units 206 and 204, separated by the aisle 243, on the left of each illustrated storage container.

[0084] Inventory Receiving Workers 207b located at Inventory Receiving stations within the Inventory Receiving Container 220, sort goods from unpacked pallets 255 into Inventory Totes which are in position on conveyors 248 and 268. The totes filled with sorted goods are then conveyed, respectively, into the rear ends of aisles 233 and 243, and are then loaded on robotic tote carriers which deliver them to storage within the Inventory Units 203-206.

[0085] Based on orders placed by customers, robotic carriers then carry totes of interest from the Inventory Units to conveyors 208 and 228. The conveyors 208 and 228 then convey the totes of interest to Picking Stations where Picking Workers 207c are positioned. Once an order has been consolidated into a delivery tote 221, each delivery container is collected by a courier into a vehicle, e.g. a motorcycle 280, which can carry the respective delivery tote 22 Id to its ordered destination.

[0086] Fig. 2D illustrates in isometric enlarged view a portion of the Fast Deployment Fulfillment Center 200 illustrated by Figure 2, as seen to a viewer located from its back side with a rear portion of the Inventory Receiving Container 220 being removed to allow viewing inside. Inventory Receiving Workers 207b are positioned in inventory receiving stations for unpacking pallets 255, and for sorting the goods into inventory totes 211. Totes 211 are positioned on Inventory Receiving Conveyors 248, such that once filled are conveyed through openings 264 from the Inventory receiving Stations into the respective storage containers 231-235. Each Inventory Receiving Station includes two conveyors, one per each aisle in the respective storage container. Each of the two conveyors includes an upper outgoing conveyor 248 for filled totes intended to be returned for storage in the Inventory Units, and a lower ingoing conveyor 249, carrying empty or low inventory totes brough from the Inventory Units for being filled with fresh goods before returning to storage by the upper outgoing conveyor 248.

[0087] Fig. 2E illustrates in isometric enlarged view an Inventory Receiving Station of the Fast Deployment Fulfillment Center illustrated by Figure 2. An inventory Receiving Worker 207b is position in the station, for filling inventory totes 211 with incoming goods unpacked from pallet 255. [0088] Inventory totes 211 of low inventory are conveyed from the storage containers by respective lower ingoing conveyors 249, through openings 264, for being filled with the incoming goods. Once filled with fresh sorted goods, the inventory totes are conveyed back into respective aisles, by upper outgoing conveyors 248, for being carried by robotic carriers for storage in the Inventory Units.

[0089] Referring now to Fig. 2F, the structure of a Modular Fulfillment Container 292 according to another exemplary embodiment of the presently disclosed subject matter, is shown. The Modular Fulfillment Container 292 may differ from the embodiment of Figure 1 in the length of the container. For example, Modular Fulfillment Container 292 may represent a container 20 feet (6m) long, instead of 40 fear long, thus accommodating less totes 211 along its length, e.g., sixteen totes. This in contrast to Modular Fulfillment Container 102 of Fig. 1, which may represent a container 40 feet (12m) long, thus accommodating a large number of totes 211 along its length, e.g., twenty six totes. Both sized containers, as well as any other sized container, may comprise two aisles between four inventory units. The aisles may enable robotic carriers such as mini-load cranes to operate and perform inventory managing tasks. Modular Fulfillment Container 292 may be chilled in some cases, e.g., in case the stored merchandise requires chilling. In an exemplary embodiment in which the length of each tote is 350mm and assuming 10 mm gap between neighboring totes, the inventory units of The Modular Fulfillment Container 292 may have a total length about sixteen times 0.36m, which is equal to about 5.76 m, leaving a space of about 0.24m. In some utilizations of the Modular Fulfillment Container 292, this space may be utilized as a location for utilities such as power supply systems, computerized control systems, communication systems, air conditioning, refrigeration and the like (see 171 in Figure 1). Such systems may be arranged in a closed compartment for fast removal, replacement, and installation. Referring now to Fig. 21, this space may alternatively be utilized e.g. for having the proximal ends of conveyors such as the picking conveyors 208, 209, 228 and 229, slightly emerging into the container through openings in its rear wall, corresponding to and in alignment with the openings 264 in the side wall 240S of the picking container 240. This slight shifting of the conveyors into the Modular Fulfillment Container 292, may respectively free about 0.24m in the picking container 240, along entire length thereof. As can be appreciated, no free space for picking stations may be required in the Modular Fulfillment Container 292, in case it is utilized as a storage container such as 231 - 235, which benefit from the cooperation with the picking container 240 within which picking stations are presented. In case a Modular Fulfillment Container is to be utilized as a mobile fulfillment storage container to be caried on a trailer or on a semitrailer, e.g. as disclosed by Figure 1, space for picking stations may be required within the container 292 next to its rear wall. To that goal, the inventory units may have a removable portion e.g. having a length of five or six tote storage spaces. Once removed, the removable portion may free the space required for presenting the picking station, including its picking conveyors and any other related equipment, within the container. Referring again to Figure 1, a standard 12m shipping container may be used. Such container may accommodate along its length as twice totes as may be accommodated by a standard 6m shipping container. Given the above mentioned 350mm length of tote, the 12m container may contain thirty-two totes per a row, lengthwise. Once said removable portion of the inventory units is removed, a space for the picking station is formed, leaving the container with a capacity of e.g. twenty- six totes per a row, as depicted.

[0090] The in various embodiments of the presently disclosed subject matter, the Modular Fulfillment Container may be configured for having the robotic carriers tethered to immovable infrastructure within the container, for preventing removal of the robotic carriers from their intended locations and/or routs to be followed by, when the Modular Fulfillment Container is in motion, is in a mobile phase of the truck, a mobile period of the truck, or the like.

[0091] Fig. 2G illustrates a top view of the Modular Fulfillment Container illustrated by Figure 2F, as seen from under its ceiling. Four Inventory units are arranged in pairs within the container, each comprising sixteen inventory totes 211 along its length. A first inventory unit is arranged along a first axis marked Al, a second inventory unit is arranged along a second axis marked A2, both together, separated by a first aisle 233, constitute a first pair of inventory units. Likewise, a third inventory unit is arranged along a third axis marked A3, a fourth inventory unit is arranged along a fourth axis marked A4, both together, separated by a second aisle 243, constitute a second pair of inventory units. Both said pairs of inventory units are arranged back to back, about a middle longitudinal line of the container in mirroring configuration. Arrows 250 indicate that the Modular Fulfillment Container 290 may be configured to allow the inventory units along axes A2 and A3 to be shifted sideways, into one of the aisles (in this figure the arrows exemplify the shift into aisle 233), for widening the other aisle for maintenance and/or repairing purposes. In various embodiments of the presently disclosed subject matter the Modular Fulfillment Container 290 may be configured to allow the inventory units along axes A2 and A3 to be shifted sideways either moving in the same lateral direction, or moving each to the opposite direction, e.g. the inventory unit along axis A2 into aisle 233, and the inventory unit along axis A3 into aisle 243, whereby a corridor may be formed in the central area which is normally occupied by said inventory units.

[0092] Referring now to Fig. 2H with reference being made also to Fig. 21 for more details, an isometric enlarged view a portion of the Fast Deployment Fulfillment Center 200 illustrated by Figure 2, as seen to a viewer located from its front side with a front portion of the Picking Container 240, removed to allow viewing inside. Only a portion of the top wall 240t of the picking container is thus illustrated. Likewise, only a portion of the bottom wall 240f of the picking container is illustrated.

[0093] Picking workers 270c are in position in a plurality of picking stations, each corresponding to a storage container with which ingoing and outgoing conveyors 209 and 208 communicate through respective openings 264 formed in the side wall 240s, of container 240, in alignment of similar openings formed in front walls of the storage containers 231-235.

[0094] The direction of motion of totes by the conveyors 208, 209 and 228, 229, are indicated by arrows Rll and R12. Arrow R13 indicates the transitioning of totes from the ingoing upper conveyors 208 and 228, respectively, onto the outgoing lower conveyors 209 and 229. Once picking from a tote of interest located on the respective upper ingoing conveyor is accomplished, the tote may be transitioned onto the lower outgoing conveyor, for being returned to the front end of an aisle in a respective storage container.

[0095] Fig. 2J illustrates schematics of the arrangement of totes and dimensions thereof in some exemplifying embodiments of the presently disclosed subject matter.

[0096] Inventory totes are arranged 13 in a column, between a down positioned tote 21 Id and an up positioned tote 21 lu. The totes may be each 163mm high, and 380 mm wide. Gaps of 10 mm may be provided from above and from below each tote. A total height of a column of totes including said gaps, may thus amount to 2259 mm.

[0097] Given an aisle width 393mm per each of the two aisles 233 and 243, and given the width of totes per four rows R1 - R4, which constitute respectively four Inventory Units, with additional 10mm gap between back to back totes on rows R2 and R3, the total width of the inventory storage may amount to 2316 mm. This may reasonably fit into the inner width between sidewalls of a standard shipping container 8 feet (2.4m) wide.

[0098] In the context of the present disclosure, unless otherwise explicitly described, a face of an inventory unit is to be understood as the plane perpendicular to the plane of the figure, e.g. through dashed lined F, virtually bordering between the tote storage spaces and the respective neighboring aisle.

[0099] In various embodiments of the presently disclosed subject matter, a Modular Fulfilment Container, e.g. of the types disclosed by Figure 1, may be easily adapted for use as a storage container in the Fast Deployment Fulfillment Center of the embodiment disclosed by Figure 2. This can be accomplished easily by removing the conveyors and any other related parts which are special to a Picking Station, and extending the Inventory Units into the container's space occupied by the equipment of the picking station. The equipment related to the picking station may then by utilized for assembling a respective picking station in the Picking Container 240.

[0100] As can be appreciated, the picking container 240 and the inventory receiving container 220, can be made from standard forty feet (12m) long shipping containers, thereby allowing for five standard containers, each eight feet (2.4m) wide, to be used as the storage containers 231-235. The length of the storage containers 231-235 may be selected accordingly, and as a matter of design, to be based either on forty feet (12m) long standard containers, or on twenty feet (6m) long standard containers.

[0101] In various embodiments of the presently disclosed subject matter, the Fulfillment Center further comprises a second plurality of storage containers leveled on top of the first plurality of storage containers. The storage containers of the second level may include Inventory Units and aisles arranged in a design corresponding to that of the design of Inventory Units and aisles in the first plurality of storage containers. [0102] In various embodiments, the Fulfillment Center may further comprise additional storage containers, arranged in a few levels. Each additional level may comprise a plurality of storage containers leveled on top of a previous level, such that a third plurality of storage containers is leveled on top of said second plurality of storage containers, and so forth. The maximal number of storage levels may depend on the maximal expected weight of each level and on the total load which lower leveled containers can safely support on top of them.

[0103] For benefitting from the storage spaces in the additional levels of storage containers, at least some of the robotic carriers may be configured to move vertically into and from the storage containers of the second plurality (or additional pluralities, according to the case) of storage containers, through respective openings communicating between the aisles of differently leveled storage containers.

[0104] It is appreciated that the use of shipping containers as building blocks of the Fulfilment Center may facilitate and expedite the deployment of fulfillment centers, while providing for cost effective and instantly available storage spaces, even on small areas that may not allow the construction of a warehouse based on traditional building methods.

[0105] It will be appreciated by persons skilled in the art that the present invention is not limited by what has been particularly shown and described hereinabove. Rather the scope of the invention also includes variations and modifications that would occur to persons skilled in the art upon reading the foregoing description and which are not in the prior art.

[0106] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms "comprises" and/or "comprising," when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

[0107] The corresponding structures, materials, acts, and equivalents of all means or step plus function elements in the claims below are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. The description of the present invention has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the invention. The embodiment was chosen and described in order to best explain the principles of the invention and the practical application, and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated.