From Simulation to Real-World Robotic Mobile Fulfillment Systems

In a new type of automated parts-to-picker warehouse system - a Robotic Mobile Fulfillment System (RMFS) - robots are sent to transport pods (movable shelves) to human operators at stations to pick/put items from/to pods. There are many operational decision problems in such a system, and some of them are interdependent and influence each other. In order to analyze the decision problems and the relationships between them, there are two open-source simulation frameworks in the literature, Alphabet Soup and RAWSim-O. However, the steps between simulation and real-world RMFS are not clear in the literature. Therefore, this paper aims to bridge this gap. The simulator is firstly transferred as core software. The core software is connected with an open-source ERP system, called Odoo, while it is also connected with real robots and stations through an XOR-bench. The XOR-bench enables the RMFS to be integrated with several mini-robots and mobile industrial robots in (removed) experiments for the purpose of research and education

Efficient order picking methods in robotic mobile fulfillment systems

Robotic mobile fulfillment systems (RMFSs) are a new type of warehousing system, which has received more attention recently, due to increasing growth in the e-commerce sector. Instead of sending pickers to the inventory area to search for and pick the ordered items, robots carry shelves (called "pods") including ordered items from the inventory area to picking stations. In the picking stations, human pickers put ordered items into totes; then these items are transported by a conveyor to the packing stations. This type of warehousing system relieves the human pickers and improves the picking process. In this paper, we concentrate on decisions about the assignment of pods to stations and orders to stations to fulfill picking for each incoming customer's order. In previous research for an RMFS with multiple picking stations, these decisions are made sequentially. Instead, we present a new integrated model. To improve the system performance even more, we extend our model by splitting orders. This means parts of an order are allowed to be picked at different stations. To the best of the authors' knowledge, this is the first publication on split orders in an RMFS. We analyze different performance metrics, such as pile-on, pod-station visits, robot moving distance and order turn-over time. We compare the results of our models in different instances with the sequential method in our open-source simulation framework RAWSim-O

Deterministic Pod Repositioning Problem in Robotic Mobile Fulfillment Systems

In a robotic mobile fulfillment system, robots bring shelves, called pods, with storage items from the storage area to pick stations. At every pick station there is a person -- the picker -- who takes parts from the pod and packs them into boxes according to orders. Usually there are multiple shelves at the pick station. In this case, they build a queue with the picker at its head. When the picker does not need the pod any more, a robot transports the pod back to the storage area. At that time, we need to answer a question: "Where is the optimal place in the inventory to put this pod back?". It is a tough question, because there are many uncertainties to consider before answering it. Moreover, each decision made to answer the question influences the subsequent ones. The goal of this paper is to answer the question properly. We call this problem the Pod Repositioning Problem and formulate a deterministic model. This model is tested with different algorithms, including binary integer programming, cheapest place, fixed place, random place, genetic algorithms, and a novel algorithm called tetris

Design and Development of an automated Robotic Pick & Stow System for an e-Commerce Warehouse

In this paper, we provide details of a robotic system that can automate the task of picking and stowing objects from and to a rack in an e-commerce fulfillment warehouse. The system primarily comprises of four main modules: (1) Perception module responsible for recognizing query objects and localizing them in the 3-dimensional robot workspace; (2) Planning module generates necessary paths that the robot end- effector has to take for reaching the objects in the rack or in the tote; (3) Calibration module that defines the physical workspace for the robot visible through the on-board vision system; and (4) Gripping and suction system for picking and stowing different kinds of objects. The perception module uses a faster region-based Convolutional Neural Network (R-CNN) to recognize objects. We designed a novel two finger gripper that incorporates pneumatic valve based suction effect to enhance its ability to pick different kinds of objects. The system was developed by IITK-TCS team for participation in the Amazon Picking Challenge 2016 event. The team secured a fifth place in the stowing task in the event. The purpose of this article is to share our experiences with students and practicing engineers and enable them to build similar systems. The overall efficacy of the system is demonstrated through several simulation as well as real-world experiments with actual robots.Comment: 15 Pages, 25 Figures, 4 Tables, Journal Pape

Order allocation, rack allocation and rack sequencing for pickers in a mobile rack environment

In this paper we investigate the problem of simultaneously allocating orders and mobile storage racks to static pickers. Here storage racks are allocated to pickers to enable them to pick all of the products for the orders that have been allocated to them. Problems of the type considered here arise in facilities operating as robotic mobile fulfilment systems. We present a formulation of the problem of allocating orders and racks to pickers as an integer program and discuss the complexity of the problem. We present two heuristics (matheuristics) for the problem, one using partial integer optimisation, that are directly based upon our formulation. We also consider the problem of how to sequence the racks for presentation at each individual picker and formulate this problem as an integer program. We prove that, subject to certain conditions being satisfied, a feasible rack sequence for all orders can be produced by focusing on just a subset of the orders to be dealt with by the picker. Computational results are presented, both for order and rack allocation, and for rack sequencing, for randomly generated test problems (that are made publicly available) involving up to 500 products, 150 orders, 150 racks and 10 pickers

Decentralized identification and control of networks of coupled mobile platforms through adaptive synchronization of chaos

In this paper we propose an application of adaptive synchronization of chaos to detect changes in the topology of a mobile robotic network. We assume that the network may evolve in time due to the relative motion of the mobile robots and due to unknown environmental conditions, such as the presence of obstacles in the environment. We consider that each robotic agent is equipped with a chaotic oscillator whose state is propagated to the other robots through wireless communication, with the goal of synchronizing the oscillators. We introduce an adaptive strategy that each agent independently implements to: (i) estimate the net coupling of all the oscillators in its neighborhood and (ii) synchronize the state of the oscillators onto the same time evolution. We show that by using this strategy, synchronization can be attained and changes in the network topology can be detected. We go one step forward and consider the possibility of using this information to control the mobile network. We show the potential applicability of our technique to the problem of maintaining a formation between a set of mobile platforms, which operate in an inhomogeneous and uncertain environment. We discuss the importance of using chaotic oscillators and validate our methodology by numerical simulations.Comment: 17 pages, 10 figures, accepted for publication in Physica

Dealing with Run-Time Variability in Service Robotics: Towards a DSL for Non-Functional Properties

Service robots act in open-ended, natural environments. Therefore, due to combinatorial explosion of potential situations, it is not possible to foresee all eventualities in advance during robot design. In addition, due to limited resources on a mobile robot, it is not feasible to plan any action on demand. Hence, it is necessary to provide a mechanism to express variability at design-time that can be efficiently resolved on the robot at run-time based on the then available information. In this paper, we introduce a DSL to express run- time variability focused on the execution quality of the robot (in terms of non-functional properties like safety and task efficiency) under changing situations and limited resources. We underpin the applicability of our approach by an example integrated into an overall robotics architecture.Comment: Presented at DSLRob 2012 (arXiv:cs/1302.5082

Path planning for Robotic Mobile Fulfillment Systems

This paper presents a collection of path planning algorithms for real-time movement of multiple robots across a Robotic Mobile Fulfillment System (RMFS). Robots are assigned to move storage units to pickers at working stations instead of requiring pickers to go to the storage area. Path planning algorithms aim to find paths for the robots to fulfill the requests without collisions or deadlocks. The state-of-the-art path planning algorithms, including WHCA*, FAR, BCP, OD&ID and CBS, were adapted to suit path planning in RMFS and integrated within a simulation tool to guide the robots from their starting points to their destinations during the storage and retrieval processes. Ten different layouts with a variety of numbers of robots, floors, pods, stations and the sizes of storage areas were considered in the simulation study. Performance metrics of throughput, path length and search time were monitored. Simulation results demonstrate the best algorithm based on each performance metric

The Swarmathon: An Autonomous Swarm Robotics Competition

The Swarmathon is a swarm robotics programming challenge that engages college students from minority-serving institutions in NASA's Journey to Mars. Teams compete by programming a group of robots to search for, pick up, and drop off resources in a collection zone. The Swarmathon produces prototypes for robot swarms that would collect resources on the surface of Mars. Robots operate completely autonomously with no global map, and each team's algorithm must be sufficiently flexible to effectively find resources from a variety of unknown distributions. The Swarmathon includes Physical and Virtual Competitions. Physical competitors test their algorithms on robots they build at their schools; they then upload their code to run autonomously on identical robots during the three day competition in an outdoor arena at Kennedy Space Center. Virtual competitors complete an identical challenge in simulation. Participants mentor local teams to compete in a separate High School Division. In the first 2 years, over 1,100 students participated. 63% of students were from underrepresented ethnic and racial groups. Participants had significant gains in both interest and core robotic competencies that were equivalent across gender and racial groups, suggesting that the Swarmathon is effectively educating a diverse population of future roboticists.Comment: Paper presented May 2018 at ICRA 2018 Workshop: "Swarms: From Biology to Robotics and Back

Tight Robot Packing in the Real World: A Complete Manipulation Pipeline with Robust Primitives

Many order fulfillment applications in logistics, such as packing, involve picking objects from unstructured piles before tightly arranging them in bins or shipping containers. Desirable robotic solutions in this space need to be low-cost, robust, easily deployable and simple to control. The current work proposes a complete pipeline for solving packing tasks for cuboid objects, given access only to RGB-D data and a single robot arm with a vacuum-based end-effector, which is also used as a pushing or dragging finger. The pipeline integrates perception for detecting the objects and planning so as to properly pick and place objects. The key challenges correspond to sensing noise and failures in execution, which appear at multiple steps of the process. To achieve robustness, three uncertainty-reducing manipulation primitives are proposed, which take advantage of the end-effector's and the workspace's compliance, to successfully and tightly pack multiple cuboid objects. The overall solution is demonstrated to be robust to execution and perception errors. The impact of each manipulation primitive is evaluated in extensive real-world experiments by considering different versions of the pipeline. Furthermore, an open-source simulation framework is provided for modeling such packing operations. Ablation studies are performed within this simulation environment to evaluate features of the proposed primitives