EP4680533A2 - Lagersystem zum ein- und auslagern von lagergut in behältern - Google Patents

Lagersystem zum ein- und auslagern von lagergut in behältern

Info

Publication number
EP4680533A2
EP4680533A2 EP24775408.8A EP24775408A EP4680533A2 EP 4680533 A2 EP4680533 A2 EP 4680533A2 EP 24775408 A EP24775408 A EP 24775408A EP 4680533 A2 EP4680533 A2 EP 4680533A2
Authority
EP
European Patent Office
Prior art keywords
container
goods
closing
lid
transport
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP24775408.8A
Other languages
English (en)
French (fr)
Inventor
Jeffrey Adam TRAINA
Matt BRECHER
Rich BENDER
Erik Cussins
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Symbotic Inc
Original Assignee
Symbotic Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Symbotic Inc filed Critical Symbotic Inc
Publication of EP4680533A2 publication Critical patent/EP4680533A2/de
Pending legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
    • B65G1/00—Storing articles, individually or in orderly arrangement, in warehouses or magazines
    • B65G1/02—Storage devices
    • B65G1/04—Storage devices mechanical
    • B65G1/137—Storage devices mechanical with arrangements or automatic control means for selecting which articles are to be removed
    • B65G1/1373—Storage devices mechanical with arrangements or automatic control means for selecting which articles are to be removed for fulfilling orders in warehouses
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B1/00—Packaging fluent solid material, e.g. powders, granular or loose fibrous material, loose masses of small articles, in individual containers or receptacles, e.g. bags, sacks, boxes, cartons, cans, or jars
    • B65B1/20—Reducing volume of filled material
    • B65B1/22—Reducing volume of filled material by vibration
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B7/00—Closing containers or receptacles after filling
    • B65B7/16—Closing semi-rigid or rigid containers or receptacles not deformed by, or not taking-up shape of, contents, e.g. boxes or cartons
    • B65B7/26—Closing semi-rigid or rigid containers or receptacles not deformed by, or not taking-up shape of, contents, e.g. boxes or cartons by closing hinged lids
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
    • B65G1/00—Storing articles, individually or in orderly arrangement, in warehouses or magazines
    • B65G1/02—Storage devices
    • B65G1/04—Storage devices mechanical
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
    • B65G1/00—Storing articles, individually or in orderly arrangement, in warehouses or magazines
    • B65G1/02—Storage devices
    • B65G1/04—Storage devices mechanical
    • B65G1/0492—Storage devices mechanical with cars adapted to travel in storage aisles

Definitions

  • the disclosed embodiment generally relates to material handling systems, and more particularly, to transport and storage of items within the material handling system.
  • any given order container may have mixed/different products or product types held by a common container such as in cases of direct to consumer fulfillment, or if indirect to consumer, such as via a retail order pick up location, the ordered mix of products in the order container is generated, at least in part, at the logistic facility prior to output from the logistic facility) conventionally, generation of mixed product containers is effected with the automated storage and retrieval system goods to person configuration by the automated storage and retrieval system outputting the product/supply containers (each containing one or more goods items of a common good type, i.e.
  • each goods item in the product container is the same or substantially similar) from storage locations throughout the three-dimensional array of storage racks to workstations, manual or automated, to pick and remove goods from the different product/supply containers, fed by the automated storage and retrieval system to the given workstation, pursuant to a given fulfillment (or fill) order, and to place the different picked goods (mixed or common if a given order contained is so filled) into order containers.
  • Such workstations may be referred to as breakpack stations, wherein the product container is “broken” down and its contents may be placed in order containers in whole or in part, or into what may be referred to as a breakpack storage container (e.g., totes) such as where the product container is unsuitable for continued holding of remaining product items after the breakpack operation, and such remaining products (i.e., the remainder of products in the “broken” down product container) should be returned to storage in the three-dimensional array of storage racks by the automated storage and retrieval system.
  • the products placed in the order containers are placed loosely within the container by automation such that the product packing within the order container is less than ideal. Further, after the order container is filled the order container remains open and must be closed prior to placement on a storage shelf, in a pallet load, or in a customer (e.g., e-commerce) shipment.
  • FIG. 1A is a schematic illustration of an automated storage and retrieval system in accordance with aspects of the disclosed embodiment
  • FIGs. IB, 1C, and ID are schematic illustrations of portions of the automated storage and retrieval system in accordance with aspects of the disclosed embodiment
  • Fig. IE is a schematic illustration of a mixed pallet load formed by the automated storage and retrieval system in accordance with aspects of the disclosed embodiment
  • FIG. IF is a schematic illustration of a portion of the automated storage and retrieval system in accordance with aspects of the disclosed embodiment
  • FIG. 1G is a schematic illustration of a portion of the automated storage and retrieval system in accordance with aspects of the disclosed embodiment
  • FIGS. 2A, 2B, 2C, 2D, and 2E arc schematic illustrations of portions of the storage and retrieval system in accordance with aspects of the disclosed embodiment
  • FIG. 3 A is a schematic illustration of a transport vehicle in accordance with aspects of the disclosed embodiment
  • FIG. 3B is a schematic illustration of a transport vehicle in accordance with aspects of the disclosed embodiment
  • FIG. 4 is a schematic illustration of a goods settling and container closing station of the automated storage and retrieval system in accordance with aspects of the disclosed embodiment
  • FIG. 5A is a schematic perspective illustration of a goods settling apparatus of the goods settling and container closing station of Fig. 4 in accordance with aspects of the disclosed embodiment
  • Fig. 5B is another schematic perspective illustration of a goods settling apparatus, with portions removed for clarity, in accordance with aspects of the disclosed embodiment
  • FIGs. 5C and 5D are respectively rear and front schematic illustrations of the goods settling apparatus of Fig. 5A in accordance with aspects of the disclosed embodiment
  • FIG. 5E is a front schematic illustration of the goods settling apparatus of Fig. 5A in accordance with aspects of the disclosed embodiment
  • FIG. 6A is a schematic perspective illustration of a container closing bay of the goods settling and container closing station of Fig. 4 in accordance with aspects of the disclosed embodiment
  • FIG. 6B is a schematic plan illustration of the container closing bay of Fig. 6A in accordance with aspects of the disclosed embodiment
  • FIG. 7 A is schematic side illustration of the container closing bay of Fig. 6 A in accordance with aspects of the disclosed embodiment
  • FIG.7B is a schematic end illustration of the container closing bay of Fig. 6A in accordance with aspects of the disclosed embodiment
  • FIG. 8A is a sequence of schematic illustrations showing a guided closing movement of a container that is effected with the container closing bay of Fig. 6A in accordance with aspects of the disclosed embodiment
  • FIG. 8B is a schematic illustration of the container of Fig. 8A in a partially closed configuration in accordance with aspects of the disclosed embodiment
  • Fig. 9 is a sequence of schematic illustrations showing a portion of a guided closing movement of a container that is effected with the container closing bay of Fig. 6A in accordance with aspects of the disclosed embodiment
  • FIG. 10A is a schematic plan illustration of the container closing bay of Fig. 6A in accordance with aspects of the disclosed embodiment
  • FIG. 10B is a schematic plan illustration of the container closing bay of Fig. 6A in accordance with aspects of the disclosed embodiment
  • FIGs. 11A-11F are schematic illustrations of a container closing bay of the goods settling and container closing station of Fig. 4 in accordance with aspects of the disclosed embodiment.
  • the automated storage and retrieval system 100 may operate in a retail distribution center or warehouse to, for example, fulfill orders received from retail stores for case units such as those described in United States Patent number 10,822,168 issued on November 3, 2020, the disclosure of which is incorporated by reference herein in its entirety.
  • the case units are cases or units of goods not stored in trays, on totes or on pallets (e.g. uncontained).
  • the case units are cases or units of goods that are contained in any suitable manner such as in trays, on totes, in containers (such as containers of remainder goods after breakpack where the broken down case unit structure is unsuitable for transport of the remainder goods as a unit) or on pallets.
  • orders for filled items may be stochastic (e.g., substantially random in the items ordered and a time the order is received) and may be fulfilled by the automated storage and retrieval system 100 as function of time (e.g., sortation of ordered goods at a predetermined scheduled time in advance of a time the order is to ship/be fulfilled or in a sortation of goods in a just-in-time manner).
  • stochastic orders are determinative of a pick sequence of sorted items, such as for building a pallet load or pallet PAL as described herein with respect to Fig.
  • the automated storage and retrieval system 100 includes one or more breakpack modules or stations 266 (see Fig. 2C).
  • the breakpack modules 266 are configured to break down product containers or case units CU into breakpack goods containers 264 (also referred to herein as goods containers or mixed product unit containers) for order fulfillment.
  • the breakpack goods containers 264 (referring briefly to Fig. 8B) are, for exemplary purposes (although the container may have any suitable configuration), containers having a bin portion 264B, in which goods are placed, and lid portions 264L1, 264L2 that are attached to bin portion 264B by respective hinges.
  • the automated storage and retrieval system 100 may include (in addition to or in lieu of the breakpack modules 266) one or more each pick modules substantially similar to those described in United States patent number 9,037,286 issued on May 19, 2015 (the disclosure of which is incorporated herein by reference), where the breakpack containers 264 are filled by human or robotic operators and output for transport by the container bots 110 in a manner substantially similar to that described herein with respect to the breakpack modules 266. Containers from these each pick modules may also be transported to the at least one goods settling and container closing station 155, in the manner described herein, for settling of the products and closing of the containers.
  • One or more breakpack modules 266 and one or more goods settling and container closing stations 155 may be located on a common level 130L of the automated storage and retrieval system, where one or more levels of the automated storage and retrieval system 100 include at least one breakpack module 266 and at least one goods settling and container closing station 155.
  • the goods settling and container closing station(s) 155 may be plug and play module(s) 155M (see Fig. 2 A) that may be coupled to any suitable portion of the structure of the automated storage and retrieval system 100.
  • the goods settling and container closing station(s) 155 may be coupled to a container transfer deck 130DC or picking (or pick) aisle(s) 130A of the automated storage and retrieval system 100.
  • the goods settling and container closing station(s) 155 may be disposed on any suitable number of stacked storage levels of the automated storage and retrieval system 100 and may form a stacked gang 155SG of goods settling and container closing stations 155 (see Fig. 1G).
  • the goods settling and container closing stations 155 have a synchronous transport (as described herein - see Fig. 1G) that transport containers 264 to one or more of at least one container settler 420 and at least one container lid closer 430 of the goods settling and container closing stations 155.
  • the synchronous transport is a ganged system with multiple ganged transport paths CTP (see also Fig.
  • each respective level of the ganged system has an output interface station 402 configured to communicate with an asynchronous container transport (as described herein - see Fig.
  • the output interface stations 402 form a multi-level output of the ganged system that is communicably connected via the asynchronous container transport to a lift 150.
  • the automated storage and retrieval system 100 is configured to break down product cases, product containers, and/or case units and output breakpack goods containers, product cases, containers, and/or case units to a palletizer, or in other aspects, re-enter the breakpack (order) container(s) and/or a remainder of a product cases, containers, and/or case units to a palletizer (e.g., after being broken down) into storage for later retrieval.
  • the at least one goods settling and container closing station 155 is configured to effect settling of the goods in a container and closing of a container prior to palletization and/or return to storage.
  • the controller 120 is configured to effect operation of a container bot 110 and a goods bot 262 (both of which form at least part of an asynchronous transport system) (see also, e.g., Fig. 2C) for assembling orders of breakpack goods BPG from supply containers 265 into breakpack goods containers 264 and outfeed of breakpack goods containers 264 through container outfeed stations TS as will be described herein.
  • the controller 120 is configured to effect operation of the container bot(s) 110 between the container storage locations 130S, the breakpack operation station 140, the goods settling and container closing station 155, and a breakpack goods container 264 located along the breakpack goods transfer deck 130DG.
  • the controller 120 is configured to effect operation of the container bot(s) 110 so that the container bot(s) 110 accesses corresponding breakpack goods containers 264 at the goods transfer deck 130DG and transports the breakpack goods containers 264 via traverse along the container transfer deck 130DC to at least one of the goods settling and container closing station 155 and from the at least one goods settling and container closing station 155 to at least one of a container output/transfer station TS and a corresponding container storage location 130SB of storage shelves of a corresponding level 130L of the multilevel storage array.
  • each pallet may be uniform (e.g. each pallet holds a predetermined number of the same item - one pallet holds soup and another pallet holds cereal).
  • the cases of such pallet load may be substantially similar or in other words, homogenous cases (e.g. similar dimensions), and may have the same SKU (otherwise, as noted before the pallets may be “rainbow” pallets having layers formed of homogeneous cases).
  • the pallets PAL may contain any suitable number and combination of different case units CU (e.g., each pallet may hold different types of case units - a pallet holds a combination of canned soup, cereal, beverage packs, cosmetics and household cleaners).
  • the cases combined onto a single pallet may have different dimensions and/or different SKU’ s.
  • the storage and retrieval system 100 may be configured to generally include an in-feed section, a storage and sortation section (where, in one aspect, storage of items is optional) and an output section as will be described in greater detail below.
  • the system 100 operating for example as a retail distribution center may serve to receive uniform pallet loads of cases, breakdown the pallet goods or disassociate the cases from the uniform pallet loads into independent case units handled individually by the system, retrieve and sort the different cases sought by each order into corresponding groups, and transport and assemble the corresponding groups of cases into what may be referred to as mixed case pallet loads MPL.
  • the system 100 operating for example as a retail distribution center may serve to receive uniform pallet loads of cases, breakdown the pallet goods or disassociate the cases from the uniform pallet loads into independent case units handled individually by the system, retrieve and sort the different cases sought by each order into corresponding groups, and transport and sequence the corresponding groups of cases in the manner described in United States patent number 9,856,083 issued on January 2, 2018, the disclosure of which is incorporated herein by reference in its entirety.
  • the storage and sortation section includes, as will be described in greater detail below, a multilevel automated storage system that has an automated transport system that in turn receives or feeds individual cases into the multilevel storage array for storage in a storage area (such as storage spaces 130S of the storage structure 130).
  • the storage and sortation section also defines outbound transport of case units from the multilevel storage array such that desired case units are individually retrieved in accordance with commands generated in accordance to orders entered into a warehouse management system, such as warehouse management system 2500, for transport to the output section.
  • the storage and sortation section receives individual cases, sorts the individual cases (utilizing, for example, the buffer and interface stations described herein), e.g., in a case level sortation, and transfers the individual cases to the output section in accordance to orders entered into the warehouse management system.
  • the sorting and grouping of cases according to order may be performed in whole or in part by either the storage and retrieval section or the output section, or both, the boundary between being one of convenience for the description and the sorting and grouping being capable of being performed any number of ways.
  • the intended result is that the output section assembles the appropriate group of ordered cases, that may be different in SKU, dimensions, etc. into mixed case pallet loads in the manner described in, for example, United States patent number 8,965,559 issued on February 24, 2015 and titled “Pallet Building System,” the disclosure of which is incorporated herein by reference in its entirety.
  • the output section generates the pallet load in what may be referred to as a structured architecture of mixed case stacks.
  • the structured architecture of the pallet load described herein is representative and in other aspects, the pallet load may have any other suitable configuration.
  • the structured architecture may be any suitable predetermined configuration such as a truck bay load or other suitable container or load container envelope holding a structural load.
  • the structured architecture of the pallet load may be characterized as having several flat case layers L121-L125, L12T as described in United States patent number 9,856,083, previously incorporated by reference herein in its entirety.
  • the automated storage and retrieval system 100 includes a storage array (e.g., storage structure 130 having storage spaces 130S) with at least one elevated storage level 130L.
  • a storage array e.g., storage structure 130 having storage spaces 130S
  • Mixed product units arc input and distributed in the storage array in cases CU of product units of common kind per case CU (each case input to the system 100 holds a common kind of stock keeping unit (SKU)).
  • the automated storage and retrieval system 100 includes input stations 160IN (which include depalletizers 160PA and/or conveyors 160CA for transporting items (e.g., inbound supply containers) to lift modules 150A for entry into a storage level 130L of the storage structure 130).
  • the automated storage and retrieval system 100 includes an automated transport system (e.g., hots, breakpack modules, goods settling and container closing stations, and other suitable level transports described herein) with at least one asynchronous transport system for transporting cases/products on a given storage structure level 130L (e.g., level transport).
  • the automated storage and retrieval system 100 includes at least one storage level 130L having storage aisles (also referred to herein as picking aisles) 130A and a transport deck (also referred to herein as a container transport deck) 130DC connecting the storage aisles 130A.
  • At least one breakpack station 140 is communicably coupled to the transfer deck 130DC.
  • At least one goods settling and container closing stations 155 are communicably coupled to the transfer deck 130DC by an asynchronous transport system (described herein) and at least one autonomous guided vehicle (also referred to herein as a containers bot) 262 (e.g., of the asynchronous transport system) is configured to traverse the transfer deck 130DC (as describe herein) and transport goods containers 264, having breakpack goods BPG therein, from at least one breakpack station 140 to the at least one goods settling and container closing station 155.
  • asynchronous transport system described herein
  • at least one autonomous guided vehicle also referred to herein as a containers bot
  • the at least one lift 150B is communicably connected to the storage array as described herein so as to automatically retrieve and output, from the storage array, product units distributed in the cases CU in a common part (e.g., the storage locations 130S of a respective storage level 130L) of the at least one elevated storage level 130L of the storage array.
  • the output product units being one or more of mixed singulated product units, in mixed packed groups, and in mixed cases.
  • the automated storage and retrieval system 100 includes output stations 160UT, 160EC (which include palletizers 160PB, operator stations 160EP and/or conveyors 160CB for transporting items (e.g., outbound supply containers and filled breakpack goods (order) containers) from lift modules 150B for removal from storage (e.g., to a palletizer (for palletizer load) or to a truck (for truck load)).
  • the output station 160EC is an individual fulfillment (or e-commerce) output station where, for example, filled breakpack goods (order) containers including single goods items and/or small bunches of goods are transported for fulfilling an individual fulfillment order (such as an order placed over the Internet by a consumer).
  • the output station 160UT is a commercial output station where large numbers of goods are generally provided on pallets for fulfilling orders from commercial entities (e.g., commercial stores, warehouse clubs, restaurants, etc.).
  • commercial entities e.g., commercial stores, warehouse clubs, restaurants, etc.
  • the automated storage and retrieval system 100 includes both the commercial output station 160UT and the individual fulfillment output station 160EC; while in other aspects, the automated storage and retrieval system includes one or more of the commercial output station 160UT and the individual fulfillment output station 160EC.
  • the automated storage and retrieval system 100 also includes the input and output vertical lift modules 150A, 150B (generally referred to as lift modules 150 - it is noted that while input and output lift modules are shown, a single lift module may be used to both input and remove case units from the storage structure), a storage structure 130 (which may have at least one elevated storage level as noted above and in some aspects, forms a multilevel storage array), and at least one autonomous container transport vehicle 110 (referred to herein as “container bots” or “autonomous guided vehicles” and which form at least a pail of the asynchronous transport system for level transport) which may be confined to a respective storage level of the storage structure 130 and are distinct from a transfer deck 130DC on which they travel.
  • the input and output vertical lift modules 150A, 150B generally referred to as lift modules 150 - it is noted that while input and output lift modules are shown, a single lift module may be used to both input and remove case units from the storage structure
  • a storage structure 130 which may have at least one elevated storage level as noted above
  • the depalletizers 160PA may be configured to remove case units from pallets so that the input station 160IN can transport the items to the lift modules 150 for input into the storage structure 130.
  • the palletizers 160PB may be configured to place items removed from the storage structure 130 on pallets PAL (Fig. IE) for shipping.
  • the lift modules 150, storage structure 130 and container bots 110 may be collectively referred to herein as the multilevel automated storage system (e.g. storage and sorting section) noted above, which has an integral “on the fly sortation” (e.g. sortation of case units during transport of the case units) so that case unit sorting and throughput occurs substantially simultaneously without dedicated sorters as described in United States patent number 9,856,083, previously incorporated herein by reference in its entirety.
  • the storage structure 130 may include a container autonomous transport travel loop(s) 233, 233A (e.g., formed on and along a container transfer deck 130DC), disposed at a respective level of the storage structure 130.
  • the lifts 150 are connected via transfer stations TS (also referred to herein as container infeed stations when the lift 150 is an inbound lift 150A or as container outfeed stations when the lift 150 is an outbound lift 150B) to the container transfer deck 130DC, and each lift is configured to lift one or both of supply containers 265 (empty or filled) (see Fig. 2C) and the breakpack goods containers 264 (empty or filled) (see Fig.
  • Container storage locations (or spaces) 130S are arrayed peripherally along the container transfer deck 130DC.
  • multiple storage rack modules RM configured in a high density three dimensional rack array RMA, are accessible by storage or deck levels 130L.
  • high density three dimensional rack array refers to the three dimensional rack array RMA having undeterministic open shelving distributed along picking aisles 130A where, in some aspects, multiple stacked shelves are accessible from a common picking aisle travel surface or picking aisle level as described in United States patent number 9,856,083, previously incorporated by reference herein in its entirety.
  • Each storage level 130L includes pickface storage/handoff spaces 130S (referred to herein as storage spaces 130S or container storage locations 1308) arrayed peripherally along the container transfer deck 130DC. At least one of the storage locations 130S is a supply container storage location 130SS, and another of the container storage locations is a breakpack goods (or order) container storage location 130SB.
  • the storage spaces 130S are in one aspect formed by the rack modules RM where the rack modules include shelves that are disposed along storage or picking aisles 130A (that are connected to the container transfer deck 130DC) which, e.g., extend linearly through the rack module array RM A and provide container hot 110 access to the storage spaces 130S and transfer deck(s) 130B.
  • the shelves of the rack modules RM are arranged as multi-level shelves that are distributed along the picking aisles 130A.
  • the container bots 110 travel on a respective storage level 130L along the picking aisles 130A and the container transfer deck 130DC for transferring case units between any of the storage spaces 130S of the storage structure 130 (e.g. on the level which the container bot 110 is located) and any of the lift modules 150 (e.g. each of the container bots 110 has access to each storage space 130S on a respective level and each lift module 150 on a respective storage level 130L).
  • the transfer decks 130B are arranged at different levels (corresponding to each level 130L of the storage and retrieval system) that may be stacked one over the other or horizontally offset, such as having one container transfer deck 130DC at one end or side RMAE1 of the storage rack array RMA or at several ends or sides RMAE1, RMAE2 of the storage rack array RMA as described in, for example, United States patent number 10,822,168 issued on November 3, 2020, the disclosure of which is incorporated herein by reference in its entirety.
  • the container transfer decks 130DC arc substantially open and configured for the undeterministic traversal of container bots 110 along multiple travel lanes across and along the transfer decks 130B.
  • the multiple travel lanes may be configured to provide multiple access paths or routes to each storage location 130S (e.g., pickface, case unit, container, or other items stored on the storage shelves of rack modules RM) so that container bots 110 may reach each storage location using, for example, a secondary path if a primary path to the storage location is obstructed.
  • the transfer deck(s) 130B at each storage level 130L communicate with each of the picking aisles 130A on the respective storage level 130L.
  • Container bots 110 bi- directionally traverse between the container transfer deck(s) 130DC and picking aisles 130A on each respective storage level 130L so as to travel along the picking aisles and access the storage spaces 130S disposed in the rack shelves alongside each of the picking aisles 130A (e.g. container hots 110 may access storage spaces 130S distributed on both sides of each aisle such that the container bot 110 may have a different facing when traversing each picking aisle 130A, for example, referring to Fig. 3A, drive wheels 202 leading a direction of travel or drive wheels trailing a direction of travel).
  • the container transfer deck(s) 130DC also provides container bot 110 access to each of the lifts 150 on the respective storage level 130L where the lifts 150 feed and remove case units to and/or from each storage level 130L and where the container bots 110 effect case unit transfer between the lifts 150 and the storage spaces 130S.
  • the storage structure 130 includes multiple storage rack modules RM, configured in a three dimensional array RMA where the racks are arranged in aisles 130A.
  • the aisles 130A are configured for container bot 110 travel within the aisles 130A.
  • the container transfer deck 130DC has an undeterministic transport surface on which the container bots 110 travel where the undeterministic transport surface (also referred to herein as a deck surface) I30BS has multiple travel lanes (e.g., more than one juxtaposed travel lane (e.g.
  • high speed bot travel paths HSTP) for travel of the container bot 110 along the container autonomous transport travel loop(s) 233, 233A formed by the container transfer deck 130DC, where the multiple travel lanes connect the aisles 130A.
  • the container autonomous transport travel loop 233A provides the container bot 110 with random access to any and each picking aisle 130A and random access to any and each lift 150A, 150B on the respective level 130L of the storage structure 130.
  • At least one of the multiple travel lanes has a travel sense opposite to another travel lane sense of another of the multiple travel lanes (so as to form the container autonomous transport travel loop 233).
  • the storage and retrieval system 100 may include one or more bypass aisles 132 that run substantially transverse to the picking aisles 130 to allow the container bots 110 to move between picking aisles 130 in lieu of traversing the container transfer decks 130DC, 130DC2.
  • the bypass aisles 132 may be substantially similar to travel lanes of the container transfer decks 130DC, 130DC2, as described herein, and may allow bidirectional or unidirectional travel of the container bots through the bypass aisle 132.
  • the bypass aisle 132 may provide one or more lanes of container bot travel where each lane has a floor and suitable guides for guiding the bot along the bypass aisle 132 in a manner similar to that described herein with respect to the transfer decks 130DC, 130DC2.
  • bypass aisles 132 may have any suitable configuration for allowing the container bots 110 to traverse between the picking aisles 130. It is noted that while the bypass aisle 132 is shown with respect to a storage and retrieval system having transfer decks 130DC, 130DC2 disposed on opposite ends of the storage structure, in other aspects, a storage and retrieval system 100 having only one transfer deck may also include one or more bypass aisles 132.
  • breakpack module 266 AL may be located on a side of the container transfer deck 130DC on which the picking aisles 130A are located and one or more picking aisles 130A extend into the breakpack module 266AL so as to form container bot riding surface(s) 266RS.
  • a goods settling and container closing station 155 AL may be located on a side of the container transfer deck 130DC on which the picking aisles 130A are located and one or more picking aisles 130 A extend into the goods settling and container closing station 155 AL so as to form container bot riding surface(s) 155RS.
  • the bypass aisle 132 may be employed to provide a secondary or alternative route for the container bot 110 to transport the supply container 265 to the breakpack module 266AL or the breakpack container 264 to the goods settling and container closing station 155AL.
  • the storage and retrieval systems shown and described herein have exemplary configurations only and in other aspects, the storage and retrieval systems may have any suitable configuration and components for storing and retrieving items as described herein.
  • the storage and retrieval system may have any suitable number of storage sections, any suitable number of transfer decks, any suitable number of breakpack modules, and corresponding input/output stations.
  • the juxtaposed travel lanes are juxtaposed along a common undeterministic transport surface 130BS between opposing sides 130BD1, 130BD2 of the container transfer deck 130DC.
  • the aisles 130A are joined to the container transfer deck 130DC on one side 130BD2 of the container transfer deck 130DC but in other aspects, the aisles are joined to more than one side 130BD1, 130BD2 of the container transfer deck 130DC in a manner substantially similar to that described in United States patent number 10,822,168 issued on November 3, 2020, the disclosure of which is previously incorporated by reference herein in its entirety.
  • the other side 130BD1 of the container transfer deck 130DC may include deck storage racks (e.g.
  • interface stations also referred to as transfer stations
  • TS and buffer stations BS that are distributed along the other side 130BD1 of the container transfer deck 130DC so that at least one part of the transfer deck is interposed between the deck storage racks (such as, for example, buffer stations BS or transfer stations TS) and the aisles 130A.
  • the deck storage racks are arranged along the other side 130BD1 of the container transfer deck 130DC so that the deck storage racks communicate with the container bots 110 from the container transfer deck 130DC and with the lift modules 150 (e.g.
  • the deck storage racks are accessed by the container bots 110 from the container transfer deck 130DC and by the lifts 150 for picking and placing pickfaces so that pickfaces are transferred between the container bots 110 and the deck storage racks and between the deck storage racks and the lifts 150 and hence between the container bots 110 and the lifts 150).
  • each storage level 130L may also include charging stations 130C for charging an on-board power supply of the container bots 110 on that storage level 130L such as described in, for example, United States patent application number 14/209,086 filed on March 13, 2014 and United States patent number 9,082,112 issued on July 14, 2015, the disclosures of which are incorporated herein by reference in their entireties.
  • each breakpack module 266 has a container bot riding surface 266RS that forms a portion 130DCP of the container transfer deck 130DC, where the riding surface 2666RS is substantially similar to that of container transfer deck 130DC, while in other aspects, the container bot riding surface 266RS may be substantially similar to that of the picking aisles 130A.
  • the aspects of the disclosed embodiment will refer to the container bot riding surface 266RS within the breakpack module 266 as a portion of the container transfer deck 130DC.
  • the transport loop of the breakpack module 266 may be a multilane transport loop substantially similar to container transport deck illustrated in Fig. 2A.
  • the container bot travel surface 266RS is an open undeterministic travel surface having multiple travel inbound and outbound lanes. For example, there are multiple inbound travel lanes TL1, TL2 where travel lane TL2 is a bypass lane for travelling around obstructions on travel lane TL1 (or vice versa).
  • travel lane TL5 defines a queue lane 130QL (Fig. 2C) for the container bots 110 at the breakpack goods interface 263 while travel lanes TL4 and TL5 may be used for egress from the breakpack module 266, with travel lane TL5 being a bypass for travelling around obstructions on travel lane TL4 (or vice versa).
  • Each of the breakpack modules 266 includes a breakpack goods autonomous transport travel loop 234 (see exemplary breakpack goods autonomous transport travel loops 234A-234E formed on and along a goods deck or goods transfer deck 130DG), at least one breakpack operation station 140, and a breakpack goods interface 263 disposed between and interfacing the goods transfer deck 130DG with the container transfer deck 130DC.
  • the goods deck 130DG is illustrated as having three travel lanes that form the (variable length) travel loops 234A-234E; however, in other aspects, the goods deck may have any suitable number of travel lanes that form any suitable number of breakpack goods autonomous transport travel loops 234.
  • each component of the breakpack modules 166 is independent (e.g., self-contained as a unit) and/or independently automated in guidance and travel of the bots (e.g., goods bots 262) from the components of the automated storage and retrieval system, so that the interface between the components of the breakpack modules 266 and the components of the automated storage and retrieval system 100 is undeterministic.
  • the breakpack module(s) 266 may be coupled to the structure of the automated storage and retrieval system 100 at any suitable location and at any suitable level(s) 130L.
  • a break pack module 266 may be located at one or more ends 130BE1, 130BE2 of the container transfer deck 130DC or at one or more sides 130BD1, 130BD2 of the container transfer deck 130DC (such as in lieu of storage rack modules RM/picking aisles 130A or lifts 150A, 150B, or as an extension of one or more picking aisles 130A).
  • Each of the breakpack modules 266 is a plug and play module that is integrated with (or otherwise connected to) the container transfer deck 130DC so that the container transfer deck 130DC is communicably coupled to the container bot riding surface 266RS.
  • the container bot riding surface 266RS is formed by rails 1200S the riding surface may include an undeterministic turn around area 1200UTA (that is similar to the open undeterministic container transfer deck 130DC) on which the container bots 110 turn to transition between different travel portions (e.g., inbound and outbound) of the breakpack goods autonomous transport travel loop 234.
  • Fig. 2C queue lane 130QL
  • the container bot travel surface 266RS of the breakpack module 266 forms a travel loop 233 around which the container bots 110 travel to respectively transport along the container bot travel surface 266RS travel loop 233 a supply container (e.g., case unit, pickface, remainder container, etc.) between the storage locations 130S and a breakpack operation station 140 (and/or vice versa), and a breakpack goods container (also referred to as a breakpack container) 264 between the breakpack goods interface 263 and the breakpack goods container storage location 130SB or a lift 150A (and/or vice versa).
  • the travel loop 233 provides the container bot 110 with random access to any and each breakpack goods interface locations 263L of the breakpack goods interface 263 along the bot travel surface 266RS, where the breakpack goods interface locations 263L form an asynchronous product distribution system.
  • the goods transfer deck 130DG forms a goods autonomous transport travel loop 234 disposed at the storage level 130L.
  • the goods transfer deck 130DG is separate and distinct from the travel loop 233 formed by the container bot travel surface 266RS, and has the breakpack goods interface 263 coupling respective edges of the container autonomous transport travel loop 233 of the container transfer deck 130DC and the breakpack goods autonomous transport travel loop 234 of the goods transfer deck 130DG.
  • the goods autonomous transport travel loop 234 formed by the goods transfer deck 130DG is disposed on a deck surface 130DGS of a deck (e.g., goods transfer deck 130DG) at a respective storage level 130L, and the breakpack goods autonomous transport travel loop(s) 234 of the goods transfer deck 130DG is disposed on a different deck surface 130DGS of the deck (e.g., goods transfer deck 130DG), separate and distinct from the deck surface 130BS of the container bot travel surface 266RS (formed by the container transfer deck 130DC and/or rails 1200S) where the container autonomous transport travel loop 233 is disposed.
  • a deck surface 130DGS of a deck e.g., goods transfer deck 130DG
  • the breakpack goods autonomous transport travel loop(s) 234 of the goods transfer deck 130DG is disposed on a different deck surface 130DGS of the deck (e.g., goods transfer deck 130DG), separate and distinct from the deck surface 130BS of the container bot travel surface 266RS (formed by the container transfer deck 130DC and/or rails
  • the breakpack goods autonomous transport travel loop 234 formed by the goods transfer deck 130DG (and hence the goods travel deck 130DG) is disposed to confine at least one autonomous breakpack goods transport vehicle (also referred to as goods bots, or goods transport vehicles) 262 to the respective storage level 130L.
  • the at least one goods bot 262 is arranged or otherwise configured for transporting, along the breakpack goods autonomous transport travel loop 234 formed by the goods transfer deck 130DG, one or more breakpack goods BPG (e.g., a pack that is unpacked from the supply container in a pack level sort or a unit/each unpacked from a pack in a unit/each level sort) between the breakpack operation station 140 and the breakpack goods interface 263.
  • the container bot(s) 110 is also configured to autonomously pick and place the breakpack goods containers 264 at the breakpack goods interface 263 as described herein.
  • the breakpack goods interface 263 may be substantially similar to one or more of the transfer stations TS and buffer stations BS described herein and include an undeterministic surface (similar to that of the rack storage spaces 130S described herein) upon which breakpack goods containers 264 are placed so as to form an undeterministic interface between the goods transfer deck 130DG and the container transfer deck 130DC.
  • the goods transfer deck 130DG facilitates a decanting process where goods are picked from one container (such as a supply container 265 or any other suitable standardized container 265S) at the breakpack operation station 140 and consolidated with goods (generally of the same type) in another (e.g., outbound as noted below) supply container 265 or standardized container 265 S at the breakpack goods interface 263, where the other supply container 265 or standardized container 265S is returned to storage.
  • supply containers 265 inbound to the breakpack modules 266 are picked until empty but only some (not all) of the goods from the inbound supply container may be decanted.
  • outbound i.e., outbound from the breakpack modules 266
  • supply containers 265 or standardized containers 265S may also be placed on the breakpack goods interface 263 by the container bot(s) 110 in a manner similar to that described herein for the breakpack goods containers 264 to facilitate the decanting process.
  • goods are removed from a supply container 265 (which may be an original product/good(s) case packaging) at the breakpack operation station 140 and consolidated into the outbound supply container(s) 265 or standardized container 265S (e.g., having the same type of goods as those being removed at the breakpack operation station 140) located on the breakpack goods interface 263.
  • Consolidation of goods having the same type from multiple supply containers 265 into a lesser number of supply containers 265 (and then returned to storage by the container bot(s) 110) may increase the storage density of the automated storage and retrieval system 100 as the supply containers 265 stored in the storage racks can be maintained in a substantially “full” state (rather than having multiple containers that are less than full with the same type of goods therein.
  • the decanted goods in the standardized container or outbound supply container
  • the goods bots 262 may be any suitable type of autonomously guided bot with a payload configured for holding breakpack goods, not product containers (e.g., case units, pickfaces, etc.). Each of the goods bots 262 has a payload hold configured dissimilar from a payload hold of the container bot 110.
  • the goods bots 262 are configured to autonomously travel unconstrained along and across the breakpack goods autonomous transport travel loop(s) 234 formed by the goods deck 130DG.
  • the goods bots 262 are configured so as to automatically unload one or more breakpack goods BPG (retrieved from the breakpack operation station 140) from the goods bot 262 to breakpack goods containers 264 at the breakpack goods interface 263.
  • Suitable examples of goods bots 262 are those produced by Tompkins International of Raleigh, North Carolina (United States), see for example, United States patent number 10,248,112 issued on April 2, 2019.
  • the breakpack goods autonomous transport travel loop(s) 234 formed by the goods deck 130DG has multiple travel lanes (see Fig. 2C) for travel of the goods bots 262 along the breakpack goods autonomous transport travel loop(s) 234 (see, e.g., travel loops 234A-234E) formed by the goods deck 130DG.
  • three travel lanes are illustrated for exemplary purposes only and in other aspects, there may be more or less than three travel lanes.
  • At least one of the multiple travel lanes is a passing lane for the goods bot 262 travel passing an obstruction on another of the multiple travel lanes in a manner similar to that described herein with respect to the multiple travel lanes of the container transfer deck 130DC.
  • the breakpack goods autonomous transport travel loop(s) 234 provide the goods bots 262 with random access to any and each of the breakpack goods interface locations 263L of the breakpack goods interface 263.
  • One or more portions of the goods transfer deck 130DG can be, in one or more aspects, reserved to provide an exit (or off) ramp or entrance (or on) ramp (see also Fig. 2D) from or to a travel loop travel 234A-234E to effect a transfer of breakpack goods BPG to or from the breakpack goods container(s) 264 (or supply containers 265, 265S) at the breakpack goods interface locations 263L.
  • Exit ramps (referred to herein as ramps 222, 222C, 222R) will be described herein but it should be understood that the entrance ramps are substantially opposite in direction to the exit ramps 222, 222C, 222R (e.g., provide access to rather than access from a travel loop).
  • One or more ramps 222, 222C, 333R are provided depending on, for example, bot 110 kinematics (velocity, direction, etc.) and location(s) of (destination) breakpack goods interface locations 263L (e.g., near corners of the goods transfer deck 130DG, away from the corners of the goods transfer deck 130DG, etc.) being accessed by the goods bots 262.
  • ramp 222 is a generic depiction of an on/off ramp that may be located anywhere on the goods transfer deck 130DG and have any suitable length.
  • Ramp 222C is located in a corner of the goods transfer deck 130DG.
  • Ramp 222R is a “rolling” ramp that moves to follow a path of a goods bot 262 traveling along the ramp 222R, [0060]
  • the ramps 222, 222C, 222R (both on and off ramps) may be “closed” temporarily from general access by the goods bots 262 (e.g., only predetermined goods bots delivering breakpack goods to and from the breakpack goods interface locations 263L within the areas designated by the ramps 222, 222C, 222R have access to respective on and off ramps).
  • the ramps 222, 222C, 222R provide passage to and from a passing lane to a destination breakpack goods interface location 263L.
  • Each ramp 222, 222C, 222R may be bidirectional (such as where a goods bot 2662 enters the ramp and travels in one direction along the ramp to pick or place a breakpack good BPG and then travels in the opposite direction along the ramp to exit from the ramp).
  • the ramp may be a “counter- flow ramp” where travel along a ramp 222, 222C, 222R is in a generally opposing direction to a travel direction around one or more of the travel loop(s) 234 (e.g., a goods bot 262 exits the travel loop and travels in the generally opposing direction along the ramp 222, 222C, 222R).
  • the ramp 222, 222C, 222R is an off ramp
  • the ramp 222, 222C, 222R may terminate at the destination breakpack goods interface location 263L.
  • the ramp 222, 222C, 222R is an on ramp
  • the ramp 222, 222C, 222R may begin at the destination breakpack goods interface location 263L.
  • the ramps 222, 222C, 222R may be located anywhere on the goods transfer deck 130DG such that ramp entry locations vary in what may be referred to as a parking lane (e.g., a lane or a portion of a travel loop in which the goods bot stops to pick or place breakpack goods BPG) based on one or more of bot kinematics and locations of available breakpack goods interface locations 263L.
  • a parking lane e.g., a lane or a portion of a travel loop in which the goods bot stops to pick or place breakpack goods BPG
  • the ramp 222, 222C, 222R is extended to the destination breakpack goods interface location 263L; however, if the blockage does not clear the goods bot 262 travelling along the ramp 222, 222C, 222R is redirected to, for example, a passing lane and a new ramp is calculated/determined so that the goods bot 262 can place breakpack goods BPG at the destination breakpack goods interface location 263L or another destination breakpack goods interface location 263L.
  • the breakpack operation station 140 is configured so that one or more breakpack goods BPG are unpacked from supply container(s) 265 at the breakpack operation station 140, and at least one goods bot 262 is configured so as to be loaded with the one or more breakpack goods BPG at the breakpack operation station 140.
  • the breakpack operation station 140 includes any suitable supply container 265 support surface 140S.
  • the support surface 140S is an undeterministic surface substantially similar to that of the storage shelves described herein and include slats 1210S that form the support surface 140S.
  • the support surface 1408 may be an undeterministic roller conveyor (powered or unpowered), having rollers MORL with an arrangement similar to rollers 110RL (see Figs.
  • the container bot 110 is configured to autonomously transfer the supply container(s) 265 from the container bot 110 to the breakpack operation station 140 (such as to the support surface 1408) in the manner described herein.
  • the support surface 140S may be configured so that as the supply containers 265 are placed by the container bot 110 the supply containers 265 move along the support surface 1408 towards an operator 141 (e.g., a human operator or any suitable robotic operator (e.g., articulated arm, gantry, etc.)) for picking of breakpack goods BPG from the supply containers 265 and placement of the picked breakpack goods to goods bots 262 or to one or more of standardized containers 265S (such as totes, trays, etc.) and breakpack goods containers 264 located at an operator staging area 140A in any suitable manner to effect one or more of a pack level sortation of goods or a unit/each level sortation of goods.
  • an operator 141 e.g., a human operator or any suitable robotic operator (e.g., articulated arm, gantry, etc.)) for picking of breakpack goods BPG from the supply containers 265 and placement of the picked breakpack goods to goods bots 262 or to one or more of standardized containers 265S (such as to
  • the supply containers 265 may be moved along the support surface 140S to a respective operator staging area 140A where the operator 141 picks the breakpack goods BPG from the supply containers 265 for placement in a goods bot 262 or in another container 265S, 264.
  • the operator staging area 140A may be contiguous with and/or formed by the support surface 140S.
  • supply cases 265 with remaining goods therein after breakpack is performed may be picked by the container bots 110 from the support surface 140S or staging area 140A and returned to storage or to a lift 150.
  • Empty supply containers 265 may be removed from the support surface 140S or staging area 140A by the operator 141 and stored at the breakpack operation station 140 for later removal in any suitable manner.
  • container bots 110 may transport empty containers from the storage and retrieval system via the lifts 150.
  • the breakpack operation station 140 includes any suitable refuse removal system 223 for removing refuse (or trash, e.g., shrink wrapping, packaging, boxes, etc.) from the storage and retrieval system.
  • the refuse removal system 223 includes one or more of chutes, conveyors, lifts, or any other suitable transport configured to move refuse to a predetermined location; while in other aspects, the refuse may be placed in containers and removed from the storage and retrieval system by the container bots 110 via the lifts 150. As can be seen in Figs.
  • the breakpack goods transfer deck 130DG joins the breakpack operation station 140 and the container transfer deck 130DC at a separate location (e.g., at the breakpack goods interface locations 263L) from each access of the container transfer deck 130DC to the breakpack operation station 140 (e.g., at the common support surface 140S) for the container bot 110.
  • one or more of the breakpack modules 266 includes two or more (i.e., multiple levels) goods transfer decks 130DG1-130DG3 stacked one above the other; however, in other aspects the breakpack module(s) may have a single level where an elevated level of at least one breakpack module is connected to a container transfer deck level.
  • the breakpack goods interface 263 may be substantially similar to the racks as shown in Fig. IB and include multilevel levels 130DGL1-130DGL3 that are each accessible from a common (level) container transfer deck 130DC.
  • the container bots 110 may be any suitable independently operable autonomous transport vehicles that carry and transfer case units along the X and Y throughput axes throughout the storage and retrieval system 100.
  • the container bots 110 are automated, independent (e.g. free riding) autonomous transport vehicles.
  • Suitable examples of bots can be found in, for exemplary purposes only, United States patent number 10,822,168 issued on November 3, 2020; United States patent number 8,425,173 issued on April 23, 2013; United States patent number 9,561,905 issued on February 7, 2017; United States patent number 8,965,619 issued on February 24, 2015; United States patent number 8,696,010 issued on April 15, 2014; United States patent number 9,187,244 issued on November 17, 2015; United States Patent number 11,078,017 issued on August 3, 2021; United States patent number 9,499,338 issued on November 22, 2016; United States patent number 10,894,663 issued on January 19, 2021; and United States patent number 9,850,079 issued on December 26, 2017, the disclosures of which are incorporated by reference herein in their entireties.
  • the container bots 110 may be configured to place case units, such as the above described retail merchandise, into picking stock in the one or more levels of the storage structure 130 and then selectively retrieve ordered case units.
  • the pickfaces (which in one aspect include supply containers 265) are transported between an inbound section of the storage and retrieval system 100, where pickfaces inbound to the array are generated (such as, for example, input station 160IN) and a load fill section of the storage and retrieval system 100 (such as for example, output station 160UT or output station 160EC), where outbound pickfaces from the array are arranged to fill a load in accordance with a predetermined load fill order sequence or an individual fulfillment order(s) in accordance with a predetermined individual fulfillment order sequence.
  • pickfaces inbound to the array are generated (such as, for example, input station 160IN) and a load fill section of the storage and retrieval system 100 (such as for example, output station 160UT or output station 160EC), where outbound pickfaces from the array are arranged to fill a load in accordance with a predetermined load fill order sequence or an individual fulfillment order(s) in accordance with a predetermined individual fulfillment order sequence.
  • pickfaces e.g., of supply containers 265 are transported between the storage spaces 130S and a load fill section of the storage and retrieval system 100 (such as for example, output station 160UT or output station 160EC) to fill a load in accordance with a predetermined load fill order sequence or an individual fulfillment order(s) in accordance with a predetermined individual fulfillment order sequence.
  • a load fill section of the storage and retrieval system 100 such as for example, output station 160UT or output station 160EC
  • breakpack goods container(s) 264 (which, in one aspect, multiple breakpack goods containers may be arranged in and transported as a pickface) are transported between the storage spaces 130S and the load fill section and/or between the breakpack goods interface 263 of the breakpack module(s) 266 and the load fill section of the storage and retrieval system 100 (such as for example, output station 160UT or output station 160EC) to fill a load in accordance with a predetermined load fill order sequence or an individual fulfillment order(s) in accordance with a predetermined individual fulfillment order sequence.
  • the container bots 110, lift modules 150 and other suitable features of the storage and retrieval system 100 are controlled in any suitable manner such as by, for example, one or more central system control computers (e.g. control server) 120 through, for example, any suitable network 180.
  • the network 180 is a wired network, a wireless network or a combination of wireless and wired networks using any suitable type and/or number of communication protocols.
  • the control server 120 includes a collection of substantially concurrently running programs (e.g. system management software) for substantially automatic control of the automated storage and retrieval system 100.
  • the collection of substantially concurrently running programs being configured to manage the storage and retrieval system 100 including, for exemplary purposes only, controlling, scheduling, and monitoring the activities of all active system components, managing inventory (e.g. which case units are input and removed, the order in which the cases are removed and where the case units are stored) and pickfaces (e.g. one or more case units that are movable as a unit and handled as a unit by components of the storage and retrieval system), and interfacing with a warehouse management system 2500.
  • the control server 120 may, in one aspect, be configured to control the features of the storage and retrieval system in the manner described herein.
  • the term “case unit(s)” is generally used herein for referring to both individual case units and pickfaces (a pickface is formed of multiple case units that are moved as a unit).
  • the rack module array RMA of the storage structure 130 includes vertical support members 1212 and horizontal support members 1200 that define the high density automated storage array as will be described in greater detail below.
  • Rails 1200S may be mounted to one or more of the vertical and horizontal support members 1212, 1200 in, for example, picking aisles 130A and be configured so that the container bots 110 ride along the rails 1200S through the picking aisles 130A.
  • At least one side of at least one of the picking aisles 130A of at least one storage level 130L may have one or more storage shelves (e.g. formed by rails 1210, 1200 and slats 1210S).
  • the one or more shelves may be provided at differing heights so as to form multiple shelf levels 13OLS1-13OLS3 between the storage or deck levels 130L defined by the transfer decks 130B (and the rails 1200S which form an aisle deck). Accordingly, there are multiple rack shelf levels 130LS1-130LS3, corresponding to each storage level 130L, extending along one or more picking aisles 130A communicating with the container transfer deck 130DC of the respective storage level 130L.
  • the multiple rack shelf levels 130LS1-130LS3 effect each storage level 130L having stacks of stored case units/supply containers 265 (or case layers) and/or stacks of stored breakpack goods containers 264 (or breakpack layers) that are accessible from a common deck 1200S of a respective storage level 130L (e.g. the stacks of stored cases are located between storage levels).
  • container bots 110 traversing a picking aisle 130A, at a corresponding storage level 130L have access (e.g. for picking and placing case units and/or breakpack goods containers) to each storage space 130S that is available on each shelf level 13OLS1-13OLS3, where each shelf level 130LS1-130LS3 is located between adjacent vertically stacked storage levels 130L on one or more side(s) PAS1, PAS2 (see e.g. Fig. 2A) of the picking aisle 130A.
  • each of the storage shelf levels 130LS1-130LS3 is accessible by the container bot 110 from the rails 1200 (e.g.
  • Figs. IB and 1C there arc one or more intermediate shelf rails 1210B, 1210C vertically spaced (e.g. in the Z direction) from one another (and from rails 1200) to form multiple stacked storage spaces 130S each being accessible by the container bot 110 from the common rails 1200S.
  • the horizontal support members 1200 also form shelf rails (in addition to shelf rails 1210) on which case units are placed.
  • Each stacked shelf level 130LS1-130LS3 (and/or each single shelf level as described below) of a corresponding storage level 130L defines an open and undeterministic two dimensional storage surface (e.g. having a case unit/breakpack container support plane CUSP as shown in Fig. 1C) that facilitates a dynamic allocation of pickfaces (e.g., supply containers 265) and/or breakpack goods containers 264 both longitudinally (e.g. along a length of the aisle or coincident with a path of bot travel defined by the picking aisle) and laterally (e.g. with respect to rack depth, transverse to the aisle or the path of bot travel).
  • pickfaces e.g., supply containers 265
  • breakpack goods containers 264 both longitudinally (e.g. along a length of the aisle or coincident with a path of bot travel defined by the picking aisle) and laterally (e.g. with respect to rack depth, transverse to the aisle or the path of bot travel).
  • Dynamic allocation of the pickfaces and case units that make up the pickfaces is provided, for example, in the manner described in United States patent number 8,594,835 issued on November 26, 2013, the disclosure of which is incorporated by reference herein in its entirety. While supply containers 265 are illustrated in Fig. IB as being stored on side PAS2 of picking aisle 130A and breakpack goods containers 264 are shown stored on side PAS1 of picking aisle 130A, in other aspects, there may be a mix of supply containers 265 and breakpack goods containers 264 stored on a common side PAS1, PAS2 (e.g., either one or both of sides PAS1, PAS2) of the picking aisle 130A and/or a mix of supply containers 265 and breakpack goods containers 264 stored on a common shelf surface.
  • PAS1 e.g., either one or both of sides PAS1, PAS2
  • each of the storage levels 130L includes a single level of storage shelves to store a single level of case units (e.g. each storage level includes a single case unit support plane CUSP) and the container bots 110 are configured to transfer case units to and from the storage shelves of the respective storage level 130L.
  • the container bot 110’ illustrated in Fig. 3B is substantially similar to container bot 110 described herein however, the container bot 110’ is not provided with sufficient Z-travel of the transfer arm 110PA for placing case units on the multiple storage shelf levels 130LS1-130LS3 (e.g. accessible from a common rail 1200S) as described above.
  • the transfer arm drive 250 (which may be substantially similar to one or more of drive 250A, 250B) includes only sufficient Z-travel for lifting the case units from the case unit support plane CUSP of the single level of storage shelves, for transferring the case units to and from the pay load area 110PL and for transferring the case units between the fingers 273 of the transfer arm 110PA and the pay load bed 110PB.
  • Suitable examples of container bots 110’ can be found in, for example, United States patent number 9,499,338 issued on November 22, 2016, the disclosure of which is incorporated herein by reference in its entirety.
  • each container transfer deck 130DC or storage level 130L includes one or more lift pickface interface/handoff stations TS (referred to herein as interface stations TS) where case unit(s) (e.g. individual case units, pickfaces, supply containers, etc.), totes and/or breakpack goods containers 264 are transferred between the lift load handling devices LHD and container bots 110 on the container transfer deck 130DC.
  • the interface stations TS are located at a side of the container transfer deck 130DC opposite the picking aisles 130A and rack modules RM, so that the container transfer deck 130DC is interposed between the picking aisles and each interface station TS.
  • each container bot 110 on each picking level 130L has access (via a respective container transfer deck 130DC) to each storage location 130S, each picking aisle 130A and each lift 150 on the respective storage level 130L, as such each container bot 110 also has access to each interface station TS on the respective level 130L.
  • the interface stations arc offset from high-speed bot travel paths HSTP along the container transfer deck 130DC so that container bot 110 access to the interface stations TS is undeterministic to bot speed on the high speed travel paths HSTP.
  • each container bot 110 can move a case unit(s) (e.g. individual case units, pickfaces (built by the bot), supply containers, etc.), totes and/or breakpack goods containers 264 from every interface station TS to every storage space 130S corresponding to the deck level 130L and vice versa.
  • the interface stations TS are configured for a passive transfer (e.g. handoff) of case units (e.g. individual case units, pickfaces, supply containers, etc.), totes and/or breakpack goods containers 264 between the container bot 110 and the load handing devices LHD of the lifts 150 (e.g. the interface stations TS have no moving parts for transporting the case units) which will be described in greater detail below.
  • case units e.g. individual case units, pickfaces, supply containers, etc.
  • the load handing devices LHD of the lifts 150 e.g. the interface stations TS have no moving parts for transporting the case units
  • the interface stations TS and/or buffer stations BS include one or more stacked levels TL1, TL2 of transfer rack shelves RTS (e.g.
  • the container bot 110 with respect to the stacked rack shelves RTS which in one aspect are substantially similar to the storage shelves described above (e.g. each being formed by rails 1210, 1200 and slats 1210S) such that container bot 110 handoff (e.g. pick and place) occurs in a passive manner substantially similar to that between the container bot 110 and the storage spaces 130S (as described herein) where the case units or totes arc transferred to and from the shelves.
  • the buffer stations BS on one or more of the stacked levels TL1, TL2 also serve as a handoff/interface station with respect to the load handling device LHD of the lift 150.
  • the interface stations TS and/or buffer stations BS also include a single level of transfer rack shelves (which are substantially similar to the storage rack shelves of the storage levels 130L described above with respect to, for example, Fig. 1C).
  • load handling device LHD or lift
  • handoff e.g. pick and place
  • the shelves may include transfer arms for picking and placing case units, totes and/or breakpack goods containers 264 from one or more of the container bot 110 and load handling device LHD of the lift 150.
  • Suitable examples of an interface station with an active transfer arm are described in, for example, United States patent number 9,694,975 issued on luly 4, 2017, the disclosure of which is incorporated by reference herein in its entirety.
  • the location of the container hot 110 relative to the interface stations TS occurs in a manner substantially similar to bot location relative to the storage spaces 130S.
  • location of the container bot 110 relative to the storage spaces 130S and the interface stations TS occurs in a manner substantially similar to that described in United States patent number 9,008,884 issued on April 14, 2015 and United States patent number 8,954,188 issued on February 10, 2015, the disclosures of which are incorporated herein by reference in their entireties.
  • the container bot 110 includes one or more sensors 110S that detect the slats 1210S or a locating feature 130F (such as an aperture, reflective surface, RFID tag, etc.) disposed on/in the rail 1200.
  • the Slats and/or locating features 130F are arranged so as to identify a location of the container bot 110 within the storage and retrieval system, relative to e.g. the storages spaces and/or interface stations TS.
  • the container bot 110 includes a controller 110C that, for example, counts the slats 1210S to at least in part determine a location of the container bot 110 within the storage and retrieval system 100.
  • the location features 130F may be arranged so as to form an absolute or incremental encoder which when detected by the container bot 110 provides for a container bot 110 location determination within the storage and retrieval system 100.
  • the transfer rack shelves RTS at each interface/handoff station TS define multi-load stations (e.g. having one or more storage case unit holding locations for holding a corresponding number of case units or totes) on a common transfer rack shelf RS.
  • each load of the multi-load station is a single case unit/tote/breakpack container or a multi-case pickface (e.g. having multiple case units/totes/breakpack goods containers that are moved as a single unit) that is picked and paced by either the container bot 110 or load handling device LHD.
  • the bot location described above allows for the container bot 110 to position itself relative to the multi-load stations for picking and placing the case units/totes and pickfaces from a predetermined one of the holding locations of the multi-load station.
  • the interface/handoff stations TS define multi-place buffers (e.g. buffers having one or more case holding location) where inbound and/or outbound case units/totes/breakpack goods containers and pickfaces are temporarily stored when being transferred between the container bots 110 and the load handling devices LHD of the lifts 150.
  • one or more peripheral buffer/handoff stations BS are also located at the side of the container transfer deck 130DC opposite the picking aisles 130A and rack modules RM, so that the container transfer deck 130DC is interposed between the picking aisles and each buffer station BS.
  • the peripheral buffer stations BS are interspersed between or, in one aspect as shown in Figs. 2A and 2B, otherwise in line with the interface stations TS.
  • the peripheral buffer stations BS are formed by rails 1210, 1200 and slats 1210S and are a continuation of (but a separate section of) the interface stations TS (e.g.
  • the interface stations and the peripheral buffer stations are formed by common rails 1210, 1200).
  • the peripheral buffer stations BS in one aspect, also include one or more stacked levels TL1, TL2 of transfer rack shelves RTS as described above with respect to the interface stations TS while in other aspects the buffer stations include a single level of transfer rack shelves.
  • the peripheral buffer stations BS define buffers where case units/totes/breakpack goods containers and/or pickfaces are temporarily stored when being transferred from one container bot 110 to another different container bot 110 on the same storage level 130L as will be described in greater detail below.
  • the peripheral buffer stations are located at any suitable location of the storage and retrieval system including within the picking aisles 130A and anywhere along the container transfer deck 130DC.
  • the interface stations TS are located on an extension portion or pier 130BD that extends from the container transfer deck 130DC, although in other aspects a length of the interface stations TS may be arranged and extend along the container transfer deck.
  • the pier 130BD is similar to the picking aisles where the container bot 110 travels along rails 1200S affixed to horizontal support members 1200 (in a manner substantially similar to that described above).
  • the travel surface of the pier 130BD may be substantially similar to that of the container transfer deck 130DC.
  • Each pier 130BD is located at the side of the container transfer deck 130DC, such as a side that is opposite the picking aisles 130A and rack modules RM, so that the container transfer deck 130DC is interposed between the picking aisles and each pier 130BD.
  • the pier(s) 130BD extends from the transfer deck at a non-zero angle relative to at least a portion of the high speed hot transport path HSTP. In other aspects the pier(s) 130BD extend from any suitable portion of the container transfer deck 130DC including the ends 130BE1, 130BE2 of the container transfer deck 130DCD.
  • peripheral buffer stations BSD substantially similar to peripheral buffers stations BS described above may also be located at least along a portion of the pier 130BD.
  • each drive wheel 202 is independently controlled so that the container bot 110 may be steered through a differential rotation of the drive wheels 202 while in other aspects the rotation of the drive wheels 202 may be coupled so as to rotate at substantially the same speed.
  • Any suitable wheels 201 are mounted to the frame on opposite sides of the container bot 110 at end 110E2 (e.g. second longitudinal end) of the container bot 110 for supporting the container bot 110 on the drive surface.
  • the wheels 201 are caster wheels that freely rotate allowing the container bot 110 to pivot through differential rotation of the drive wheels 202 for changing a travel direction of the container bot 110.
  • the wheels 201 are steerable wheels that turn under control of, for example, a bot controller HOC (which is configured to effect control of the container bot 110 as described herein) for changing a travel direction of the container bot 110.
  • the container bot 110 includes one or more guide wheels 110GW located at, for example, one or more corners of the frame 110F.
  • the guide wheels 110GW may interface with the storage structure 130, such as guide rails (not shown) within the picking aisles 130A, on the container transfer deck 130DC and/or at interface or transfer stations for interfacing with the lift modules 150 for guiding the container hot 110 and/or positioning the container hot 110 a predetermined distance from a location to/from which one or more case units are placed and/or picked up as described in, for example, United States patent number 9,561,905 issued on February 7, 2017 the disclosure of which is incorporated herein by reference in its entirety.
  • the container bots 110 may enter the picking aisles 130A having different facing directions for accessing storage spaces 130S located on both sides of the picking aisles 130A.
  • the container hot 110 may enter a picking aisle 130A with end 110E2 leading the direction of travel or the bot may enter the picking aisle 130 A with end 110E1 leading the direction of travel.
  • the payload section 110PL of the container bot 110 includes a payload bed 110PB, a fence or datum member 110PF, a transfer arm 110PA and a pusher bar or member 110PR.
  • the payload bed 110PB includes one or more rollers 110RL that are transversely mounted (e.g. relative to a longitudinal axis LX of the container bot 110) to the frame 110F so that one or more case units and/or breakpack goods containers carried within the payload section 110PL can be longitudinally moved (e.g.
  • case unit and/or breakpack goods containers are justified with respect to a predetermined location of the frame/payload section and/or a datum reference of one or more case units) along the longitudinal axis of the bot, e.g., to position the case unit and/or breakpack goods containers at a predetermined position within the payload section 110PL and/or relative to other case units and/or breakpack goods containers within the payload section 110PL (e.g. longitudinal forward/aft justification of case units).
  • the container bot 110 includes one or more longitudinally movable pusher bar (substantially similar to that described in, for example, United States patent 11,078,017 issued on August 3, 2021, the disclosure of which was previously incorporated by reference herein in its entirety) for pushing the case units and/or breakpack goods containers over the rollers 110RL for moving the case unit(s) and/or breakpack container(s) to the predetermined position within the payload section 110PL.
  • longitudinally movable pusher bar substantially similar to that described in, for example, United States patent 11,078,017 issued on August 3, 2021, the disclosure of which was previously incorporated by reference herein in its entirety
  • the case units and/or breakpack goods containers are placed on the payload bed 110PB and removed from the payload bed 110PB with the transfer arm 110PA.
  • the transfer arm 110PA includes a lift mechanism or unit 200 located substantially within the payload section 110PL as described in, for example, United States patent number 9,850,079 issued on December 26, 2017, previously incorporated herein by reference in its entirety.
  • the lift mechanism 200 provides both gross and fine positioning of pickfaces (which may include either case units or breakpack goods containers, or both case units and breakpack goods containers) carried by the container bot 110 which are to be lifted vertically into position in the storage structure 130 for picking and/or placing the pickfaces and/or individual case units to the storage spaces 130S (e.g.
  • the lift mechanism 200 provides for picking and placing case units at the multiple elevated storage shelf levels 130LS1-130LS3, TL1, TL2 accessible from the common picking aisle or interface station deck 1200S (see e.g. Figs. IB, 2B and 2D).
  • the pick head 270 of the container bot 110 transfers case units between the container bot 110 and a case unit and/or breakpack goods container pick/place location such as, for example, the storage spaces 130S, peripheral buffer stations BS, BSD, interface stations TS (see Figs. 2A-2B), breakpack operation station 140 (see Figs. 1 and 2C), goods settling and container closing station 155, and/or breakpack goods interface 263 (see Figs. 1A and 2C) and in other aspects, substantially directly between the container bot 110 and a lift module(s) 150.
  • a case unit and/or breakpack goods container pick/place location such as, for example, the storage spaces 130S, peripheral buffer stations BS, BSD, interface stations TS (see Figs. 2A-2B), breakpack operation station 140 (see Figs. 1 and 2C), goods settling and container closing station 155, and/or breakpack goods interface 263 (see Figs. 1A and 2C) and in other aspects, substantially directly between the container bot 110 and a
  • the pick head 270 includes a base member 272, one or more tines or fingers 273A- 273E and one or more actuators 274A, 274B.
  • the base member 272 is mounted to the mast 200M, as described above, so as to ride along the guide rails 280A, 280B.
  • the one or more tines 273A- 273E are mounted to the base member 272 at a proximate end of the tines 273A-273E so that a distal end of the tines 273A-273E (e.g. a free end) is cantilevered from the base member 272. Referring again to Fig.
  • the tines 273A-273E arc configured for insertion between slats 1210S that form the case unit support plane CUSP of the storage shelves (and similar slats of the peripheral buffer stations BS, BSD, interface stations TS, breakpack operation station 140, and/or breakpack goods interface 263).
  • the pusher bar 110PR is movable independent of the transfer arm 110PA.
  • the pusher bar 110PR is movably mounted to the frame in any suitable manner such as by, for example, a guide rod and slide arrangement and is actuated along the Y direction (e.g. in a lateral direction substantially parallel to the extension/retraction direction of the transfer arm 110PA).
  • at least one guide rod 360 is mounted within the payload section 110PL so as to extend transversely relative to the longitudinal axis LX of the frame 110F.
  • the pusher bar 110PR may include at least one slide member 360S configured to engage and slide along a respective guide rod 360.
  • the guide rod/slide arrangement holds the pusher bar 110PR captive within the payload section 110PL.
  • the pusher bar 110PR is actuated by any suitable motor and transmission, such as by motor 303 and transmission 303T.
  • the motor 303 is a rotary motor and the transmission 303T is a belt and pulley transmission, hr other aspects, the pusher bar 110PR may be actuated by a linear actuator having substantially no rotary components.
  • the pusher bar 110PR may effect justification of case units CY in the pay load bed 110PB along a lateral axis of the container bot and may effect gripping of case units CU within the payload bed 110PB (e.g., gripped between the pusher bar 110PB and fence HOPF).
  • the at least one goods settling and container closing station 155 may be coupled to the structure of the automated storage and retrieval system 100 at any suitable location and at any suitable level(s) 130L.
  • a goods settling and container closing station may be located at one or more ends 130BE1, 130BE2 of the container transfer deck 130DC or at one or more sides 130BD1, 130BD2 of the container transfer deck 130DC (such as in lieu of storage rack modules RM/picking aisles 130A or lifts 150A, 150B, or as an extension of one or more picking aisles 130A).
  • Each of the goods settling and container closing station 155 is a plug and play module that is integrated with (or otherwise connected to) the container transfer deck 130DC so that the container transfer deck 130DC is communicably coupled to at least one autonomous guided vehicle interface 401, 402 (also respectively referred to as a container infeed 401, an input 401 or an input interface station 401, and an output or output interface station 402) of the goods settling and container closing station 155, so that container bots 110 transfer breakpack containers 264 from the at least one breakpack station 266 to the at least one goods settling and container closing station 155 via the container transport deck 130DC.
  • at least one autonomous guided vehicle interface 401, 402 also respectively referred to as a container infeed 401, an input 401 or an input interface station 401, and an output or output interface station 402
  • container bots 110 transfer breakpack containers 264 from the at least one breakpack station 266 to the at least one goods settling and container closing station 155 via the container transport deck 130DC.
  • the at least one autonomous guided vehicle interface 401, 402 interfaces with container bots 110 travelling along, and is/are communicably coupled to, picking aisles (see Fig. 2A) that extend from the container transport deck 130DC, so that container bots 110 transfer breakpack containers 264 from the at least one breakpack station 266 to the at least one goods settling and container closing station 155 via the picking aisles 130 A.
  • picking aisles 130A may include an undeterministic turn around area (that is similar to the open undeterministic container transfer deck 130DC) on which the container bots 110 turn to transfer breakpack containers 264 to the at least one autonomous guided vehicle interface 401, 402.
  • the container transfer deck includes a transfer lane in which the container bots 110 can “parallel park” adjacent a predetermined autonomous guided vehicle interface 401, 402 for transfer of breakpack containers 264 between the container bot 110 and the autonomous guided vehicle interface 401, 402.
  • the goods settling and container closing station(s) 155 form a product order fulfillment system (or a portion thereof) of mixed product units held in a container 264 for transport.
  • each goods settling and closing station 155 includes a synchronous transport system 410S forming a container transport path CTP transporting the container 264.
  • the synchronous transport system 410S has a container infeed (also referred to as an autonomous guided vehicle interface) 401 arranged for communication with an asynchronous container transport (such as container bot 110) so as to load the container 264 in the synchronous transport system 4 IOS.
  • At least one container settler (also referred to herein as a goods settling apparatus) 420 is configured to engage and agitate the container 264, transported along the container transport path CTP, so as to settle mixed product units held within the container 264.
  • At least one container lid closer (also referred to herein as a container closing bay) 430 is configured to engage with and close a lid 264L (see Fig. 8B) of the container 264, transported along the container transport path CTP.
  • the at least one container lid closer 430 and the at least one container settler 420 are communicably connected by the container transport path CTP and the synchronous transport 410S includes an intervening switch selector 499 controllably selecting the container transport path CTP so as to direct the container 264 to at least one of the at least one container settler 420, the at least one container lid closer 430, and both the at least one container settler 420 and the at least one container lid closer 430.
  • the intervening switch selector 499 includes at least one container inspection station 498 (see container inspection station 498A) with a sensor 498S configured so as to detect a height of at least the mixed product units BPG in the container 264.
  • the height of the mixed product units BPG (see, e.g., height 264H in Fig. 8B) may a distance measure from a bottom of the container 264 to a top of the container as defined by top 264T (see Fig.
  • the intervening switch selector 499 is arranged to controllably select the container transport path CTP to direct the container 264 to at least one of the at least one container settler 420 and bypass the container settler 320, based on the height. For example, where the mixed product units BPG do not extend above the top 264T of the container 264 the intervening switch selector 499 selects the container transport path CTP to bypass the container settler 320.
  • the intervening switch selector 499 comprises another container inspection station 498B, downstream along the container transport path CTP from the at least one container inspection station 498A.
  • the other container inspection station 498B has another sensor 498S configured so as to detect the height of the mixed product units BPG in the container 264 passing the other container inspection station 498B.
  • the intervening switch selector 499 is arranged to controllably select the container transport path CTP to direct the container 264 to at least one of the at least one container lid closer 430 and bypass the container lid closer 430, based on the height.
  • the intervening switch selector 499 selects the container transport path CTP to bypass the container lid closer 320.
  • the other container inspection station 498B is located on the transport path CTP between the at least one container settler 420 and the at least one container lid closer 430.
  • the intervening switch selector 499 may also include a further container inspection station 498C that has further sensor 498S configured so as to detect the height of the mixed product units BPG in the container 264 passing the further container inspection station 498C.
  • the intervening switch selector 499 is arranged to controllably select the container transport path CTP to direct the container 264 to at least one of the output interface station 402 and bypass the output interface station 402, based on the height.
  • the intervening switch selector 499 selects the container transport path CTP to bypass the output interface station 402 and to divert the container 264 to an intervention station 466 for rectification.
  • the other container inspection station 498C is located on the transport path CTP between the at least one container lid closer 430 and the output interface station 402.
  • Each of the goods settling and container closing stations 155 includes the at least one autonomous guided vehicle interface 401, 402, a conveyance 410, a goods settling apparatus (also referred to herein as a container settler) 420, and a container closing bay 430.
  • the conveyance 410 is a synchronous transport and is configured to transport breakpack goods containers 264 within a respective goods settling and container closing station 155.
  • the conveyance 410 includes a container input, formed by autonomous guided vehicle interface 401, that is configured to communicate with the asynchronous container transport so as to load the container 264 with the lid 264L open from the asynchronous container transport to the synchronous transport.
  • the conveyance 410 also includes a container output, formed by autonomous guided vehicle interface 402, that is configured to communicate with the asynchronous container transport so as to unload the container 264 with the lid 264L closed from the synchronous transport to the asynchronous transport.
  • the conveyance 410 is any suitable conveyance configured to transport breakpack goods containers 264 between the autonomous guided vehicle interfaces 401, 402 and one or more of the goods settling apparatus 420, and the container closing bay 430.
  • the conveyance 410 may be a roller conveyor, a belt conveyor, a ball conveyor, and/or any other suitable conveyor type or combination of conveyor types that effects transport of the breakpack goods containers 264 within a respective goods settling and container closing station 155.
  • autonomous guided vehicle interfaces 401, 402 are described as forming a respective input and output of the conveyance 410, in other aspects a single bidirectional autonomous guided vehicle interface 401, 402 may be provided that forms an input/output of the settling and container closing station 155.
  • the autonomous guided vehicle interfaces 401, 402 may be passive interfaces that are substantially similar in structure to what is illustrated in Figs. 1C, and 2B with respect to the storage shelves of the rack modules RM and the buffer and transfer stations BS, TS so that the container bot 110 transfers the breakpack containers 264 between the autonomous guided vehicle interfaces 401, 402 and the transfer arm 110PA in a manner substantially similar to that described herein.
  • the autonomous guided vehicle interfaces 401, 402 include any suitable container drive device (e.g., pusher, driven spaced apart rollers (spaced apart in a manner similar to the slats 1210S where the fingers of the transfer arm 110PA are inserted in the space between the rollers), etc.) configured to move the breakpack container from (or to) the respective autonomous guided vehicle interfaces 401, 402 to (or from) the conveyance 410.
  • suitable container drive device e.g., pusher, driven spaced apart rollers (spaced apart in a manner similar to the slats 1210S where the fingers of the transfer arm 110PA are inserted in the space between the rollers), etc.
  • the goods settling apparatus 420 is configured to cyclically agitate or otherwise rock a breakpack goods container 264 along a multi-dimensional reciprocating path of (cyclical) motion so that goods within the breakpack goods container settle within the breakpack goods container 264.
  • the goods BPG arc moved within the breakpack goods container 264, under impetus of the goods settling apparatus 420.
  • the agitating movement of the goods BPD is such that space between the goods BPG is minimized and the goods BPG are substantially entirely disposed below the plane PL defined by the top 264T (see Fig. 5D) of the breakpack goods container 264 so that the lid 264L (see Fig.
  • the goods settling apparatus 420 includes a frame 500, a container platform 520, and a drive unit 530. As may be realized, the goods settling apparatus 420 includes any suitable controller 598 configured to effect operation of the goods settling apparatus 420 in the manner described herein. The controller 598 may be communicably coupled to the control server 120 in any suitable manner or form a part of the control server 120.
  • the container platform 520 has opposing sides or ends 521, 522. Each of the opposing sides 521, 522 is coupled to the frame 500 at a respective pivot joint 523, 524.
  • One end of the container platform 520 is coupled to the frame 500 at pivot joint 523 by a link (also referred to herein as a pivot link) 525.
  • An opposite end of the pivot link 525 is pivotally coupled to the frame at pivot joint 505.
  • the other pivot joint 524 forms a fulcrum 524F about which the side 522 pivots.
  • the fulcrum 524F is offset, along a length of the container platform 520, from the pivot joint 523 of the link 525 to the container platform 520.
  • the fulcrum 524F formed by the pivot joint 524 is fixed to the frame 500 at a stationary position.
  • the container platform 520 slides on and pivots about the fulcrum 524F.
  • the container platform 520 includes a rail 599R that slidingly engages the pivot joint 524 so that the container platform moves in direction MA relative to the fulcrum 524F.
  • the pivot joint 524 also provides for rotation or pivoting of the rail 599R (and the container platform) about a pivot axis of the fulcrum 524F so that the side 522 of the container platform 520 moves in direction MC.
  • the container platform 520 is suspended from the frame 500 by the pivot link 525 and the fulcrum 524F such that the pivot link 525 and fulcrum 524F constrain movement of the container platform 520 to travelling along a multi-dimensional reciprocating path of motion (see directions MA, MB, MC in Fig. 5E) as described in greater detail herein.
  • the fulcrum 524F formed by the pivot joint 524 is a moving or floating fulcrum where another pivot link 526 is coupled at one end to the pivot platform 520 at pivot joint
  • pivot link 526 An opposite end of the other pivot link 526 is pivotally coupled to the frame 500 at pivot joint 506.
  • the container platform 520 is suspended from the frame 500 by the pivot links
  • the container platform 520 includes a container support surface 529 configured to support a breakpack goods container 264 held on the container platform 520.
  • the container support surface 529 includes at least one platform roller 528 configured to, one or more of, guide ingress of a breakpack goods container onto the container platform 520 and drive egress of the breakpack goods container from the container platform 520.
  • Input-output rollers 527 may also be coupled to the frame 500 and disposed to infeed and outfeed breakpack goods containers 264 to and from the container platform 520.
  • the input-output roller may be driven rollers while in other aspects the input-output rollers may be passive rollers.
  • one or more of the at least one platform roller 528 and the input-output rollers 527 may be driven by any suitable roller drive 528D and be positioned to drive containers on and off the container platform 520.
  • the container platform 520 includes a pusher 575 (see Fig. 5C) that extends linearly across at least a portion of the support surface 529 to push a container from the container platform 520 and onto the (driven or passive) rollers 257, 528 and/or the conveyance 410.
  • the goods settling apparatus 420 also includes a container grip 550 that is movably coupled to the frame 500 and configured to grip a breakpack goods container 264 so that the breakpack good container 264 and the container platform 520 move as a unit.
  • the container grip 550 is mounted to the container platform 520 so as to move as a unit with the container platform 520.
  • the container grip includes opposing grip plates 551 A, 55 IB that are each coupled to the container platform by a respective actuator 552A, 552B.
  • the actuators 552A, 552B arc any suitable actuators (e.g., linear actuator, screw drive, etc.) configured to move the opposing grip plates 551 A, 55 IB towards and away from each other to respectively effect gripping and releasing of a breakpack goods container 264 located on the container platform 520 (see Figs. 5B and 5D illustrating gripping of a breakpack goods container 264).
  • Each grip plate 551 A, 55 IB includes a container grip portion 551 AG, 551BG and a goods containment portion 551 AC, 551BC.
  • the container grip portions 551 AG, 551BG are configured to opposingly engage opposite sides of the breakpack goods container 264 and securely hold the breakpack goods container 264 so that the breakpack goods container 264 and the container platform 520 move as a unit.
  • the goods containment portions 551 AC, 551BC are configured to contain goods within the breakpack goods container 264 with the breakpack goods container 264 being moved (e.g., to effect settling of the goods) by the container platform 520.
  • the frame 500 may also include a fixed (e.g., stationary relative to the frame 500) goods containment wall 501 (not shown in Fig. 5E for clarity) and a pivotable goods containment wall 502 (not shown in Fig. 5E for clarity).
  • the fixed goods containment wall 501 is disposed on an opposite side of the frame 500 relative to container ingress/egress effected by the at least one driven platform roller 528.
  • the fixed goods containment wall 501 is disposed on the frame so as to contain goods from exiting the breakpack goods container 264 with the breakpack goods container 264 being moved (e.g., to effect settling of the goods) by the container platform 520.
  • the pivotable goods containment wall 502 is pivotally coupled to the frame 500 and is disposed to block ingress/egress of the containers to and from the container platform 520.
  • the pivotable goods containment wall 502 is pivotable between a deployed configuration and a retracted configuration (the retracted configuration is shown in Figs. 5A and 5D).
  • the deployed configuration of the pivotable goods containment wall 502 blocks ingress/egress of containers to the container platform and contains goods within the breakpack goods container 264 with the breakpack goods container 264 being moved (e.g., to effect settling of the goods) by the container platform 520.
  • the retracted configuration of the pivotable goods containment wall 502 (illustrated in Figs. 5A and 5D) provides for unhindered ingress/egress of containers to and from the container platform 520.
  • the drive unit 530 is coupled to the container platform 520 and is configured to drive the container platform 520 in a multi-dimensional reciprocating movement.
  • the respective pivot link 525 and fulcrum 524F (whether the fulcrum is stationary and constrained by the coupling to the frame 500 as illustrated in Fig. 5E or floating and constrained by the pivot link 526 as illustrated in Figs. 5B-5D) constrain the reciprocating movement of the respective pivot joints 523, 524, and the container platform 520, to travel along the multi-dimensional reciprocating path of motion (see Figs. 5C and 5E as described herein).
  • the drive unit includes a drive motor 53OM, a cam 530C, and a crank link 530L.
  • the drive motor 530M is coupled to the frame in any suitable manner (such as with fasteners).
  • the cam 530C is coupled to an output of the drive motor 53OM so that the drive motor 530M drives rotation of the cam 530C about a drive axis of rotation 53OX.
  • the crank link 530L has one end that is eccentrically coupled to the cam 53OC about pivot joint 530CJ where the pivot joint 53OCJ follows a circular path CP around the drive axis of rotation 53OX.
  • the other end of the crank link 530L is pivotally coupled to the container platform 520 at the pivot axis 523.
  • crank link 530L causes a swinging motion of side 521 of the container platform in direction MB, where the swinging motion is constrained by the pivot link 525.
  • the other side 522 of the container platform moves in a reciprocal swinging motion in direction MC that is constrained by the pivot link 526 (in Fig. 5C) or by the fixed position of the fulcrum 524F (in Fig. 5E).
  • the multi-dimensional reciprocating path of motion of the container platform 520 is a cyclical motion configured to jostle or otherwise move the goods within the breakpack goods container 264 so that the goods settle, within the breakpack goods container 264, below the top 264T (e.g., the goods do not extend above a plane PL formed by the top 264T) of the breakpack goods container as described herein.
  • the conveyance 410 may include, upstream from the goods settling apparatus 420, a goods detection station 444 that is configured to determine whether the breakpack goods BPG within a respective breakpack goods container 264 extend above the plane PL formed by the top 264T of the breakpack goods container 264.
  • the goods detections station 444 includes any suitable sensor 444S disposed so that breakpack goods containers 264 travelling along the conveyance 410 are within a field of view (in the case of an imaging sensor) or an electromagnetic beam (in the case of a break-the-beam or reflective beam sensor) of the sensor 444S.
  • the goods detection station 444 effects, with the conveyance 410, transport of the breakpack goods container 264 to the goods settling apparatus 420, otherwise the breakpack container 264 may bypass the goods settling apparatus 420 and be transported to the container closing bay 430.
  • the container closing bay 430 is communicably coupled to the goods settling apparatus 420 by the conveyance 410.
  • the container closing bay 430 includes an opposing container lid manipulator having opposing helical guides 620A, 620B configured to engage and guide a closing movement of respective lid portions 264L1, 264L2 of the breakpack goods container 264 from an open configuration to a closed configuration, as will be described herein.
  • the container closing bay 430 includes a frame 600, a bi-directional conveyor 610, and at least one opposing container lid manipulator (e.g., at least an inbound opposing container lid manipulator 620).
  • the frame 600 includes a terminal end plate 600P as described further herein.
  • the bi-directional conveyor 610 is coupled to the frame 600 in any suitable manner (such as with any suitable fasteners).
  • the bi-directional conveyor 610 is a roller conveyor, a belt conveyor, a ball conveyor, or any other suitable conveyor that is bi-directionally driven by a conveyor drive 610D so as to transport breakpack goods containers 264 into and out of engagement with the at least one opposing container lid manipulator 620, 630.
  • the bi-directional conveyor 610 includes a goods container conveying surface 610S and a drive section 610D configured to drive the goods container conveying surface 610S alternately in a first or inbound direction 888 into the container closing bay 430 and in a second or outbound direction 889 out of the container closing bay 430, where the second direction 889 is opposite the first direction 888.
  • the bi-directional conveyor 610 receives an open breakpack goods container 264 from the conveyance 410.
  • the bi-directional conveyor 610 transports the open breakpack goods container 264 into engagement with the at least one opposing container lid manipulator 620, 630 so that a lid of the breakpack goods container is closed.
  • the bi-directional conveyor 610 transports the now closed breakpack goods container 264 back to the conveyance 410 for output from the goods settling and container closing station 155.
  • the container closing bay 430 includes any suitable controller 698 configured to effect operation of the bi-directional conveyor 610 (and, where applicable, actuated portions of the container closing bay 430) in the manner described herein.
  • the at least one opposing container lid manipulator (e.g., the inbound opposing container lid manipulator 620) has opposing helical guides or cams 620A, 620B, 630A, 630B configured to engage and guide a closing movement of respective lid portions 264L1, 264L2 of a breakpack goods container 264 from an open configuration to a closed configuration.
  • the at least one opposing lid container manipulator 620, 630 includes inbound opposing helical guides 620A, 620B that are disposed to guide respective lid portions 264L1, 264L2 of a breakpack goods container 264 into a semi-closed orientation, with the breakpack goods container 264 travelling in a first or inbound direction 888 (see Fig. 8A).
  • the inbound opposing helical guides 620A, 620B are configured to effect a closing lifting motion of the respective lid portion 264L1, 264L2 (see Fig. 8A).
  • leading helical guide 620A is a leading helix and will be referred to herein for explanatory purposes as leading helical guide 620A.
  • the other of the opposing helical guides 620B is a trailing helix and will be referred to herein for explanatory purposes as trailing helical guide 620B.
  • leading helical guide 620A has a different camming profile than trailing helical guide 620B such that the lid portion 264L1 engaging the leading helical guide 620 A reaches and passes a vertical orientation before the lid portion 264L2 engaging the trailing helical guide reaches and passes a vertical orientation.
  • the different camming profiles of the leading helical guide 620A and trailing helical guide 620B can be referred to as an offset camming profile that effects an offset timed camming clamshell closure of the lid portions 264L1, 264L2 so that the superior lock portions 264F and inferior lock portions 264M of the lid portions 264L1, 264L2 engage and interlock with one another as shown in Fig. 8B.
  • the at least one opposing container lid manipulator may include an outbound opposing container lid manipulator 630.
  • the outbound opposing container lid manipulator 630 includes outbound opposing helical guides 630A, 630B disposed to guide the respective lid portions 264L1, 264L2 from the semi-closed orientation/configuration (similar to that illustrated in Fig. 8B) to a closed orientation/configuration, with the breakpack goods container 264 travelling in the second direction 889.
  • One of the outbound opposing helical guides 630A is a leading helix and will be referred to herein for explanatory purposes as leading outbound helical guide 630A.
  • outbound trailing helical guide 630B The other of the outbound opposing helical guides 630B is a trailing helix and will be referred to herein for explanatory purposes as outbound trailing helical guide 630B.
  • outbound leading helical guide 630A has a different camming profile than outbound trailing helical guide 630B such that the lid portion 264L1 engaging the outbound leading helical guide 630A is lower relative to the lid portion 264L2 engaging the outbound trailing helical guide 630B so that the superior lock portions 264F and inferior lock portions 264M of the lid portions 264L1, 264L2 arc guided by the outbound opposing helical guides 630A, 630B throughout the offset timed camming clamshell closure, with the breakpack goods container 264 travelling in the second direction 889, of the lid portions 264L1, 264L2 into the closed orientation.
  • the outbound opposing container lid manipulator 630 includes double outbound opposing helical guides 900 disposed along the second direction 889, opposite the first direction 888, so that one of the outbound opposing helical guides 910 (also referred to as a first stage double helix) engages a leading portion of the respective lid portions 264L1, 264L2 in the semi-closed orientation and a second of the outbound opposing helical guides 920 (also referred to as a second stage double helix) engages a trailing portion of the respective lid portions 264L1, 264L2 in the semi-closed orientation so as to guide the respective lid portions 264L1, 264L2 from the semi-closed orientation to a closed orientation with the breakpack goods container 264 travelling in the second direction 889 (see Fig.
  • the double outbound opposing helical guides 900 are configured for a staged offset timed camming clamshell closure of the lid portions 264L1, 264L2 so that the superior lock portions 264F and inferior lock portions 264M of the lid portions 264L1, 264L2 engage and interlock with one another as shown in Fig. 8B.
  • the double outbound opposing helical guides 900 includes the first stage double helix 910 configured to guide closure of the lid portions 264L1, 264L2 from a vertical orientation to an intermediate orientation.
  • the double outbound opposing helical guides 900 also includes the second stage double helix 920 (e.g., inline with the first stage double helix 910 along the outbound direction 889) configured to guide closure of the lid portions 264L1, 264L2 from the intermediate orientation to the closed orientation.
  • the intermediate orientation may be a position of the respective lid portions 264L1, 264L2 that is about half way between the vertical orientation and the closed orientation, although in other aspects, the intermediate orientation may be more or less than about half way between the vertical orientation and the closed orientation.
  • the first stage double helix 910 includes helical guides 910A, 910B that are substantially similar to those described herein with respect helical guides 630 A, 630B.
  • the second stage double helix 920 also includes helical guides 920A, 920B that arc also substantially similar to those described herein with respect to helical guides 630 A, 630B.
  • the second stage double helix 920 is offset from the first stage double helix 910 along the direction 889 of outbound container travel guided movement of the lid portion 264L1 transitions from being guided by the leading helical guide 910A to being guided by the leading helical guide 920A substantially with the lid portion 264L1 at the intermediate orientation.
  • the lid portion 264L2 transitions from being guided by the trailing helical guide 910B to being guided by the trailing helical guide 920B substantially with the lid portion 264L2 at the intermediate orientation.
  • the lid portions 264L1, 264L2 are guided in closure throughout substantially an entirety of the offset timed camming clamshell closure of the lid portions 264L1, 264L2 so that the superior lock portions 264F and inferior lock portions 264M of the lid portions 264L1, 264L2 engage and interlock with one another as shown in Fig. 8B.
  • the container closing bay 430 may also include lid guides 650A, 650B.
  • the lid guides 650A, 650B are disposed on the frame 600, relative to the bi-directional conveyor 610 and the breakpack goods containers 264 travelling thereon, so as to pivot respective lid portions 264L1, 264L2 away from the bin portion 264B. Pivoting the lid portions 264L1, 264L2 away from the bin portion 264B positions the lid portions 264L1, 264L2 for engagement with the respective inbound opposing helical guide 620A, 620B.
  • the lid guides 650A, 650B may be integral with the inbound opposing helical guides 620A, 620B.
  • the container closing bay 430 is described as being bi-directional such that movement of the breakpack goods container 264 in the combined first direction 888 and second direction 889 closes the lid portions 264L1, 264L2, in other aspects (see Figs. 10A and 10B) the container closing bay 430 may have a pass-though (e.g., single direction) configuration.
  • the terminal end plate is removed and the conveyor 610 is extended past the downstream ends DSE of the opposing helical guides 620A, 620B.
  • the breakpack goods container travels only in the direction 888 through the container closing bay 430 so as to sequentially engage the opposing helical guides 620 A, 620B and one of the helical guides 630A, 630B (Fig. 10A) and double outbound opposing helical guides 900 (Fig. 10B).
  • the conveyance 410 may include, downstream from the container closing bay 430, an open lid detection station 445 configured to detect closure of the lid portions 264L1, 264L2 of a respective breakpack goods container 264.
  • the open lid detection station 445 includes any suitable sensor 445S disposed so that breakpack goods containers 264 travelling along the conveyance 410 are within a field of view (in the case of an imaging sensor) or an electromagnetic beam (in the case of a break-the-beam or reflective beam sensor) of the sensor 445S.
  • the open lid detection station 445 effects, with the conveyance 410, transport of the breakpack goods container 264 to an intervention station 446, otherwise the breakpack container 264 may bypass the intervention station 446 and be transported to the output interface station 402.
  • An operator (human or robotic) at the intervention station 446 may remedy the open lid and, via the conveyance 410, transport the breakpack goods container 264 to the output interface station 402.
  • the non-linear guides or cams 1320A, 1320B of the inbound opposing lid manipulator 1320 may be substantially similar to inbound opposing container lid manipulator 620 described above, while in other aspects the non-linear guides 1320A, 1320B may not be helical, but rather have a nonlinear or arcuate lid guide or cam surface(s)/shape(s) (e.g., portions of the guide surface may be linear but together form a non-linear or generally arcuate guide surface) configured to manipulate the lid portions 264L1, 264L2 as described herein.
  • non-linear guides 1320A, 1320B may be substantially similar so as to have a non-offset camming profile (e.g., the lid portions 264L1, 264L2 of the container 264 may be engaged by the non-linear guides 1320A, 1320B substantially simultaneously instead of in a staggered/offset manner as described above with respect to inbound opposing container lid manipulator 620).
  • a non-offset camming profile e.g., the lid portions 264L1, 264L2 of the container 264 may be engaged by the non-linear guides 1320A, 1320B substantially simultaneously instead of in a staggered/offset manner as described above with respect to inbound opposing container lid manipulator 620).
  • the frame 600 includes a linear guide 600G that extends substantially orthogonal to the goods container conveying surface 610S.
  • the lid support 1330 includes a carriage 1331 that is mounted to the linear guide 600G in any suitable manner (e.g., such as any suitable linear bearing, etc.) so as to reciprocate along the linear guide 600G in Z direction.
  • the lid support 1330 includes lid support tines 1330A, 133OB that extend from the carriage 1331 over the goods container conveying surface 610S of the bi-directional conveyor 610.
  • the container closing bay 430 includes a lid support actuator 1371 that is mounted to the frame 600.
  • the lid support actuator 1371 is coupled to and drives the carriage 1331 (and lid support tines 133OA, 1330B carried thereby) in the Z direction along the linear- guide 600G.
  • the lid support actuator 1371 is any suitable actuator including, but not limited to, one or more of hydraulic and/or pneumatic pistons, belts and pulleys, chains and sprockets, screw drives, magnetic drives, etc.
  • the outbound lid manipulator 1350 includes a carriage 1351 that is mounted to the linear guide 600G in any suitable manner (e.g., such as any suitable linear bearing, etc.) so as to reciprocate along the linear- guide 600G in Z direction.
  • the outbound lid manipulator 1350 includes lid closing tines 1350A, 1350B that extend from the carriage 1351 over the goods container conveying surface 610S of the bi-directional conveyor 610.
  • the lid closing tines 135OA, 1350B include friction reducing elements such as rollers 1350AR, 1350BR that engage the lid portions 264L1, 264L2.
  • the container closing bay 430 includes a manipulator actuator 1372 that is mounted to the frame 600.
  • the manipulator actuator 1372 is coupled to and drives the carriage 1351 (and lid closing tines 1350A, 1350B carried thereby) in the Z direction along the linear guide 600G.
  • the manipulator actuator 1371 is any suitable actuator including, but not limited to, one or more of hydraulic and/or pneumatic pistons, belts and pulleys, chains and sprockets, screw drives, magnetic drives, etc.
  • the bidirectional conveyor 610 receives an open breakpack goods container 264 from the conveyance 410.
  • the bi-directional conveyor 610 transports the open breakpack goods container 264 in direction 888 into engagement with the opposing container lid manipulator 1320 so that each of the lid portions 264L1, 264L2 of the breakpack goods container 264 is moved, from an open configuration (see Figs. 11A and 1 IB) to rest on a respective lid support tine 1330A, 133OB in a semi-closed orientation (see Fig. 11C).
  • the outbound lid manipulator 1350 is moved in the Z direction towards the lid portions 264L1, 264L2 supported on the lid support tines 133OA, 1330B (see Fig. 11D) so that the lid closing tines 1350A, 1350B are in substantial contact with the respective lid portions 264L1, 264L2.
  • the outbound lid manipulator 1350 and the lid support 1330 are both moved in the Z direction (as substantially the same rate/speed) towards the goods container conveying surface 610S so that the lid support tines 1330A, 133OB are in substantial contact with the upper rim of the container 264 (see Fig. HE).
  • the lid portions 264L1, 264L2 are pivoted towards each other so that the respective superior lock portions 264F and respective inferior lock portions 264M of the lid portions 264L1, 264L2 engage each other.
  • the outbound lid manipulator 1350 may continue to move or otherwise apply a pressure/force, in the Z direction, against the lid portions so that the respective superior lock portions 264F and respective inferior lock portions 264M of the lid portions 264L1, 264L2 interlock with each other (see Fig. HE).
  • the bi-directional conveyor 610 is operated to drive the goods container conveying surface 610S in outbound direction 889.
  • the goods container conveying surface 610S transports the container 264 in direction 889 and moves the container 264 away from the outbound lid manipulator 1350 and the lid support 1330. As illustrated in Figs.
  • the lid closing tines 1350A, 135OB of the outbound lid manipulator 1350 have a length LL1 that is greater than a length LL2 of the lid support tines 1330A, 1330B of the lid support 1330 so that, as the container 264 is moved away from the outbound lid manipulator 1350 and the lid support 1330, contact between the lid closing tines 1350A, 1350B and the lid portions 264L1, 264L2 trails contact between the lid support tines 1330A, 1330B and the lid portions 264L1, 264L2 (i.e.
  • the lid support tines 1330A, 133OB disengage the lid portions 264L1, 264L2 before the lid closing tines 135OA, 1350B with the container 264 moved in the outbound direction 889).
  • the trailing disengagement of the lid closing tines 1350A, 1350B from the lid portions 264L1, 264L2 maintains interlocking of the respective superior lock portions 264F and respective inferior lock portions 264M of the lid portions 264L1, 264L2 as the container 264 is moved in outbound direction 889 for removal from the container closing bay 430.
  • the bi-directional conveyor 610 transports the now closed breakpack goods container 264 back to the conveyance 410 for output from the goods settling and container closing station 155.
  • the container closing bay 430 includes any suitable controller 698 configured to effect operation of the bi-directional conveyor 610, the outbound lid manipulator 1530, and the lid support 1330 in the manner described herein.
  • a method for container transport in a product order fulfillment system 100 of mixed product units BPG will be described in accordance with aspects of the disclosed embodiment, where the mixed product units BPG are held in a container 264 for transport.
  • the method includes transporting the container 264 with a synchronous transport system (see Fig. 1G - Fig. 12, Block 12100) that forms a container transport path CTP transporting the container 264, and loading the container 264 in the synchronous transport system with a container infeed 401, of the synchronous transport system, that communicates with an asynchronous container transport (see Fig. 1G).
  • At least one container settler 420 engages and agitates (as described herein) the container 264 (Fig. 12, Block 12110), transported along the container transport path CTP, to settle the mixed product units BPG in the container 264.
  • At least one container lid closer engages and closes a lid 264L of the container 264 (as described herein - Fig. 12, Block 12120), transported along the container transport path CTP, wherein the at least one container lid closer 430 and the at least one container settler 420 are communicably connected by the container transport path CTP.
  • the container transport path CTP is controllably selected (Fig.
  • Block 12130 with an intervening switch selector 499 of the synchronous transport to direct the container 264 to at least one of the at least one container settler 420, the at least one container lid closer 430, and both the at least one container settler 420 and the at least one container lid closer 430.
  • the method includes providing at least one storage level 130L (Fig. 13, Block 13100) having storage aisles 130A and a transport deck 130DC connecting the storage aisles 130A.
  • At least one breakpack station 140 is provided (Fig. 13, Block 13110) and is communicably coupled to the transfer deckl30DC.
  • At least one goods settling and container closing stations 155 is provided (Fig. 13, Block 13120) and is/are communicably coupled to the transfer deck 130DC by an asynchronous transport system (as described herein - see Fig. 1G).
  • the goods containers 264 are transported (Fig. 13, Block 13130), with at least one autonomous guided vehicle 110 traversing the transfer deck 130DC, from the at least one breakpack station 140 to the at least one goods settling and container closing station 155, where the goods containers 264 have breakpack goods BPG therein.
  • the method includes providing a goods settling and container closing station 155 (Fig. 14, Block 14100).
  • the goods settling and container closing station 155 includes a container settler 420 and a container closing bay 430.
  • the container settler 420 has a frame 500, a container platform 520 coupled to the frame 500 by a link 525 at one end 521 of the container platform 520, and by a fulcrum 524F at the other end 522 of the container platform 520, where the fulcrum 524F is offset, along the container platform 520, from a pivot joint 523 of the link 525 to the container platform 520.
  • the goods settler 520 also includes a drive unit 530 coupled to the container platform 520.
  • the container platform 520 is driven (Fig. 14, Block 14110) by the drive unit 530 in a cyclic movement.
  • the container 264 is conveyed (Fig. 14, Block 14120), with the conveyance 410, between the container settler 420 and the container closing bay 430.
  • a method for transporting goods BPG in containers 264 in a warehousing system 100 for storing and retrieving goods in the containers 264 will be described in accordance with aspects of the disclosed embodiment.
  • the method includes providing at least one goods settling and container closing station 155 (Fig. 15, Block 15100) for a mixed product unit container 264.
  • the system comprising: a synchronous transport system forming a container transport path transporting the container, the synchronous transport system having a container infeed arranged for communication with an asynchronous container transport so as to load the container in the synchronous transport system; at least one container settler configured to engage and agitate the container, transported along the container transport path, so as to settle the mixed product units therein; and at least one container lid closer configured to engage with and close a lid of the container, transported along the container transport path; wherein the at least one container lid closer and the at least one container settler are communicably connected by the container transport path and wherein the synchronous transport includes an intervening switch selector controllably selecting the container transport path so as to direct the container to at least one of the at least one container settler, the at least one container lid closer, and both the at least one container settler and the at least one container lid closer.
  • the intervening switch selector comprises at least one container inspection station with a sensor configured so as to detect a height of the mixed product units in the container, and the intervening switch selector is arranged to controllably select the container transport path to direct the container to at least one of the at least one container settler and bypass the container settler, based on the height.
  • the intervening switch selector comprises another container inspection station, downstream along the container transport path from the at least one container inspection station, with another sensor configured so as to detect the height of the mixed product units in the container passing the other container inspection station, and the intervening switch selector is arranged to controllably select the container transport path to direct the container to at least one of the at least one container lid closer and bypass the container lid closer, based on the height.
  • the other container inspection station is located on the transport path between the at least one container settler and the at least one container lid closer.
  • the synchronous transport has an output configured to communicate with the asynchronous container transport so as to unload the container with the lid closed from the synchronous transport to the asynchronous transport.
  • the synchronous transport is a ganged system with multiple ganged transport paths at different levels, each transport path at each respective level of the different levels directs the container at the respective level to the at least one of the at least one container settler, the at least one container lid closer, and both the at least one container settler and the at least one container lid closer at the respective level.
  • each respective level has an output configured to communicate with the asynchronous container transport so as to unload the container with the lid closed from the synchronous transport to the asynchronous transport at each respective level.
  • the ganged system has a multilevel output communicably connected via the asynchronous container transport to a lift.
  • a method for container transport in a product order fulfillment system of mixed product units comprising: transporting the container with a synchronous transport system that forms a container transport path transporting the container, and loading the container in the synchronous transport system with a container infeed, of the synchronous transport system, that communicates with an asynchronous container transport; engaging and agitating the container, transported along the container transport path, with at least one container settler to settle the mixed product units in the container; engaging and closing a lid of the container, transported along the container transport path, with at least one container lid closer, wherein the at least one container lid closer and the at least one container settler are communicably connected by the container transport path; and controllably selecting the container transport path with an intervening switch selector of the synchronous transport to direct the container to at least one of the at least one container settler, the at least one container lid closer, and both the at least one container settler and
  • the method further comprises: detecting a height of the mixed product units in the container with a sensor of at least one container inspection station of the intervening switch selector; and controllably selecting the container transport path with the intervening switch selector to direct the container to at least one of the at least one container settler and bypass the container settler, based on the height.
  • the method further comprises: detecting, with another sensor of another container inspection station of the intervening switch selector, the height of the mixed product units in the container passing the other container inspection station , where the other container inspection station is downstream along the container transport path from the at least one container inspection station; and controllably selecting, with the intervening switch selector, the container transport path to direct the container to at least one of the at least one container lid closer and bypass the container lid closer, based on the height.
  • the other container inspection station is located on the transport path between the at least one container settler and the at least one container lid closer.
  • the method further comprises unloading the container with the lid closed from the synchronous transport to the asynchronous transport with an output of the synchronous transport, the output being in communication with the asynchronous container transport.
  • the synchronous transport is a ganged system with multiple ganged transport paths at different levels, the method further comprising directing the container at the respective level, with each transport path at each respective level of the different levels, to the at least one of the at least one container settler, the at least one container lid closer, and both the at least one container settler and the at least one container lid closer at the respective level.
  • the method further comprises unloading the container with the lid closed from the synchronous transport to the asynchronous transport at each respective level, where each respective level has an output communicating with the asynchronous container transport.
  • the ganged system has a multilevel output communicably connected via the asynchronous container transport to a lift.
  • a warehousing system for storing and retrieving goods in containers.
  • the warehousing system comprising: at least one storage level having storage aisles and a transport deck connecting the storage aisles; at least one breakpack station communicably coupled to the transfer deck; at least one goods settling and container closing stations communicably coupled to the transfer deck by an asynchronous transport system; and at least one autonomous guided vehicle configured to traverse the transfer deck and transport goods containers, having breakpack goods therein, from the at least one breakpack station to the at least one goods settling and container closing station.
  • the goods settling and container closing station further comprises at least one autonomous guided vehicle interface adjacent the transfer deck, where the at least one autonomous guided vehicle interface is configured to effect transfer of the goods containers between the goods settling and container closing station and the at least one autonomous guided vehicle.
  • each storage level comprises a respective goods settling and container closing station where the respective goods settling and container closing stations form a stacked gang of goods settling and container closing stations.
  • the at least one goods settling and container closing stations comprises a synchronous transport system configured to transfer the goods containers between the asynchronous transport system and the at least one goods settling and container closing stations.
  • the synchronous transport system transports the goods containers to one or more of a container settler and a container closing bay.
  • a warehousing system for storing and retrieving goods in containers.
  • the warehousing system comprising: a goods settling and container closing station comprising: a container settler having: a frame, a container platform coupled to the frame by a link at one end of the container platform, and by a fulcrum at the other end of the container platform, where the fulcrum is offset, along the container platform, from a pivot joint of the link to the container platform, and a drive unit coupled to the container platform and configured to drive the container platform in a cyclic movement; a container closing bay; and a conveyance communicably coupling the container settler and the container closing bay.
  • the at least one opposing container lid manipulator comprises inbound opposing helical guides disposed to guide the respective lid portions into a semi-closed orientation, with the goods container travelling in a first direction.
  • the at least one opposing container lid manipulator comprises outbound opposing helical guides disposed to guide the respective lid portions from the semi-closed orientation to a closed orientation, with the goods container travelling in a second direction that is opposite the first direction.
  • the container closing bay comprises double outbound opposing helical guides disposed along a second direction, opposite the first direction, so that one of the outbound opposing helical guides engages a leading portion of the respective lid portions in the semi-closed orientation and a second of the outbound opposing helical guides engages a trailing portion of the respective lid portions in the semi-closed orientation so as to guide the respective lid portions from the semi-closed orientation to a closed orientation with the goods container travelling in the second direction.
  • the container closing bay further includes: a frame to which the at least one opposing container lid manipulator is coupled; a lid support movably coupled to the frame and configured to hold the respective lid portions in a semi-closed orientation; and an outbound lid manipulator movably coupled to the frame and configured to engage the respective lid portions and effect interlocking of the respective lid portions with each other.
  • the container closing bay comprises: a goods container conveying surface; and a drive section configured to drive the goods container conveying surface alternately in a first direction into the container closing bay and in a second direction out of the container closing bay, where the second direction is opposite the first direction.
  • the container settler further comprises a container grip movably coupled to the frame, the container grip is configured to grip a goods container, of the goods containers, so that the goods container and the platform move as a unit.
  • the drive unit is coupled to the frame, and comprises a drive, a cam coupled to an output of the drive, and a connecting link coupling the cam to the container platform.
  • the fulcrum forms a pivot joint of another link that couples the container platform to the frame, and the drive unit drives the container platform in a reciprocating movement, where the respective links constrain reciprocating movement of the respective pivot joints, and the container platform, to travel along a multi-dimensional reciprocating path of motion.
  • a warehousing system for storing and retrieving goods in containers.
  • the warehousing system comprising: at least one goods settling and container closing station for a mixed product unit container, the goods settling and container closing station comprising: a container closing bay that includes an opposing container lid manipulator having opposing helical guides configured to engage and guide a closing movement of respective lid portions of the mixed product unit container from an open configuration to a closed configuration.
  • the warehousing system further comprises a conveyance with an input interface station and an output interface station, where the input interface station is configured to effect inbound transfer of mixed product unit containers to the at least one goods settling and container closing station and the output interface station is configured to effect outbound transfer of the mixed product unit containers from the at least one goods settling and container closing station.
  • the warehousing system further comprises a container settler configured grip and agitate the mixed product unit container, and effect settling of product units within the mixed product unit container.
  • the conveyance communicably couples the container settler and container closing bay, where the container closing bay is disposed downstream of the container settler.
  • the container settler comprises: a frame; a container platform coupled to the frame by a link at one end of the container platform, and by a fulcrum at the other end of the container platform, where the fulcrum is offset, along the container platform, from a pivot joint of the link to the container platform, and a drive unit coupled to the container platform and configured to drive the container platform in a cyclic movement.
  • the container settler further comprises a container grip movably coupled to the frame, the container grip is configured to grip a goods container, of the goods containers, so that the goods container and the platform move as a unit.
  • the container settler further comprises a drive section coupled to the frame, the drive section comprises a drive, a cam coupled to an output of the drive, and a connecting link coupling the cam to the container platform.
  • the at least one opposing container lid manipulator comprises inbound opposing helical guides disposed to guide the respective lid portions into a semi-closed orientation, with the goods container travelling in a first direction.
  • the at least one opposing container lid manipulator comprises outbound opposing helical guides disposed to guide the respective lid portions from the semi-closed orientation to a closed orientation, with the goods container travelling in a second direction that is opposite the first direction.
  • the container closing bay comprises double outbound opposing helical guides disposed along a second direction, opposite the first direction, so that one of the outbound opposing helical guides engages a leading portion of the respective lid portions in the semi-closed orientation and a second of the outbound opposing helical guides engages a trailing portion of the respective lid portions in the semi-closed orientation so as to guide the respective lid portions from the semi-closed orientation to a closed orientation with the goods container travelling in the second direction.
  • the container closing bay further includes: a frame to which the at least one opposing container lid manipulator is coupled; a lid support movably coupled to the frame and configured to hold the respective lid portions in a semi-closed orientation; and an outbound lid manipulator movably coupled to the frame and configured to engage the respective lid portions and effect interlocking of the respective lid portions with each other.
  • the container closing bay comprises: a goods container conveying surface; and a drive section configured to drive the goods container conveying surface alternately in a first direction into the container closing bay and in a second direction out of the container closing bay, where the second direction is opposite the first direction.
  • the warehousing system comprises stacked storage levels, each storage level comprising a respective goods settling and container closing station where the respective goods settling and container closing stations form a stacked gang of goods settling and container closing stations.
  • a method for storing and retrieving goods in containers in a warehousing system comprising: providing at least one storage level having storage aisles and a transport deck connecting the storage aisles; providing at least one breakpack station communicably coupled to the transfer deck; providing at least one goods settling and container closing stations communicably coupled to the transfer deck by an asynchronous transport system; and transporting goods containers, with at least one autonomous guided vehicle traversing the transfer deck, from the at least one breakpack station to the at least one goods settling and container closing station, where the goods containers have breakpack goods therein.
  • the method further comprises effecting transfer of the goods containers between the goods settling and container closing stations and the at least one autonomous guided vehicle with at least one autonomous guided vehicle interface of the goods settling and container closing stations, where the at least one autonomous guided vehicle interface is adjacent the transfer deck.
  • each storage level comprises a respective goods settling and container closing station where the respective goods settling and container closing stations form a stacked gang of goods settling and container closing stations.
  • the method further comprises transferring the goods containers between the asynchronous transport system and the at least one goods settling and container closing stations with a synchronous transport system of the at least one goods settling and container closing stations.
  • the synchronous transport system transports the goods containers to one or more of a container settler and a container closing bay.
  • a method for storing and retrieving goods in containers in a warehousing system comprising: providing a goods settling and container closing station comprising: a container settler having: a frame, a container platform coupled to the frame by a link at one end of the container platform, and by a fulcrum at the other end of the container platform, where the fulcrum is offset, along the container platform, from a pivot joint of the link to the container platform, and a drive unit coupled to the container platform, a container closing bay; and driving, with the drive unit, the container platform in a cyclic movement; and conveying, with a conveyance, a container between the container settler and the container closing bay.
  • the method further comprises engaging and guiding a closing movement, from an open configuration to a closed configuration, of respective lid portions of a container with opposing guides of at least one opposing container lid manipulator of the container closing bay.
  • the method further comprises guiding the respective lid portions into a semi-closed orientation with inbound opposing helical guides of the at least one opposing container lid manipulator with the goods container travelling in a first direction.
  • the method further comprises guiding the respective lid portions from the semi-closed orientation to a closed orientation with outbound opposing helical guides of the at least one opposing container lid manipulator , with the goods container travelling in a second direction that is opposite the first direction.
  • the container closing bay comprises double outbound opposing helical guides disposed along a second direction, opposite the first direction, the method further comprising engaging a leading portion of the respective lid portions in the semi-closed orientation with one of the outbound opposing helical guides and engaging a trailing portion of the respective lid portions in the semi-closed orientation with a second of the outbound opposing helical guides so as to guide the respective lid portions from the semi-closed orientation to a closed orientation with the goods container travelling in the second direction.
  • the method further comprises: providing a frame of the container closing bay, to which the at least one opposing container lid manipulator is coupled; holding the respective lid portions in a semi-closed orientation with a lid support of the container closing bay, the lid support being movably coupled to the frame; and engaging, with an outbound lid manipulator of the container closing bay, the respective lid portions and effecting interlocking of the respective lid portions with each other, the outbound lid manipulator being movably coupled to the frame.
  • the method further comprises: providing a goods container conveying surface of the container closing bay; and driving the goods container conveying surface, with a drive section of the container closing bay, alternately in a first direction into the container closing bay and in a second direction out of the container closing bay, where the second direction is opposite the first direction.
  • the method further comprises gripping a container with a container grip of the container settler so that the goods container and the platform move as a unit, the container grip being movably coupled to the frame.
  • the drive unit is coupled to the frame, and comprises a drive, a cam coupled to an output of the drive, and a connecting link coupling the cam to the container platform.
  • the fulcrum forms a pivot joint of another link that couples the container platform to the frame, and the drive unit drives the container platform in a reciprocating movement, where the respective links constrain reciprocating movement of the respective pivot joints, and the container platform, to travel along a multi-dimensional reciprocating path of motion.
  • a method for transporting goods in containers in a warehousing system for storing and retrieving goods in the containers comprising: providing at least one goods settling and container closing station for a mixed product unit container; and engaging and guiding, with an opposing container lid manipulator having opposing helical guides, a closing movement of respective lid portions of the mixed product unit container from an open configuration to a closed configuration, where the goods settling and container closing station has a container closing bay that includes the opposing container lid manipulator.
  • the method further comprises: effecting, with an input interface station of a conveyance, inbound transfer of mixed product unit containers to the at least one goods settling and container closing station; and effecting, with an output interface station of the conveyance, outbound transfer of the mixed product unit containers from the at least one goods settling and container closing station.
  • the method further comprises gripping and agitating, with a container settler, the mixed product unit container to effect settling of product units within the mixed product unit container.
  • the conveyance communicably couples the container settler and container closing bay, where the container closing bay is disposed downstream of the container settler.
  • the method further comprises: providing the container settler with: a frame, and a container platform coupled to the frame by a link at one end of the container platform, and by a fulcrum at the other end of the container platform, where the fulcrum is offset, along the container platform, from a pivot joint of the link to the container platform; and driving the container platform, with a drive unit coupled to the container platform in a cyclic movement.
  • the method further comprises gripping the mixed product unit container with a container grip of the container settler so that the goods container and the platform move as a unit, where the container grip is movably coupled to the frame.
  • the method further comprises effecting agitation of the mixed product unit container with a drive section of the container settler, where the drive section is coupled to the frame and comprises a drive, a cam coupled to an output of the drive, and a connecting link coupling the cam to the container platform.
  • the method further comprises guiding the respective lid portions into a semi-closed orientation, with inbound opposing helical guides of the at least one opposing container lid manipulator, with the goods container travelling in a first direction.
  • the method further comprises guiding the respective lid portions from the semi-closed orientation to a closed orientation, with outbound opposing helical guides of the at least one opposing container lid manipulator, with the goods container travelling in a second direction that is opposite the first direction.
  • the container closing bay comprises double outbound opposing helical guides disposed along a second direction, opposite the first direction, the method further comprising engaging a leading portion of the respective lid portions in the semi-closed orientation with one of the outbound opposing helical guides, and engaging a trailing portion of the respective lid portions in the semi-closed orientation with a second of the outbound opposing helical guides so as to guide the respective lid portions from the semi-closed orientation to a closed orientation with the goods container travelling in the second direction.
  • the method further comprises: providing a frame, of the container closing bay, to which the at least one opposing container lid manipulator is coupled; holding the respective lid portions in a semi-closed orientation with a lid support movably coupled to the frame; and engaging, with an outbound lid manipulator movably coupled to the frame, the respective lid portions and effecting interlocking of the respective lid portions with each other.
  • the method further comprises driving, with a drive section of the container closing bay, a goods container conveying surface, of the container closing bay, alternately in a first direction into the container closing bay and in a second direction out of the container closing bay, where the second direction is opposite the first direction.
  • the warehousing system comprises stacked storage levels, each storage level comprising a respective goods settling and container closing station where the respective goods settling and container closing stations form a stacked gang of goods settling and container closing stations.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Warehouses Or Storage Devices (AREA)
EP24775408.8A 2023-03-17 2024-03-14 Lagersystem zum ein- und auslagern von lagergut in behältern Pending EP4680533A2 (de)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US202363452749P 2023-03-17 2023-03-17
PCT/US2024/019932 WO2024196703A2 (en) 2023-03-17 2024-03-14 Warehousing system for storing and retrieving goods in containers

Publications (1)

Publication Number Publication Date
EP4680533A2 true EP4680533A2 (de) 2026-01-21

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Application Number Title Priority Date Filing Date
EP24775408.8A Pending EP4680533A2 (de) 2023-03-17 2024-03-14 Lagersystem zum ein- und auslagern von lagergut in behältern

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EP (1) EP4680533A2 (de)
KR (1) KR20250159249A (de)
CN (1) CN121335839A (de)
WO (1) WO2024196703A2 (de)

Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB228038A (en) * 1924-04-07 1925-01-29 Francesco Ferdinando Molie Improvements in or relating to the separation of caramels
DE2340209A1 (de) * 1973-08-08 1975-02-20 Franz Schneider Verlag Verwalt Kommissioniereinrichtung
US9856083B2 (en) * 2015-01-16 2018-01-02 Symbotic, LLC Storage and retrieval system
US11741519B2 (en) * 2018-07-31 2023-08-29 Trilliant Food And Nutrition, LLC End-consumer customizable product variety pack
US11596951B2 (en) * 2020-12-15 2023-03-07 Best Process Solutions, Inc. Shaker table

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WO2024196703A3 (en) 2025-01-16
WO2024196703A2 (en) 2024-09-26
CN121335839A (zh) 2026-01-13
KR20250159249A (ko) 2025-11-10

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