JP2024512705A - Warehouse system for storing and retrieving goods in containers - Google Patents

Abstract

The warehouse system includes a multi-level container storage array, each level of which has a transport area and a storage area, and a container on each storage shelf at each level of the multi-level storage array. a container transport vehicle and a put wall located at each level for transport to the storage location and thence to a break pack handling station, with a corresponding break pack product transfer deck at each level of the put wall; Multiple levels of put walls of break pack goods container stations distributed along each level and along corresponding break pack goods transfer decks and between corresponding break pack goods transfer decks at different levels of the put wall , the Break Pack product transportation vehicle that passes to each Break Pack product container station and transports the Break Pack product, and the Break Pack product container located at the container storage location, Break Pack operating station, and Break Pack product container station. and a controller for effecting operation of the container transport vehicle between the containers.

Description

[Cross reference to related applications]
This application claims the benefit of U.S. Provisional Patent Application No. 63/044,721, filed June 25, 2021, the entire disclosure of which is incorporated herein by reference. This is a continuation in part of filed U.S. patent application Ser. No. 17/358,383. This application also includes U.S. Provisional Patent Application No. 63/170,282, filed April 2, 2021, and U.S. Provisional Patent Application No. 63/170,282, filed April 6, 2021, the entire disclosure of which is incorporated herein by reference. This is a non-provisional application and claims the benefit of Provisional Patent Application No. 63/171,465.

[Technical field]
TECHNICAL FIELD The disclosed embodiments relate generally to material handling systems, and more specifically to transporting and storing items within material handling systems.

Brief Description of Related Developments It is well recognized that the integration of automated storage and retrieval systems into logistics chains, especially goods-to-man systems, has significant benefits throughout the efficiency and costs of the logistics chain. has been done. Traditional systems, even with the integration of highly automated storage and retrieval systems within logistics facilities, generally operate by storing product (e.g., supply) containers, where supply containers hold common types of goods. (also called a product), including the case, pack, etc. that contains it. Product containers may arrive on pallets (e.g., common supply containers) or as truck loads, be depalletized or unloaded from trucks, stored at a logistics facility, and transported by automated storage and retrieval systems. Distributed throughout the storage volume of the facility (e.g., in a three-dimensional array of storage racks).

Especially if combined product containers are desired (e.g., where any given order container is held by a common container, such as in direct to consumer fulfillment). The combination of ordered products in the order container may have combined/different products or product types, or in the case of joint fulfillment to the consumer, such as through a pick-up point of a retail order, the combination of ordered products in the order container may have at least some Traditionally, the fabrication of a combined product container is a goods-to-person system for automated storage and retrieval. Using a goods to person (GTP) configuration, an automated storage and retrieval system runs from storage locations to workstations across a three-dimensional array of storage racks, each containing one or more product/supply containers of a common product type. (i.e. each product item within a product container is the same or substantially similar), manually or automatically, according to a given fulfillment (or filling) order; Picking and retrieving goods from the various products/supply containers supplied to a given workstation by the storage and retrieval system, and picking and retrieving goods from the various picked goods (combined or included in a given order) (common when the container is filled in such a way) into the order container. Such a workstation may be referred to as a breakpack station, where the product container may be "broken down" and its contents may be placed, in whole or in part, into an order container or breakpack storage. may be placed in what is called a container (e.g. a tote bag), for example, where the product container is not suitable for continuously holding items of product remaining after a break-pack operation, and any such remaining of the product (i.e., the remainder of the product in the "disassembled" product container) should be returned to the storage position in the three-dimensional array of storage racks by an automated storage and retrieval system. To increase efficiency, order containers may be placed in a three-dimensional array of storage racks, possibly in storage positions on storage racks that store product containers, and then, such as when order output is desired. Both input and output from the three-dimensional array of storage racks are otherwise provided by an automated storage and retrieval system.

Traditionally, break pack stations are located at a single common level (e.g., at ground level, or at a level common to or proximate to the fill load exit of a logistics facility) to transport order containers from the break pack station to the exit to fulfill the order. or distributed at various levels around or within a three-dimensional array of storage racks to transport product containers between storage locations and break pack stations by automated storage and retrieval systems, and automated storage and effecting the entry/re-entry of order containers and break pack storage containers (collectively referred to herein as break pack merchandise containers) from the break pack station to the storage location by the retrieval system. An example of a conventional system and method for order fulfillment by preparing storage units at a pick station is disclosed in U.S. Pat. No. 9,988,212, issued June 5, 2018. US Pat. No. 9,988,212 describes a method of order fulfillment by making order units and/or product units available from a storage facility in a desired arrangement at a pick station. The storage facility includes a plurality of multi-level storage racks in which order units and/or product units are stored, automated storage and retrieval equipment, such as shuttles, to retrieve and store order units and/or product units, and automated storage and retrieval equipment, such as shuttles, to retrieve and store order units and/or product units. and/or a lift used to transport product units to at least one storage-exit conveyor, where each lift is connected to a picking station at a picking level by a storage-inlet conveyor and a storage-exit conveyor. Directly connected. Conventional systems, such as those described above, are constrained to a limited exchange interface (substantially defined by the footprint of the break pack station) between the supply container and the break pack goods container. This limits the throughput through the pick station to that performed in the immediate space of the break pack operator. An improved system is desired.

The foregoing aspects and other features of the disclosed embodiments are explained in the following description taken in conjunction with the accompanying drawings.

1 is a schematic diagram of an automated storage and retrieval system in accordance with aspects of the disclosed embodiments; FIG. 1 is a schematic diagram of an automated storage and retrieval system in accordance with aspects of the disclosed embodiments; FIG. 1 is a schematic diagram of an automated storage and retrieval system in accordance with aspects of the disclosed embodiments; FIG. 1 is a schematic illustration of a mixed pallet load formed by an automated storage and retrieval system in accordance with aspects of the disclosed embodiments; FIG. 1 is a schematic diagram of an automated storage and retrieval system in accordance with aspects of the disclosed embodiments; FIG. 1A, 1B, 1C, and 1E are schematic perspective views of the break pack merchandise module of the automated storage and retrieval system in accordance with aspects of the disclosed embodiments; FIG. 3 is a schematic perspective view of a portion of the break pack merchandise module of FIG. 2 in accordance with aspects of the disclosed embodiment; FIG. 3 is a schematic side view of a portion of the break pack merchandise module of FIG. 2 in accordance with aspects of the disclosed embodiments; FIG. 3 is a schematic perspective view of a portion of the break pack product module of FIG. 2 in accordance with aspects of the present disclosure; FIG. 3 is a schematic perspective view of a portion of the break pack merchandise module of FIG. 2 in accordance with aspects of the disclosed embodiments; FIG. 3 is a schematic perspective view of a portion of the break pack merchandise module of FIG. 2 in accordance with aspects of the disclosed embodiments; FIG. 3 is a schematic perspective view of a portion of the break pack merchandise module of FIG. 2 in accordance with aspects of the disclosed embodiment; FIG. 3 is a schematic perspective view of a portion of the break pack merchandise module of FIG. 2 in accordance with aspects of the disclosed embodiments; FIG. 3 is a schematic perspective view of a portion of the break pack merchandise module of FIG. 2 in accordance with aspects of the disclosed embodiment; FIG. 3 is a schematic perspective view of a portion of the break pack merchandise module of FIG. 2 in accordance with aspects of the disclosed embodiment; FIG. 3 is a schematic perspective view of a portion of the break pack merchandise module of FIG. 2 in accordance with aspects of the disclosed embodiment; FIG. 3 is a schematic perspective view of a portion of the break pack product module of FIG. 2 in accordance with aspects of the disclosed embodiment; FIG. 3 is a schematic perspective view of a portion of the break pack merchandise module of FIG. 2 in accordance with aspects of the disclosed embodiment; FIG. 3 is a schematic perspective view of a portion of the break pack merchandise module of FIG. 2 in accordance with aspects of the disclosed embodiment; FIG. 3 is a schematic perspective view of a portion of the break pack merchandise module of FIG. 2 in accordance with aspects of the disclosed embodiment; FIG. 3 is a schematic perspective view of a portion of the break pack product module of FIG. 2 in accordance with aspects of the disclosed embodiment; FIG. 3 is a schematic perspective view of an operator station of the break pack product module of FIG. 2 in accordance with aspects of the disclosed embodiment; FIG. 3 is a schematic perspective view of an operator station of the break pack product module of FIG. 2 in accordance with aspects of the disclosed embodiment; FIG. 3 is an example flow diagram of a break pack operating method of the break pack product module of FIG. 2 in accordance with aspects of the disclosed embodiments. FIG. FIG. 2 is a schematic diagram of transporting break pack merchandise in accordance with aspects of the disclosed embodiments. FIG. 3 is an example flow diagram of a break pack operation method in accordance with aspects of the disclosed embodiments. 3 is an exemplary schematic perspective view of the BreakPak product bot introduction/retrieval system of the BreakPak product module of FIG. 2 in accordance with aspects of the disclosed embodiments; FIG. 11 is an exemplary flow diagram of a method of operating the BreakPak product bot installation/retrieval system of FIG. 10 in accordance with aspects of the disclosed embodiments. FIG. 1A is a schematic diagram of a portion of the automated storage and retrieval system of FIGS. 1A, 1B, 1C, and 1E in accordance with aspects of the disclosed embodiments; FIG. 1A is a schematic diagram of a portion of the automated storage and retrieval system of FIGS. 1A, 1B, 1C, and 1E in accordance with aspects of the disclosed embodiments; FIG. 1A is a schematic diagram of a portion of the automated storage and retrieval system of FIGS. 1A, 1B, 1C, and 1E in accordance with aspects of the disclosed embodiments; FIG. 1 is a schematic illustration of a transport vehicle in accordance with aspects of the disclosed embodiments; FIG. 1 is a schematic illustration of a transport vehicle in accordance with aspects of the disclosed embodiments; FIG. 1A is a schematic diagram of a portion of the automated storage and retrieval system of FIGS. 1A, 1B, 1C, and 1E in accordance with aspects of the disclosed embodiments; FIG. 1A is a schematic diagram of a portion of the automated storage and retrieval system of FIGS. 1A, 1B, 1C, and 1E in accordance with aspects of the disclosed embodiments; FIG. 1A is a schematic diagram of a portion of the automated storage and retrieval system of FIGS. 1A, 1B, 1C, and 1E in accordance with aspects of the disclosed embodiments; FIG. 1A is a schematic diagram of a portion of the automated storage and retrieval system of FIGS. 1A, 1B, 1C, and 1E in accordance with aspects of the disclosed embodiments; FIG. 13A and 13B are schematic illustrations of portions of the transport vehicle of FIGS. 13A and 13B in accordance with aspects of the disclosed embodiments; FIG. 13A and 13B are schematic illustrations of portions of the transport vehicle of FIGS. 13A and 13B in accordance with aspects of the disclosed embodiments; FIG. 13A and 13B are schematic illustrations of portions of the transport vehicle of FIGS. 13A and 13B in accordance with aspects of the disclosed embodiments; FIG. 13A and 13B are schematic illustrations of portions of the transport vehicle of FIGS. 13A and 13B in accordance with aspects of the disclosed embodiments; FIG. 13A and 13B are schematic illustrations of portions of the transport vehicle of FIGS. 13A and 13B in accordance with aspects of the disclosed embodiments; FIG. 13A and 13B are schematic illustrations of portions of the transport vehicle of FIGS. 13A and 13B in accordance with aspects of the disclosed embodiments; FIG. FIG. 3 is an example flow diagram in accordance with aspects of the disclosed embodiments. FIG. 3 is an example flow diagram in accordance with aspects of the disclosed embodiments. 3 is a schematic plan view of a portion of the break pack merchandise module of FIG. 2 in accordance with aspects of the present disclosure; FIG. 3 is a schematic side view of a portion of the break pack merchandise module of FIG. 2 in accordance with aspects of the disclosed embodiments; FIG. 3 is a schematic side view of a portion of the break pack merchandise module of FIG. 2 in accordance with aspects of the disclosed embodiments; FIG. 1 is a schematic illustration of a non-holonomic product bot having an asymmetric payload retention configuration in accordance with aspects of the disclosed embodiments; FIG. 1 is a schematic illustration of a non-holonomic product bot having a symmetrical payload holder configuration in accordance with aspects of the disclosed embodiments; FIG. 1 is a schematic illustration of a holonomic product bot having an asymmetric payload retention configuration in accordance with aspects of the disclosed embodiments; FIG. 1 is a schematic illustration of a holonomic product bot having a symmetrical payload holding configuration in accordance with aspects of the disclosed embodiments; FIG. 1 is a schematic illustration of an example portion of a merchandise deck in accordance with aspects of the disclosed embodiments; FIG. FIG. 3 is an example flow diagram in accordance with aspects of the disclosed embodiments. FIG. 3 is an example flow diagram in accordance with aspects of the disclosed embodiments. 1A is a schematic block diagram of an orthogonal sortation echelon of the automated storage and retrieval system of FIGS. 1A and 1B in accordance with aspects of the disclosed embodiments; FIG. 29 is an example diagram illustrating example classifications resulting from the orthogonal classification echelon of FIG. 28; FIG. 29 is an example diagram illustrating example classifications resulting from the orthogonal classification echelon of FIG. 28; FIG. 29 is an example diagram illustrating example classifications resulting from the orthogonal classification echelon of FIG. 28; FIG. 29 is an example diagram illustrating example classifications resulting from the orthogonal classification echelon of FIG. 28; FIG. 29 is an example diagram illustrating example classifications resulting from the orthogonal classification echelon of FIG. 28; FIG. FIG. 2 is a schematic diagram depicting a structural configuration of an orthogonal classification echelon of an automated storage and retrieval system and a controller structure of an automated storage and retrieval system, in accordance with aspects of the disclosed embodiments. FIG. 3 is an example flow diagram in accordance with aspects of the disclosed embodiments. 1 is a schematic diagram of a portion of an automated storage and retrieval system in accordance with aspects of the disclosed embodiments; FIG.

FIG. 1A is a schematic diagram of an automated storage and retrieval system (also referred to herein as a warehouse system) 100 in accordance with aspects of the disclosed embodiments. Although aspects of the disclosed embodiments are described with reference to the drawings, it is to be understood that aspects of the disclosed embodiments may be embodied in many forms. Additionally, any suitable size, shape, or type of elements or materials may be used.

As described herein, aspects of the disclosed embodiments provide an automated storage and retrieval system 100 that includes at least one break pack module 266 (also referred to herein as an automated order fulfillment system). At least one break pack module 266 includes an autonomous product bot 262 that traverses multiple (stacked, vertically distributed, or offset) levels of break pack stations to complete product bot tasks. For example, multiple levels 130DG1-130DG3 and/or 130DGL of break-pack module 266 are traversed by product bot 262 to pick break-pack products BPG from operator stations 801-804, put wall 263W (herein placement of breakpack goods BPG in breakpack goods containers 264 (e.g., multiple vertically arranged levels of container goods) (also referred to as a multilevel breakpack goods container fill array); and the return of the product bot 262 to the operator station 801-804). By placing the goods at multiple vertical levels from one or more common operator (break pack) stations 801-804, regardless of the occlusion of one or more break pack goods containers 264, if desired, Provides an increased throughput of product placement into containers at a given/desired time and in a given order of placement (eg, increases the number of locations where containers are available). Each break pack module 266 has a separate/independent flow or stream of containers into, through, and out of the break pack module 266. Container bot 110 and/or product bot 262 are configured to ensure that the flow of containers within automated storage and retrieval system 100 is balanced, for example, between different put walls 236W of different break pack modules 266 (e.g., for container transfers). (to eliminate bottlenecks, provide substantially the same output rate from each (or two or more) break pack modules 266, or any other suitable balancing of container transfers); It may be operated by a suitable controller (such as controller 120). As described herein, the break pack module 266 may span several levels 130L of the storage structure 130 such that the container bot 110 and/or the product bot 262 within the automated storage and retrieval system 100 such that the flow of containers is balanced across the storage levels 130L (e.g., eliminating container transfer bottlenecks or providing approximately the same output rate from each (or two or more) break pack modules 266). a suitable controller (to provide approximately the same output rate from each (or two or more) storage levels 130L, or for any other suitable balancing of container transfers); controller 120, etc.).

The operation of product bot 262 is autonomous operation under the control of any suitable controller, such as controller 120, where the tasks performed by product bot 262 are independent of any given product bot task. (as described herein) on the fly. The controller 120 also uses the product bot 262 to configure the placement of break-pack products BPG into one or more break-pack product containers 264 in any suitable predetermined order or classification as described herein. /sequencing echelon is configured to effect sequencing of breakpack product BPGs (as described herein) into one or more breakpack product containers 264. Aspects of the disclosed embodiments also provide for closure/restriction of product bot 262 access to one or more portions of break pack module 266, e.g., human access to closed portions of break pack module 266. bring access to.

In accordance with aspects of the disclosed embodiments, automated storage and retrieval system 100 is disclosed, for example, in U.S. Pat. within a retail distribution center or warehouse to fulfill orders received from different customers (such as those described herein) for break pack merchandise BPG and/or case units such as those described in No. 168; It can work.

By way of example, a case unit is a case or unit of merchandise that is not stored (eg, not included) in a tray, tote, or pallet. In other examples, the case unit can be placed on any tray, tote, container (such as a container for residual goods after a break pack where the disassembled case unit structure is not suitable for conveying the residual goods as a unit), on a pallet, etc. be a case or unit of goods contained in a suitable manner; In yet another example, the case unit is a combination of uncontained and included articles. A case unit is, for example, a cased unit of goods that is adapted to be removed from or placed on a pallet (e.g., a case of soup cans, a box of cereal, etc.) or an individual item. It is noted that including In accordance with aspects of the disclosed embodiments, a transport case for a case unit (e.g., a carton, barrel, box, crate, jug, or any other suitable device for holding a case unit) is a variable The case unit may have a size, may be used to hold the case unit during transportation, and may be configured to be palletized for transportation.

For example, when a bundle or pallet of case units arrives at storage and retrieval system 100, the contents of each pallet may be uniform (e.g., each pallet holds a predetermined number of the same articles; i.e., one one pallet holds soup and another holds cereal), and once the pallet exits the storage and retrieval system, the pallet may contain any suitable number and combination of different case units (e.g., each mixed pallet mixed pallets which hold case units of different types (i.e. the pallets hold combinations of soups and cereals), which are provided to a palletizer in a sorted arrangement to form a mixed pallet, for example ( For example, sorted placement is effected by at least the pallet output sorting 185 echelon of the automated storage and retrieval system 100, where at least one or more of the container bot 110 and the lift module 150B are used to sort case units for sorting. It is noted that In aspects of the disclosed embodiments, the storage and retrieval system 100 described herein may be applied to any environment in which units are stored and retrieved.

In accordance with aspects of the disclosed embodiments, automated storage and retrieval system 100 stores product containers or case units (which generally refer to supply goods containers or supply containers) to fulfill orders as further described herein. One or more break pack modules 266 (see FIG. 2) configured to disassemble containers 265 (which may be referred to as containers 265) into break pack merchandise containers 264. One or more break pack modules 266 may be communicatively coupled to one or more stacked (storage) levels 130L of automated storage and retrieval system 100, where one of the automated storage and retrieval systems 100 One or more levels 130L include at least one break pack module 266. Break pack module(s) 266 may be a plug-and-play module that may be coupled to any suitable portion of the structure of automated storage and retrieval system 100. For example, the break pack module(s) may be connected to container transfer deck 130DC (see also container transfer deck 130DC2 of FIG. 1B) or (1) of automated storage and retrieval system 100, as described in more detail below. one or more) picking passageways 130A. Break pack module(s) 266 may be arranged in any suitable number of stacked storage levels of automated storage and retrieval system 100.

Here, automated storage and retrieval system 100 may be configured, such as via any suitable controller (eg, control server 120), to have selectable modes of operation. The control server 120 determines that the pick face and break pack product container 264 (e.g., of the supply container 265) is one of orthogonal sortation echelons 15000, 15100, 15200, or as described herein. Automated storage and storage as disclosed herein for filling the load at one or more of the break pack containers 264 and pick faces (e.g., of the supply container 265) having merchandise sorted through the plurality of The automated storage and retrieval system 100 may be operated in different modes of operation such that the cargo is transferred to the load filling section of the retrieval system 100. In one mode of operation, automated storage and retrieval system 100 is configured to output product cases, containers, and/or case units to a palletizer. In another mode of operation, such as in which break pack module(s) 266 is utilized, the automated storage and retrieval system 100 disassembles the product cases, product containers, and/or case units and breaks down the break pack product containers. , output the product cases, containers, and/or case units to a palletizer, or otherwise output the break pack (order) container(s) and/or product cases, containers, and/or case units The remainder is configured to be re-entered into the palletizer (eg, after being disassembled) and stored for later retrieval.

Controller 120, as can be appreciated, is configured to effect the operation of automated storage and retrieval system 100 as described herein. For example, the controller 120 may be configured to assemble and uncontainer orders of break pack merchandise BPG from a supply container 265 (see FIG. 5A) into a break pack merchandise container 264 (see FIG. 3A) as described herein. For the removal of break pack goods containers 264 via station TS, at least one container bot or autonomously guided container transport vehicle 110 (see also FIG. 1) and at least one goods bot or autonomously guided break pack goods transport vehicle 262 (see also, e.g., FIG. 6B), as well as to effect operation of any lifts 310A, 310B, 310A', 310B' and other components of the automated storage and retrieval system 100 described herein. It is configured. For example, the controller 120 may control the container storage location 130S, the break-pack operating station 140, and the break-pack merchandise containers 264 (e.g., as described herein) located along the break-pack merchandise transfer deck or merchandise deck 130DG. The break pack product container 64 located at the break pack product interface station/container station 263L of the put wall 263W is configured to effect operation of the container bot(s) 110. As another example, controller 120 transfers break-packed products BPG (e.g., , configured to cause the operation of the product bot(s) 262 to classify (in the break pack order classification 188 echelon of the automated storage and retrieval system 100) as described herein. There is. As a further example, the controller 120 may cause the container bot(s) 110 to access the corresponding break pack product container 264 on the product transfer deck 130DG from the put wall 263W and transfer the break pack product container 264 to the container transfer deck. 130DC to at least one of a container output/transfer station TS and a corresponding container storage location 130SB of a storage shelf at a corresponding level 130L of a multi-level storage array (e.g., as described herein). The break pack output classification 189 echelon is configured to effect the behavior of the container bot(s) 110 (to at least partially effect the break pack output classification 189 echelon as described above).

The controller 120 is also disclosed in U.S. Provisional Patent Application No. 1, filed June 26, 2020, both entitled "Warehousing System for Storage and Retrieving Goods In Containers," the entire disclosure of which is incorporated herein by reference. 63/044,721 and U.S. Nonprovisional Patent Application No. 17/358,383 filed June 25, 2021, ) Empty break-pack goods containers 264 are automatically stored such that container bot(s) 110 transport empty break-pack goods containers 264 along transport/transfer loops 233BP of container transfer deck 130DC. and at the break pack product interface location(s) 263L of the break pack product interface(s) 263 for transfer of the break pack product BPG to the retrieval system and to the break pack product container 264. It is configured to effect operation of container bot(s) 110 and lift 150 (eg, form a container feeding system) for introduction into a break pack module for deployment. Break pack product interface 263 may be generally similar to one or more of transfer station TS and buffer station BS described herein (similar to non-deterministic surfaces of rack storage space 130S described herein). a non-deterministic surface (e.g., or otherwise forming part of, or communicatively coupled to, a container transfer deck); It is noted that the break pack merchandise container 264 is placed thereon to form a non-deterministic interface between the merchandise transfer deck 130DG and the container transfer deck 130DC. In other aspects, empty break pack goods containers 264 are transferred (in a manner similar to that described above with respect to lifts and container bots) to storage spaces 130SB, 130S (FIG. 1B) of rack module RM and stored therein. or buffered at an infeed station, where controller 120 transfers empty break pack product containers from storage spaces 130SB, 130S or buffer locations to break pack product interface 263 in a manner similar to that described above. is configured to provide H.264 transport.

In one or more aspects, the controller 120 transports the break packs along the transport/transfer loops 233, 233A of the container transfer deck(s) 130DC to the break pack operation station 140 of the break pack(s). Container bots 110 transport empty supply containers 265 or normalized containers 265S as described in Warehousing System for Storage and U.S. Provisional Patent Application No. 63/044,721, filed June 26, 2020, entitled “Retrieving Goods In Containers” and U.S. Nonprovisional Patent Application No. 63, filed June 25, 2021. 17/358,383) to an automated storage and retrieval system. For installation, the container bot(s) 110 and lift 150 are configured to effect operation (eg, form a container feeding system).

As can be appreciated, the container bot 110, the goods bot 262, the lift module 150, the break pack module 266, and other suitable features of the storage and retrieval system 100 can be used, e.g., via any suitable network 180. , one or more central system control computers (eg, control servers) 120, etc., in any suitable manner to effect the operations described herein. In one aspect, 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. In one aspect, control server 120 includes a collection of substantially concurrently executing programs (e.g., non-transitory computer program code/system management software). A collection of programs that run substantially simultaneously may, for example, for example purposes only, control, schedule, and monitor the activities of all active system components, inventory (e.g., which case units are entered and retrieved), , the order in which cases are retrieved, and where the case units are stored) and the pick face (e.g., one or more case units that are movable as a unit and are handled as a unit by components of the storage and retrieval system). The storage and retrieval system 100 is configured to manage the storage and retrieval system 100, including managing the storage and retrieval system 100, and interfacing with the warehouse management system 2500. Control server 120, in one aspect, may be configured to control features of the storage and retrieval system in the manner described herein.

Referring also to FIG. 1D, for example, when an incoming bundle or pallet (e.g., from a case unit manufacturer or supplier) arrives at the storage and retrieval system for replenishment of the automated storage and retrieval system 100, In addition, the contents of each pallet may be uniform (e.g., each pallet holds a predetermined number of the same items, i.e., one pallet holds soup and another holds cereal). It is noted. As can be appreciated, the cases of such pallet loads may be substantially similar or, in other words, homogeneous cases (e.g., similar dimensions) and may have the same SKU (otherwise , as mentioned earlier, the pallet can be a "rainbow" pallet with layers formed in a homogeneous case). When a pallet PAL exits the storage and retrieval system 100, with cases filling replenishment orders, the pallet PAL may include any suitable number and combination of different case units CU (e.g., each pallet has a different (i.e., pallets hold combinations of canned soups, cereals, beverage packs, cosmetics, and household detergents). Cases combined on a single pallet may have different dimensions and/or different SKUs. In one aspect of the disclosed embodiments, storage and retrieval system 100 generally includes an infeed section, a storage and sorting section (where, in one aspect, storage of items is optional), as described in more detail below. and (e.g., the classification is effected in one or more of different orthogonal classifications as described herein) and (e.g., in one or more of different orthogonal classifications as described herein) The resulting classification may also be configured to include an output section. As can be appreciated, in one aspect of the disclosed embodiments, the system 100, operating, for example, as a retail distribution center, receives a uniform pallet load of cases, disassembles the pallet goods, or transfers cases from the uniform pallet load to the system. The various cases required by each order are separated into independent case units that are processed individually by the manufacturer, and the various cases required by each order are sorted into corresponding groups, and the corresponding groups of cases are transported and called mixed case pallet load MPL. It can play a role in assembling things. As can also be appreciated, in one aspect of the disclosed embodiments, the system 100, operating, for example, as a retail distribution center, receives a uniform pallet load of cases, disassembles the pallet goods, or removes cases from the uniform pallet load. Separating into independent case units that are processed individually by the system, taking the different cases called for by each order and sorting them into corresponding groups, January 2, 2018, the entire disclosure of which is incorporated herein by reference. No. 9,856,083, issued in 1999 and having U.S. Patent Application No. 14/997,920, is responsible for transporting and ordering corresponding groups of cases. It can be accomplished.

Automated storage and retrieval system 100 is disclosed in US Pat. SKU, dimensions, etc. as described in U.S. Provisional Patent Application No. 63/044,721 filed on June 25, 2021 and U.S. Nonprovisional Patent Application No. 17/358,383 filed on June 25, 2021. is configured to assemble appropriate groups of ordered cases, which may differ in size, into mixed case pallet loads and/or break pack containers 264 (including one or more of case units and/or break pack containers 264). For example, when a mixed case pallet load is assembled, the output section of the automated storage and retrieval system 100 produces the pallet load into what may be referred to as a structured architecture of mixed case stacks. The structured architecture of the pallet load described herein is exemplary; in other aspects, the pallet load may have any other suitable configuration. For example, the structured architecture may be any suitable predetermined configuration, such as a truck bay load or other suitable container or load container envelope that holds a structural load. The structured architecture of the pallet load consists of several flat case layers L121-L125, as previously described in U.S. Pat. No. 9,856,083, incorporated herein by reference in its entirety. , L12T. As a further example, break pack containers 264 are assembled by an output section of automated storage and retrieval system 100 for individual shipment to a customer or shipment in other break pack containers 264 to one or more customers; can be output.

1C and 1E, assembly of one or more of mixed pallet loads, individual break pack containers 264, and grouped break pack containers 264, as described in more detail herein. In order to provide for the storage and Other suitable features of retrieval system 100 may be operated. For example, casebot 110 may result in a pallet out classification 185 echelon in which case units are removed from storage and output for inclusion in a mixed pallet load. The casebot 110 and one or more of the break pack module lifts 310A, 310B also provide a break pack station input classification 186 echelon (orthogonal to the pallet output classification 185) that provides supply containers 265 to the break pack module 266 in a predetermined order. (independently from palette output classification 185). Each break pack manipulation station 140 of break pack module 266 may also provide an orthogonal classification (e.g., break pack station output classification 187 echelon) of the break pack product BPG to product bot 262, where product bot 262 puts Wall 263W is configured to provide another orthogonal classification (eg, break pack order classification 188 echelon) of break pack items PGB to break pack container 264. Casebot 110 picks break pack containers 264 from put wall 263W and provides break pack output classification 189 echelon (orthogonal to echelons 185-188) to the output section of automated storage and retrieval system 100. The classification echelons 186-188 provided by the break pack module 266 may form one or more of orthogonal classification echelons 15100, 15200 as described herein. The orthogonal classification of each classification echelon 186-188 that results in output of product units in a predetermined order may be independent of one or more of order order and order time.

In accordance with aspects of the disclosed embodiments, and referring again to FIG. 1A, automated storage and retrieval system 100 includes lift module 150A for entry into storage level 130L of storage structure or multi-level container storage array 130. an input station 160IN (including a depalletizer 160PA and/or a conveyor 160CA) for conveying goods (e.g., inbound supply containers) to an input station 160IN, and from storage (e.g., a palletizer (for palletizer loads) or a truck (for truckloads) (including a palletizer 160PB, an operator station 160EP, and/or a conveyor 160CB) for transporting items (e.g., outbound supply containers and filled break-pack goods (order) containers) from the lift module 150B for retrieval (to and from the lift module 150B). ) including output stations 160UT, 160EC. Here, output station 160EC is an individual fulfillment (or e-commerce) output station, where, for example, a filled break-packed merchandise (order) container containing single merchandise items and/or small bundles of merchandise is conveyed to fulfill an individual fulfillment order (such as an order placed by a consumer over the Internet). Output station 160UT is typically located at a commercial entity (e.g., commercial store, warehouse club, restaurant, distribution center (e.g., where merchandise such as break pack merchandise, case units, pick faces, etc.) is held for shipment to individual customers. ) is a commercial output station where a large number of products are provided on pallets to fulfill orders from customers (such as ). As can be appreciated, automated storage and retrieval system 100 includes both a commercial output station 160UT and an individual fulfillment output station 160EC, while in other aspects one or more of a commercial output station 160UT and an individual fulfillment output station 160EC Including plural.

The automated storage and retrieval system 100 also includes input and output vertical lift modules 150A, 150B (generally referred to as lift modules 150, although an input lift module and an output lift module are shown) that input case units into the storage structure. (It is noted that a single lift module may be used for retrieval from the storage structure), (may have at least one elevated storage level, and in some embodiments form a multi-level storage array) a storage structure 130, and at least one transfer deck 130DC that may be constrained to a respective storage level of the storage structure 130 and that is separate from the transfer deck 130DC (also referred to herein as a transfer area) on (or within) which they move; Includes an autonomous guided container transport vehicle or container bot 110. It is noted that depalletizer 160PA may be configured to retrieve case units from pallets so that input station 160IN can convey the items to lift module 150 for input into storage structure 130. Palletizer 160PB may be configured to place items removed from storage structure 130 onto pallet PAL (FIG. 1E) for transport. As used herein, lift module 150, storage structure 130, break pack module 266, merchandise bot 262, and container bot 110 are collectively referred to herein and hereinbefore incorporated by reference in their entirety. Incorporated "on-the-fly" classification where each throughput axis is essential so that case unit classification and throughput occur nearly simultaneously without a dedicated classifier as described in U.S. Pat. No. 9,856,083. The transport/throughput axis (e.g., in three dimensions) is useful for a three-dimensional multilevel automated storage system with (e.g., the classification of case units during transport of case units) (e.g., the reference frame REF of the containerbot 110 (Fig. 6D), or any other suitable storage and retrieval system reference frame).

As an example of case unit or break pack product container throughput in relation to sorting, referring to FIG. 1E, storage and retrieval system 100 includes several areas or regions of throughput. For example, there is a multi-level case unit storage throughput 130LTP that results in the placement of case units into storage. The placement/organization of case units in storage space 130S may be separate/independent from the classification of case units and/or break pack products BPG in the different classification echelons described herein (e.g., at a prior stage). (not pre-staged). Horizontal case unit transfer throughput 110TP provides for the transfer of case unit(s) from storage along the picking aisle, transfer deck, and to/from the break pack product interface. Horizontal case unit transport throughput 110TP results, at least in part, in one or more of pallet output classification 185 echelon and break pack station input classification 186 echelon. Pallet output classification 185 classifies case units for mixed pallet loads, but such case units are not provided to break pack station 266. Break Pack Station Throughput 266 TP (e.g., disassembly of supply cases at the Break Pack Operating Station) is divided into Break Pack Station Input Classification 186 echelons (e.g., via Break Pack Module Lifts 310A, 310B) and (via Break Pack Operating Station 140) ) yields one or more of the break pack station output classification 187 echelons. Horizontal product transport throughput 262TP provides the transfer of breakpack products from breakpack operation station 140 to the breakpack product interface, resulting in a breakpack order classification 188 echelon. The case buffer throughput BTSTP provides a buffer of case units to facilitate the transfer of case units between storage/break packs and vertical conveyance, and at least in part supports the pallet output classification 185 and the break pack output classification 189. One or more may result. Vertical transport throughput 150TP may result in the transfer of case units by vertical lift 150 and further facilitate, at least in part, one or more of pallet output sorting 185 and break pack output sorting 189. Throughput at output station 160TP is also provided, including, for example, conveying by conveyor 160CB and palletizing by palletizer 160PB. In one aspect, case unit classification is performed along each throughput axis (e.g., the X, Y, Z axis relative to the reference frame of the containerbot 110 and/or lift 150) as described herein. The throughput of the case unit 130LTP, 110TP, 266TP, 262TP, BTSTP, 150TP is provided (e.g. "on the fly"), and the classification along each axis is determined by one or more X, Y, Z independently selectable to be effected along the axis.

1A and 1B, storage structure 130 includes one or more container(s) disposed at each level of storage structure 130 (e.g., formed on and along container transfer deck 130DC). It may include an autonomous transport movement loop 233, 233A. The lift 150 is transferred to the container transfer deck 130DC via a transfer station TS (also referred to herein as a container loading station when the lift 150 is an inbound lift 150A or a container unloading station when the lift 150 is an outbound lift 150B). connected, each lift has a supply container 265 (empty or filled) and a break pack goods container 264 (empty or filled, where the filled break pack goods container 264 is ready for shipment); at least one elevated storage level 130L of the storage structure 130; It is noted that it is configured to lift into and out. Array 130SA of storage shelves (e.g., forming at least a portion of the storage area of storage structure 130 and also referred to herein as a multi-level container storage array) includes containers arranged circumferentially along container transfer deck 130DC. is comprised of a storage location (or space) 130S, where the transfer area of the storage structure 130 is substantially continuous and includes at least a transfer deck 130DC and a picking aisle 130A, such that the transfer area is Each storage shelf of storage shelf array 130SA is communicatively connected to each other. For example, a plurality of storage rack modules RM arranged into a high density three-dimensional rack array RMA are accessible by storage or deck level 130L. As used herein, the term "high-density three-dimensional rack array" refers to a three-dimensional rack array RMA with non-deterministic open shelves distributed along the picking aisle 130A, where several In embodiments, a plurality of stacked shelves are connected to a common picking aisle movement, as described in U.S. Pat. No. 9,856,083, previously incorporated by reference herein in its entirety. Accessible from surface or picking aisle level.

Each storage level 130L includes pickface storage/handoff spaces 130S (referred to herein as storage spaces 130S or container storage locations 130S) arranged circumferentially along a 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 break pack product (or order) container storage location 130SB. The storage space 130S is, in one aspect, formed by rack modules RM, where the rack modules extend linearly, e.g., through the rack module array RMA, and the container bots 110 to the storage space 130S and the transfer deck 130B. For example, the container bot 110 may include a storage shed (connected to the container transfer deck 130DC) or shelving located along the picking aisle 130A (connected to the container transfer deck 130DC) that provides access to each Container transfer deck 130DC and picking aisle 130A at each level and above each storage shelf (as described herein) at each respective level of each storage structure(s) 130. The break pack handling station 140 is configured to transport containers (such as those described herein) that are accessed to/from container storage locations/spaces (such as those described herein). In one aspect, the shelves of rack module RM are arranged as multi-level shelves distributed along picking aisle 130A. As can be appreciated, the container bot 110 is configured to transport case units between any of the storage spaces 130S of the storage structure 130 (e.g., at the level at which the container bot 110 is located) and any of the lift modules 150. (e.g., each container bot 110 moves each storage space 130S at a respective level and each lift module at a respective storage level 130L) along a picking aisle 130A and a container transfer deck 130DC. 150).

Container transfer deck 130DC may be constructed as described, for example, in U.S. patent application Ser. Can be stacked on top of each other or horizontally, such as having two container transfer decks 130DC at one end or side RMAE1 of storage rack array RMA, or at several ends or sides RMAE1, RMAE2 of storage rack array RMA. located at different levels (corresponding to each level 130L of the storage and retrieval system) which may be offset. Container transfer deck 130DC is substantially open and along multiple travel lanes across and along transfer deck 130B (e.g., along the X throughput axis relative to the bot's reference frame REF illustrated in FIG. 6D). ) is configured for non-deterministic traffic of container bots 110. No. 10,556,743, issued February 11, 2020, and having U.S. Patent Application No. 15/671,591, the entire disclosure of which is incorporated herein by reference. As shown in FIG. It may be configured to provide multiple access paths or routes to location 130S (eg, a pick face, case unit, container, or other item stored on a storage shelf of rack module RM). As can be appreciated, the transfer deck(s) 130B at each storage level 130L communicate with each of the picking aisles 130A at the respective storage level 130L.

Container bots 110 move along the picking path (e.g., along the X-throughput axis with respect to the bot's reference frame REF illustrated in FIG. ) The container bot 110 passes in both directions between the container transfer deck 130DC and the picking aisle 130A, and accesses storage spaces 130S arranged on rack shelves alongside each of the picking aisles 130A (for example, the container bot 110 130A, for example, the drive wheels 110 of the container bot 110 leading in the direction of movement or the drive wheels following in the direction of movement, for each passage along the Y throughput axis. Storage spaces 130S distributed on both sides can be accessed). As can be appreciated, the outbound throughput from the storage array in the horizontal plane corresponding to a given storage or deck level 130L is also determined by the combined or integrated throughput along both the X and Y throughput axes. It will be revealed there. As mentioned above, the container transfer deck(s) 130DC also provides container bots 110 access to each of the lifts 150 at the respective storage level 130L, where the lifts 150 are connected to case units. to and/or retrieve from each storage level 130L (e.g., along the Z throughput axis), the container bot 110 facilitates the transfer of case units between the lift 150 and the storage space 130S. bring.

Container bot 110 may, for example, carry case units and/or pick faces (individually or collectively referred to as supply containers 265) along the X and Y throughput axes (see FIG. 1B) throughout storage and retrieval system 100. break pack goods containers 264) and break pack goods containers 264, respectively. In one aspect, containerbot 110 is an automated, independent (eg, free-riding) autonomous transport vehicle. A suitable example of a bot is U.S. patent application Ser. U.S. Patent Application No. 12/757,312 (now U.S. Pat. No. 8,425,173) filed on December 9, 2011; US Patent Application No. 13/326, filed on December 15, 2011 , 423, filed December 15, 2011, U.S. Patent Application No. 13/326,447 (now U.S. Pat. No. 8,965,619), filed December 15, 2011 U.S. Patent Application No. 13/326,505 (now U.S. Pat. No. 8,696,010) filed December 15, 2011; (U.S. Patent No. 9,187,244), U.S. Patent Application No. 13/326,952 filed December 15, 2011, U.S. Patent Application No. 13/326,952 filed December 15, 2011 No. 13/326,993, U.S. Patent Application No. 14/486,008 filed September 15, 2014, and U.S. Provisional Patent Application No. 62 filed January 23, 2015. No. 107,135. Container bot 110 (described in more detail below) places case units, such as the retail items described above, into pick stock at one or more levels of storage structure 130, and then places the ordered case units into pick stock at one or more levels of storage structure 130. May be configured for selective retrieval. As can be appreciated, in one aspect, the storage array throughput axes X and Y (e.g., pickface transport axes) are connected to the picking path 130A (as described herein) of the container bot 110, at least one Defined by container transfer deck 130DC, container bot 110, and an extensible end effector (and in other aspects, the extensible end effector of lift 150 also defines, at least in part, a Y throughput axis). The pickface (which, in one aspect, may include a supply container 265) is connected to an inbound section of the storage and retrieval system 100 (e.g., input station 160IN, etc.) where the pickface inbound to the array is created and to the storage and retrieval system 100. (e.g., output station 160UT or output station 160EC), where the outbound pick face from the array picks up the load according to a predetermined load fill order sequence or a predetermined individual Arranged to fulfill individual fulfillment order(s) according to a fulfillment order sequence. In another aspect, the pick face (e.g., of supply container 265) is configured to fill a load according to a predetermined load fill order sequence or to fill individual fulfillment order(s) according to a predetermined individual fulfillment order sequence. , between storage space 130S and a cargo filling section of storage and retrieval system 100 (eg, output station 160UT or output station 160EC, etc.). In yet other aspects, the break-pack merchandise containers 264 (in one aspect, a plurality of break-pack merchandise containers may be arranged and conveyed as a pick face) load loads according to a predetermined load-fill order sequence or a predetermined individual A break pack product interface between the storage space 130S and the load filling section and/or of the break pack module(s) 266 to fulfill the individual fulfillment order(s) according to the fulfillment order sequence. 263 and a cargo filling section of storage and retrieval system 100 (eg, output station 160UT or output station 160EC, etc.) by container bot 110. The control server 120 causes the pick face and break pack goods containers 264 (e.g., of the supply container 265) to fill the load with one or more of the pick face and break pack goods containers 264 (e.g., of the supply container 265). In addition, the automated storage and retrieval system 100 may be operated in different modes of operation such that the cargo is transferred to a cargo filling section according to one or more of the aspects described above.

As mentioned above and referring to FIG. 1B, in one aspect, the storage structure 130 includes a plurality of three-dimensional arrays RMA with racks arranged in the aisle 130A (e.g., forming an array of storage shelves 130SA). The passageway 130A is configured for movement of the container bot 110 within the passageway 130A. Container transfer deck 130DC has a non-deterministic transfer surface on which container bots 110 move, where non-deterministic transfer surface (also referred to herein as deck surface) 130BS is formed by container transfer deck 130DC (1 (e.g., multiple juxtaposed travel lanes (e.g., high speed bot travel path HSTP)) for movement of the container bot 110 along the container autonomous transport movement loop 233 (e.g., multiple parallel movement lanes (e.g., high speed bot movement path HSTP)) , where the plurality of travel lanes connect the passageway 130A. The container autonomous transport movement loop(s) 233 provides the container bot 110 with random access to any and each picking aisle 130A at each level 130L of the storage structure 130 and any and each lift 150A, 150B. At least one of the plurality of travel lanes has a direction of movement that is opposite to a travel lane direction of another of the plurality of travel lanes (so as to form a container autonomous transport movement loop 233).

In one aspect, the storage rack module RM and the container bot 110 are configured such that two or more pick faces are picked from one or more of the storage spaces and one different from the storage space 130S according to a predetermined load fill order sequence. The storage rack module RM and the container bot 110 combine to be positioned on one or more pick face holding locations (e.g., buffer and transfer stations BS, TS, etc.) on at least one of the throughput axes (or other Aspects are arranged to provide for on-the-fly classification (eg, such as pallet output classification 185 echelon) of mixed-case pick faces concurrent with conveyance (on at least one of each of the plurality of pieces).

As can be appreciated, any suitable controller of the storage and retrieval system 100, such as the control server 120, is described in more detail below entitled "Warehousing System for Storage and Retrieving Goods In Containers," the entire disclosure of which is incorporated herein by reference. into one or more case units (and/or break pack merchandise containers) in the manner described in U.S. Provisional Patent Application No. 63/044,721, filed June 26, 2020, filed June 26, 2020. or any suitable number of alternative routes for retrieving these case units from their respective storage locations 130S if the access provided to them is restricted or otherwise blocked. It may be configured to create a detour.

The storage and retrieval systems shown and described herein have exemplary configurations only, and in other aspects, any suitable configuration for storing and retrieving the articles described herein. It is noted that it may have components. For example, in other aspects, the storage and retrieval system includes any suitable number of storage sections, any suitable number of transfer decks, any suitable number of break pack modules 266, and corresponding input/output stations. may have.

As can be seen, the juxtaposed travel lanes are juxtaposed along a common non-deterministic transport surface 130BS between opposing sides 130BD1, 130BD2 of the container transfer deck 130DC. In one aspect, the passageway 130A is joined to the container transfer deck 130DC at one side 130BD2 of the container transfer deck 130DC, as illustrated in FIG. A plurality of container transfer decks 130DC in a manner substantially similar to that described in U.S. patent application Ser. It is joined to side surfaces 130BD1 and 130BD2 of. U.S. Provisional Patent Application No. 63/044,721, filed June 26, 2020, entitled "Warehousing System for Storage and Retrieving Goods In Containers," the entire disclosure of which is incorporated herein by reference. The other side 130BD1 of the container transfer deck 130DC is such that at least one portion of the transfer deck is between a deck storage rack (e.g., buffer station BS or transfer station TS, etc.) and the aisle 130A, as described in the document. Intervening deck storage racks (eg, interface stations (also referred to as transfer stations) TS and buffer stations BS) distributed along the other side 130BD1 of the container transfer deck 130DC may be included. A deck storage rack is disposed along the other side 130BD1 of the container transfer deck 130DC to communicate with the container bots 110 and lift modules 150 from the container transfer deck 130DC (e.g., the deck storage racks accessed by the container bot 110 from the deck 130DC so that pick faces are transferred between the container bot 110 and the deck storage rack and between the deck storage rack and the lift 150, and thus between the container bot 110 and the lift 150. accessed by lift 150 to pick and place the pick face).

Referring again to FIG. 1A, each storage level 130L also includes, for example, U.S. patent application Ser. and mounting of the container bot 110 at its storage level 130L, such as described in application Ser. A charging station 130C (eg, located at any suitable container transfer location) for charging the power source may also be included.

Referring to FIGS. 1A, 1B, 1C, and 2, as described above, automated storage and retrieval system 100 includes one or more break pack modules 266. Each break pack module includes a break pack station 140, one or more lifts (lifts 310A, 310B in one aspect, lifts 310A', 310B' in other aspects), a break pack station 140 (as described herein), one or more containerbot transfer surfaces 266RS communicatively coupled to the pack station 140 (e.g., for inputting supply containers 265 to the break pack module 266); and communicatively coupled to the break pack station 140. A predetermined number of groups include one each of product deck levels 130DGL and storage levels 130L.

Although break pack module 266 is described herein with respect to automated storage and retrieval system 100, in other aspects break pack module 266 may be integrated into a single level storage and retrieval system (e.g., any suitable (through decks or floors and/or in any other suitable manner), goods transport trucks or trailers (e.g. at loading docks, etc.), train freight vehicles (e.g. at depots, etc.), (airport terminals, etc.) or a supply container (such as those described herein) (either manually or automatically) on at least one guided conveyor 500A, 500B, 500C of each break pack module 266. It should be understood that the device may be configured to couple to any suitable input, such as any other suitable input that may be provided to the computer. Here, given that the break pack module 266 may receive supply containers from any suitable input, the break pack module 266 may , at least a portion thereof). Whether the break pack module 266 is coupled to and forms part of the automated storage and retrieval system 100 or to any of the other inputs as described above, the automated order fulfillment system includes a put wall or multi-level break pack merchandise container filling array 263W as described herein, a merchandise transfer deck 130DG, and at least one merchandise bot 262. The put wall 263W has a plurality of levels PWL, each level PWL has a container filling station area CFA, break pack product interface locations 263L are arranged along the container filling station area CFA, and each level PWL also has a container filling station area CFA. Container filling station area CFA has corresponding break pack product transfer decks 130DG1-130DG3 juxtaposed along break pack product interface locations 263L. At least one product bot 262 includes a payload support 262PS for holding at least one breakpack product BPG unit for conveyance by the at least one product bot 262, as described in more detail herein. have At least one merchandise bot 262 includes corresponding breaks along a corresponding break-pack merchandise transfer deck 130DG (e.g., as described herein) and at different levels of a multi-level break-pack merchandise container filling array. Between pack goods transfer decks 130DG1-130DG3 (see, e.g., FIGS. 3A, 3B, 4, 6A, 6B, 7A, and 7B), each break pack goods interface station/container station 263L at each level PWL of put wall 263W. (see FIGS. 4 and 5C), where each break pack product interface station 263L is accessed by at least one product bot 262 and configured to transport break pack products BPG (see FIGS. 4 and 5C). It is arranged to hold a break pack product container 264 filled with a product fill payload BPGFP. As described in more detail herein, the corresponding transfer decks 130DG1-130DG3 at each level PWL are connected to the corresponding break pack product transfer decks 130DG1-130DG3 at each level PWL and to each other level PWL. The put wall 263W is connected to the put wall 263W by an interlevel autonomous guided break pack product transfer vehicle path (e.g., a lift, ramp, etc. as described herein) passing between corresponding other break pack product transfer decks 130DG1-130DG3. (In some aspects, the interlevel transition autonomously guided break pack goods transport vehicle path is communicatively joined to other transfer decks 130DG1-130DG3 corresponding to each other level PWL of the provides for product bot migration between different sets of decks 130DGL, such that at least one product bot 262 provides corresponding inter-level transition autonomously guided break pack product transport vehicle paths. from the break pack product transfer decks 130DG1-130DG3 to each other break pack product transfer deck 130DG1-130DG3 corresponding to each other level PWL and loaded into at least one product bot 262 on one level PWL. A predetermined break pack product BPG filling payload is transported to fill the break pack product container 264 at each break pack product container station 263L at a different level PWL.

Again, break pack module 266 is coupled to each level, whether coupled to and forms part of automated storage and retrieval system 100 or to any of the other inputs as described above. PWL and inter-level transitions The corresponding break-pack goods transfer decks 130DG1-130DG3 in an autonomous guided break-pack goods transport vehicle path (e.g., ramps, lifts, etc. as described herein) include at least one inter-level detour path. (e.g., ramps 130DG1R, 130DG3R, 451, 452, 453, lift 490, etc. described herein) and at least one intralevel detour (e.g., shunts 461-463 described herein, e.g., 2, 3A, 3B, 4, 6A, 6B, and 7A-7D), including at least One product bot 262 transfers the initial break pack product container station designation from the initial break pack product container station designation CSD 1 to the initial break pack product container station designation CSD 1 on the fly via at least one of the at least one inter-level detour and the at least one inter-level detour. up to a detour break pack goods container station designation CSD2 above at least one of a level PWL common to the destination CSD1 (i.e. the same level as the initial break pack goods container station designation CSD1) and a different (e.g. relative) level PWL; Detour freely. A corresponding break pack goods transfer deck 130DG1-130DG3 at each level (e.g., for each interlocking deck level 130DGL in which a plurality of conglomerates is provided) is provided (e.g., abbreviated to container deck 130DC as described herein). the at least one interlevel detour path is non-deterministic (e.g., in a manner generally similar to the container deck 130DC described herein) such that at least one Product bots 262 may freely transition between corresponding break pack product transfer decks 130DG1-130DG3 and at least one interlevel detour. Product bot 262 provides posing and localization along product decks 130DG1-130DG2, at least one inter-level detour, and at least one intra-level detour in the manner described herein (see FIG. 25).

With respect to automated storage and retrieval system 100, each breakpack module 266 may be non-deterministically coupled (e.g., to form part of) automated storage and retrieval system 100 in any suitable manner (e.g., to form a part thereof). The pack module 266 may be coupled to the automated storage and retrieval system 100 at any suitable location thereof, such as at one or more ends 130BE1, 130BE2, or at one or more container bot mounting surfaces. Picking aisle 130A (and storage position ) instead, it may be centrally located between the two ends 130BE1, 130BE2 or in any other suitable position - see FIG. 1B). Although break pack module 266 is non-deterministically coupled to the structure of automated storage and retrieval system 100, each component of break pack module 166 is independent of the components of the automated storage and retrieval system (e.g., self-contained as a unit). self-contained) and/or independently automated in the navigation and movement of a bot (e.g., product bot 262), thereby interfacing components of break pack module 266 with components of automated storage and retrieval system 100. The interface between is non-deterministic.

Break pack module(s) 266 may be coupled to the structure of automated storage and retrieval system 100 at any suitable location and at any suitable level(s) 130L. For example, as described above, the break pack module 266 may be used (such as in place of the storage rack module RM/picking aisle 130A or the lifts 150A, 150B, or as an extension of one or more picking aisles 130A - see FIG. 1B). ) may be located at one or more ends 130BE1, 130BE2 of container transfer deck 130DC or at one or more sides 130BD1, 130BD2 of container transfer deck 130DC. Each of the break pack modules 266 has a plug-and-fit module that is integrated with (or otherwise connected to) the container transfer deck 130DC such that the container transfer deck 130DC is communicatively coupled to the container bot landing surface 266RS. It is a play module. In one aspect, the container transfer deck 130DC extends into the break pack module such that the container bots 110 move into or out of the break pack module 266 along the non-deterministic container transfer deck 130DC. to form a container bot landing surface 266RS (e.g., the break pack module forms a modular portion of the container transfer deck 130DC), and at least one of the plurality of travel lanes of the container transfer deck 130DC has a break pack module 266 Define a queue for container bots 110. In other aspects, the container bot landing surface 266RS includes a rail 1200S extending from the container transfer deck 130DC in a manner similar to that of the picking aisle 130A, such that the container bot 110 can break pack along the rail 1200S. Passing through or moving in and out of module 266, rail 1200S defines a queue for container bots 110 at break pack module 266. If the container bot landing surface 266RS is formed by a rail 1200S, the landing surface may be configured such that the container bot 110 can change direction and move between different portions of the container bot landing surface 266RS (e.g., as described herein). It is noted that a non-deterministic turning area 1200UTA (similar to an open non-deterministic container transfer deck 130DC) may be included to transition between inbound lane TL1 and outbound lane TL3 of loop 233BP. The movement loop 233BP provides the container bot 110 with random access to any and each break pack product interface position 263L of the break pack product interface 263 along the bot movement surface 266RS, where the break pack product interface position 263L form an asynchronous product distribution system.

As seen in FIG. 1C, and referring also to FIGS. 3A and 3B, two or more break pack modules 266 may be stacked one on top of the other. Although three break pack modules 266A, 266B, 266C are illustrated here stacked one above the other, in other aspects any suitable number of break pack modules 266 may be stacked one above the other. Each break pack module 266 (whether arranged in a stack or not) is connected to any one of the stacked levels 130L or Inbound supply containers 265 are received from multiple sources. For example, each break pack module 266 includes at least one container, each having a container bot landing surface 266RS, forming a portion 130DCP of the container transfer deck 130DC of the storage level 130L of the automated storage and retrieval system 100. It has a bot transfer deck 130EXT. Also referring to FIG. 2, the break pack module 266 includes three container bot mounting surfaces 266RS1, 266RS2, 266RS3 (each corresponding to a container bot transfer deck 130EXT) stacked one above the other (for clarity). Note that only a portion of the container bot mounting surfaces 266RS2, 266RS3 are shown). Each of the container bot landing surfaces 266RS1, 266RS2, 266RS3/container bot transfer deck 130EXT is coupled to and forms a portion 130DCP of the container transfer deck 130DC on the respective level 130L of the automated storage and retrieval system 100. The landing surface 2666RS is generally similar to a portion of the container transfer deck 130DC, although in other aspects the container bot landing surface 266RS may be generally similar to a portion of the picking aisle 130A. For ease of explanation, aspects of the disclosed embodiments refer to the container bot landing surface 266RS within the break pack module 266 as part of the container transfer deck 130DC. In embodiments where the bot landing surface 266RS is formed by (or is an extension of) a portion of the container transfer deck 130DC, the container transfer deck 130DC is illustrated in FIG. It is noted that in this aspect, the transport/transfer loop of the break pack module 266 may be a multi-lane transport/transfer loop generally similar to the container transport deck illustrated in FIG. 1B. For example, referring to FIG. 2, the container bot movement surface 266RS is an open non-deterministic movement surface having at least one inbound movement lane TL1 and at least one outbound lane TL3, where a plurality of movement lanes TL1, TL3 act as bypass lanes for each other so that container bots 110 can enter travel lane TL2 (or vice versa) to move around obstacles on travel lane TL1. Here, at least one travel inbound lane TL1 and at least one travel outbound lane TL3 define at least one queue for container bot 110 to interface with break pack module 266 (which is at least partially may result in one or more of a break pack station input classification 186 and a break pack output classification 189). Travel lanes TL1, TL3 provide the container bot 110 with random access to any and each break pack product interface location 263L of the break pack product interface 263 along the bot travel surface 266RS.

Still referring to FIGS. 1A, 1C, 2, 3A, and 3B, as described in more detail herein, a container bot 110 from any given level 130L (e.g., (relative to level 130L) along respective container bot movement surfaces 266RS1, 266RS2, 266RS3 and, in one aspect, deliver supply containers 265 to lifts 310A, 310B. Lifts 310A, 310B (and/or lifts 310A', 310B' described herein) may individually or collectively be referred to as intervening classifiers that provide break pack station input classification 186. The intervening sorter is positioned to communicatively couple the multi-level array transfer area (eg, formed by the picking aisles 130A and transfer decks 130DC of the various storage levels 130L) and the break pack manipulation station 140. In some aspects, the guided conveyors 500A, 500B, 500C of the break pack module 266 provide a bypass to the break pack operation station or detour from the lifts 310A, 310B, which may result, at least in part, in the break pack station input classification 186. may form part of an intervening classifier. Each lift 310A, 310B is configured to sort supply containers 265 from container bot 110 and upstream of break pack handling station 140. The sorting of the supply containers 265 by one or more of the lifts 310A, 310B upstream of the break pack handling station 140 is performed from a sub-optimal order of goods (e.g., transport from storage in a non-staged manner). arranged to facilitate sequencing of supply containers 265 up to an optimized order (e.g., sequenced for optimized delivery to different operator stations 801-804 of break pack operation station 140). sing). Sorting by one or more of the lifts 310A, 310B involves a predetermined sequence of supply containers 265 entering the break pack operating station 140, products from the supply containers 265 at operator stations 801-804 (e.g., break pack products BPG ) and the dispatch of at least one merchandise bot 262 from the break pack operation station 140 to fill the put wall 263W. The one or more lifts 310A, 310B (i.e., intervening classifiers) upstream of the break pack handling station 140 are orthogonal to each other (e.g., separate and distinct/independent) (with each lift handling a respective classification and are configured to define (via various lifts 310A, 310B) a plurality of classification axes (forming axes). At least one sorting axis in one direction has parallel sorting axes, e.g., lifts 310A, 310B, to move the supply container 265 to one or more goods deck levels 130DG1 of the same or different group of goods deck levels 130DGL. , 130DG2, and 130DG3.

Also referring to FIG. 5A, each of the container bot movement surfaces 266RS1, 266RS2, 266RS3 is disposed adjacent to a respective guiding conveyor 500A, 500B, 500C, such that the container bot movement surfaces 266RS1, 266RS2, 266RS3 are The moving container bot 110 places (eg, transfers) supply containers 265 from the container bot 110 onto the respective guiding conveyors 500A, 500B, 500C. Here, each guided conveyor 500A, 500B, 500C is configured to transfer a supply container 265 to one of the lifts 310A, 310B. At least one of the guided conveyors 500A, 500B, 500C includes a bypass conveyor portion 500AB for bypassing the one or more lifts 310A, 310B or for diverting the supply container 265 from the one or more lifts 310A, 310B. , 500BB (see FIGS. 3A, 6C, 6D, and note that the bypass conveyor portion for guide conveyor 500C is omitted from the drawings). For example, an upstream lift (e.g., upstream for the flow of supply containers 265 along a conveyor) such that supply containers 265 are delivered to a downstream lift (in the example shown, the downstream lift is lift 310B) ) may be bypassed (in the example shown, the upstream lift is lift 310A), at least partially resulting in break pack station input classification 186, while in other aspects supply containers by lifts 310A, 310B. One or more lifts 310A, 310B are bypassed, at least in part, for substantially direct delivery of supply container 265 from container bot 110 to break pack handling station 140 without transport of The break pack station input classification 186 results in a break pack station input classification 186.

Guided conveyors 500A, 500B, 500C include any suitable multi-directional drive/conveyor unit/section 370 configured to move supply containers 265 between conveyor sections or to/from lifts 310A, 310B. For example, the multi-directional conveyor portion 370 may (e.g., fit between the lengths of at least one of the lifts 310A, 310B, i.e., the guided conveyors 500A, 500B, 500C as best illustrated in FIG. 6C) (for delivery of the supply container 265 to the lifts 310A, 310B) along the longitudinal axis of the respective guiding conveyor 500A, 500B, 500C and/or moving the supply container 265 along the respective bypass Supply container 265 is configured to move in a direction transverse to the longitudinal axis for movement to/from conveyor sections 500AB, 500BB.

The output of bypass conveyors 500AB, 500BB (and the bypass conveyor for induction conveyor 500C) and the output of lifts 310A, 310B transfer break-packed goods to break-packed goods container 264 at put wall 263W as described herein. a common output that delivers supply containers 265 to break pack operation station 140 in a top-optimized order of goods resulting in a predetermined order of filling of goods (e.g., output to a single break pack station input conveyor 510). merged - see Figures 6C, 8A, and 8B). Also, as described herein, each load fill of break-packed merchandise BPG into a break-packed merchandise container 264 at a put wall includes the filling of two or more of the various break-packed merchandise containers 264. Independent/orthogonal to the cargo filling of other break pack goods containers BPG so that they can be brought in parallel. In the illustrated example, lifts 310A, 310B move supply containers from guided conveyors 500A, 500C to guided conveyor 500B, where a bypass portion 500BB of guided conveyor 500B connects a common output/break pack station input conveyor 510. (i.e., break pack station input conveyor 510 is part of guided conveyor 500B), while in other aspects guided conveyors 500A, 500C may be any suitable combination of ramps and multi-directional conveyor portions 370. It can be merged with the guiding conveyor 500B.

The lift(s) 310A, 310B are configured to deliver the supply container 265 to a given breakpack handling station 140 of the (stacked) breakpack module 266. For example, lifts 310A, 310B are configured to transfer supply container 265 between guided conveyors 500A, 500B, 500C for outputting supply container 265 to break pack station input conveyor 510. In one or more aspects, the lifts 310A, 310B are described in detail in the Control System for Storage and Retrieval System published October 15, 2019, the entire disclosure of which is incorporated herein by reference. In a manner substantially similar to that described in U.S. Pat. The supply containers 265 are configured to sort the supply containers 265 for output from the lifts 310A, 310B in a predetermined order/sequence (such as to be delivered to the lifts 140). For example, when the supply container(s) 265 is on the lifts 310A, 310B, the supply container(s) 265 is at the break pack operation station 140. may be held (e.g., buffered) on lifts 310A, 310B until a predetermined time to be delivered. In the illustrated example, lifts 310A, 310B are cyclic lifts, but in other aspects, the lifts may be operated at a predetermined range (e.g., under the control of any suitable controller, such as controller 120 and/or a dedicated lift controller). Any suitable lift may be configured to buffer any number of supply containers 265 in any suitable manner for delivery to break pack handling station 140 at a time. The predetermined order may correspond to a packing order for break pack goods BPG in break pack goods container 264, or any other suitable order corresponding to store planning rules, for example. For example, store planning rules may include, for example, the layout of aisles in a store, or the specific locations or types of items within a store from which break-pack merchandise containers 264 (or the pallets PALs from which break-pack merchandise containers 294 are shipped) are retrieved. Corresponding family groups of articles may be incorporated. The predetermined order of supply containers 265 to the break pack handling station 140 (and ultimately to the break pack product containers 294) may also correspond to the durability of the break pack products BPG. For example, after the heavier, more durable break pack product BPG is delivered to the break pack operating station 140 (and ultimately to the break pack product container 294), the crushable break pack product BPG is delivered to the break pack operating station 140 (and ultimately to the break pack product container 294). 140 (and ultimately to the break pack merchandise container 294). Here, each lift 310A, 310B is common to and serves each break pack handling station 140 of the (stacked) break pack modules 266A-266C (see FIG. 3B).

In another aspect, and referring to FIGS. 20A-20C, the break pack module 266 includes linearly reciprocating pass-through lifts 310A', 310B' in place of circulation lifts 310A, 310B. In yet other aspects, the break pack module 266 may include both linearly reciprocating pass-through lifts 310A', 310B' and circulation lifts 310A, 310B. Each of the lifts 310A', 310B' includes a mast 2010 and at least three lift platforms that reciprocate along the mast 2010 under the propulsion of any suitable drive (e.g., chain drive, ball screw drive, etc.). 2011, 2012, and 2013. The lift platforms 2011, 2012, 2013 have a fixed pitch P that is approximately equal to the pitch/spacing PP between the guided conveyors 500A, 500B, 500C (i.e., the fixed pitch P is such that the lift platforms 2011, 2012, 2013 reciprocate along the mast 2010). may be spaced apart from each other along the length of the mast 2010 by an amount that does not change during movement. As described herein, at least three lift platforms 2011, 2012, 2013 move lifts 310A', 310B' while traveling along one or more of guided conveyors 500A, 500B, 500C. 265. Each lift platform 2011, 2012, 2013 of lift 310A', 310B' is fed, at least in part, from an upstream portion of guided conveyor 500A, 500B, 500C as a supply container seating surface, as described herein. A conveyor 2021 (e.g., a belt conveyor, roller bed conveyor, etc.).

In one or more aspects, each guide conveyor 500A, 500B, 500C includes an upstream portion 500AU, 500BU, 500CU and a downstream portion 500AD, 500BD, 500CD. Lift 310A' is disposed between upstream section 500AU, 500BU, 500CU and downstream section 500AD, 500BD, 500CD to transfer supply containers from upstream section 500AU, 500BU, 500CU to downstream section 500AD, 500BD, 500CD. Ru. A lift 310B' is provided between the downstream portions 500AD, 500BD, 500CD and the break pack station input conveyor 510 to transfer supply containers 265 from the downstream portions 500AD, 500BD, 500CD to the break pack station input conveyor 510. Placed.

As seen in FIG. 20A, the lifts 310A', 310B' transport the supply container 265, which moves along each one of the guided conveyors 500A, 500B, 500C, 500C) and/or guided conveyors 500A, 500B (stacked one above the other) for transfer to lift 310B'; It is lined up in a straight line with 500C. Positioning the lifts 310A', 310B' in line with the guide conveyor provides a more compact break pack module 266 compared to having the lifts in line with the guide conveyor. In this aspect, supply container 265 may "bypass" upstream lift 310A' by "passing through" lift 310A'. For example, with reference to FIGS. 20B and 20C, a supply container 265 traveling along guided conveyor 500B may be transferred substantially directly to break pack station input conveyor 510, where lift platform 2012 of lift 310A', 310B' operates as part of the guided conveyor 500B (e.g., the supply container 265 passes from the upstream portion 500BU to the lift platform 2012 of the lift 310A' and then (with the lift platform held stationary, i.e. , without vertical movement of the lift platform) from the lift platform 2012 to the downstream portion 500BD). A similar pass-through transfer of supply containers 265 from downstream portion 500BD to break pack station input conveyor 510 occurs at lift platform 2012 of lift 310B'. Here, as described above, the outputs of guided conveyors 500A, 500B, 500C and lifts 310A', 310B' are common for delivering supply containers 265 to break pack operation station 140 as described herein. (eg, the outputs are merged into a single break pack station input conveyor 510 - see FIGS. 20A, 20B, and 20C). In the illustrated example, one or more of the lifts 310A', 310B' transport the supply containers 265 from the upstream portions 500AU, 500BU, 500CU of the guided conveyors 500A, 500B, 500C (in the case of lift 310A') to the guided conveyor 500B. or (in the case of lift 510B') to the break pack station input conveyor 510, while in other aspects, the guided conveyors 500A, 500C may be moved to the downstream portion 500BD of the ramp and multi-directional conveyor portions 370. It can be combined with the guiding conveyor 500B.

For example, referring to FIG. 20C, supply container 265B is placed by container bot 110 onto input conveyor 500A. For illustrative purposes only, feed containers 265A (such as for sequencing containers at break pack station input sorting 186 or any other suitable purpose) from upstream portion 500AU of input conveyor 500A to downstream portion 500CD of input conveyor 500C. It is desirable to transport. Here, lift 310A' transfers supply container 265A (eg, using platform 2011) from upstream portion 500AU to downstream portion 500CD. From downstream portion 500CD, lift 310B' transfers supply container 265A (using lift platform 2013) to break pack station input conveyor 510. If the lift 310A' includes three lift platforms, there is no lift platform vertically aligned with the input conveyors 500A, 500B, so the input conveyors 500A, 500B are unable to load the supply container 265A to the downstream portion 500CD of the input conveyor 500C. Can be stopped during transport. In doing so, in some aspects, lift 310A' may be configured to transport a supply container, such as supply container 265B, when at least one other supply container (e.g., supply container 265A) is being transferred between conveyor levels. additional pass-through lift platforms or detours 2014, 2015, 2016, 2017 that serve as pass-through platforms for. It is noted that pass-through lift platforms 2014, 2015, 2016, 2017 generally cannot be used to transfer supply containers between conveyor levels, and such transfer between conveyor levels may be performed expediently. be done. For example, if it is desired to transfer supply container 265B (illustrated in FIG. 20C) from upstream section 500BU to downstream section 500AD, pass-through platform 2015 may cause lift platform 2011 to move after transfer of supply container 265A to downstream section 500CD. Rather than waiting to be aligned with input conveyor 500B, it can be utilized for such transfer. In some aspects, the additional pass-through lift platforms 2014, 2015, 2016, 2017 are configured to provide stacked break pack modules (e.g., stacked (see break pack modules 266A, 266B, 266C).

In a manner similar to that described above, the lift(s) 310A', 310B' are adapted to deliver the supply containers 265 to a given break pack handling station 140 of the (stacked) break pack modules 266. It is composed of For example, lifts 310A', 310B' are configured to transfer supply containers 265 between guide conveyors 500A, 500B, 500C for outputting supply containers 265 to break pack station input conveyor 510. In one or more aspects, at least a portion of lifts 310A', 310B' and input conveyors 500A, 500B, 500C deliver supply containers 265 for output to break pack station input conveyor 510 in a predetermined order/sequence. configured to sort (e.g., break pack station input classification 186) (e.g., whereby the supply containers are arranged in a predetermined order, such as a top-optimized order of the products described herein); (delivered to the break pack handling station 140). For example, downstream portions 500AD, 500BD, 500CD of guided conveyors 500A, 500B, 500C may form a buffer, where supply containers are transferred from downstream portions 500AD, 500BD, 500CD by lift 310B' to break pack station input conveyor 510. (e.g., according to any suitable order, such as order-out load filling at operator station 140, etc.). In other aspects, guided conveyors 500A, 500B, 500C (or at least a portion thereof) are used to (e.g., intermittently) deliver to lift 310B' and subsequently from lift 310B' to break pack station input conveyor 510. A single lift 310B' may be provided to operate to buffer supply case 265 for delivery. The predetermined orders form a top-optimized order of products and correspond to pack orders for break pack products BPG in the break pack product container 264, or any other suitable orders corresponding to store planning rules, for example. It is possible. For example, store planning rules may include, for example, the layout of aisles in a store, or the specific locations or types of items within a store from which break-pack merchandise containers 264 (or the pallets PALs from which break-pack merchandise containers 294 are shipped) are retrieved. Corresponding family groups of articles may be incorporated. The predetermined order of supply containers 265 to the break pack handling station 140 (and ultimately to the break pack product containers 294) may also correspond to the durability of the break pack products BPG. For example, after the heavier, more durable break pack product BPG is delivered to the break pack operating station 140 (and ultimately to the break pack product container 294), the crushable break pack product BPG is delivered to the break pack operating station 140 (and ultimately to the break pack product container 294). 140 (and ultimately to the break pack merchandise container 294). Here, each lift 310A, 310B is common to and serves each break pack handling station 140 of the (stacked) break pack modules 266A-266C (see FIG. 3B).

3A, 6C, 7D, 8A, and 8D, from the lifts 310A, 310B (or substantially directly from the container bot 110), the supply container 265 is transported along the break pack station input conveyor 510 to the break pack operation station. Move up to 140. The break pack handling station 140 is configured such that one or more break pack items BPG are unpacked from the supply container 265 at the break pack handling station 140 and the at least one item bot 262 has a break pack station output classification 187. The break pack handling station 140 is configured to load one or more break pack items BPG. Each break-pack handling station 140 may be a manual station (see FIGS. 8A and 8B, where break-pack items BPG are picked and placed by a human operator HUM) or an automatic station (see FIG. 7D, where , break pack goods are picked and placed by a robot operator ROB). In the illustrated example, there are four operator stations 801, 802, 803, 804, but in other aspects there may be more or less than four operator stations. The picking and transferring of break-packed items BPG at one operator station 801, 802, 803, 804 is orthogonal to the picking and transferring of break-packed items BPG at other operator stations 801, 802, 803, 804 ( (e.g. separate and distinct/independent). For example, a break-pack product BPG picked at one operator station 801, 802, 803, 804 is different from a break-pack product BPG picked at another operator station 801, 802, 803, 804 (e.g., product type, (in order, pick order, etc.) may be unrelated/independent.

The supply container 265 moves along the break pack station input conveyor 510 to a predetermined operator station 801, 802, 803, 804, where a multi-directional conveyor section 370 moves the supply container 265 to the operator station 801, 802, 803, 804 to the lift 811. Input conveyor 510 is any suitable type of conveyor, such as a roller conveyor, a continuous belt conveyor, or the like. The conveyor is configured to position the supply container 265 for human or robotic picking of break pack items BPG from the supply container 265. Lift 811 may be any suitable lift configured to transfer supply containers 265 and/or break pack goods containers 264 between conveyors (e.g., between conveyors located at different heights or at the same height). be. Supply container 265 is transferred from lift 811 to pick conveyor 818 where an operator (human or robot) opens the supply container and picks up the break pack product for placement on product bot 262 and/or break pack product container 264. Pick the BPG (eg, result in break pack station output classification 187). The product bot 262 is placed in a queue 844 located on the product deck 130DG adjacent to the operator stations 801, 802, 803, 804, and the break pack product container 264 is placed in a queue 844 located on the product deck 130DG adjacent to the operator stations 801, 802, 803, 804. placed on the placement conveyor 817 (the placement conveyor is such that when a break pack product container 264 is filled and removed from the operator station 801, 802, 803, 804, another break pack product container 264 is placed on the other break pack product container 264). configured with a container queue 817Q and a lift 817L to be positioned for placement of break-packed merchandise in packed merchandise containers 264).

Operator stations 801 , 802 , 803 , 804 are used for picking, placing product(s) on product bot 262 , placing product(s) in break pack product container 264 , etc. Any suitable sensor/tracking device and/or instruction display (in the case of a manual operator) is included to indicate and verify one or more of the given products located at the operator station. The sensor/tracking device and display are described in U.S. Pat. No. 9,037,286, entitled "Each Pick," issued May 19, 2015, the entire disclosure of which is incorporated herein by reference. may be substantially similar to those described. For example, telling a (human) operator which products to pick, how many of the products to pick, and where to place the products (e.g., on the product bot 262 or in the break pack product container 264) Any suitable display 899D is provided at operator station 801, 802, 803, 804 for this purpose. Operator stations 801 , 802 , 803 , 804 also track supply container SKUs, product placement, amount of product placed, product bot 262 identification information, and break pack product containers within automated storage and retrieval system 100 . The sensor suite 899 may include a sensor suite 899 configured to verify records of break pack merchandise containers for.

Operator stations 801, 802, 803, 804 include waste conveyors 870 upon which empty (discarded) supply containers 265 and other waste are placed for removal from the operator stations.

3A, 5A, 5B, 6D, 8A, and 8B, supply container 265 and/or partially filled break pack merchandise containers containing product to be placed back into storage or supply container 265 264 and/or filled (e.g., at least about 30% of the capacity described herein or at least about Break pack product containers 264 (see FIG. 1A) (filled to 50%) are removed from operator stations 801 , 802 , 803 , 804 at least in part by pick conveyor 818 . For example, pick conveyor 818 transfers supply containers 265 and/or break pack goods containers 264 to lift 811, which transfers supply containers 265 and/or break pack goods containers 264 to container output conveyor 820. Container output conveyor 820 corresponds to operator station conveyor portion 820A, lift 667, and container bot transfer surfaces 266RS1, 266RS2, 266RS3 located adjacent to or at operator stations 801, 802, 803, 804. Stacked bot transfer conveyor sections 820B, 820C, 820D. Operator station conveyor portion 820A extends to lift 667 and is configured to transfer supply containers 265 and/or break pack product containers 264 to lift 667. The lift 667 is configured to transfer the supply container 265 and/or the break pack goods container 264 to a predetermined one of the stacked bot transfer conveyor sections 820B, 820C, 820D, where the respective transfer surface 266RS1 . Picking supply containers 265 and/or break pack product containers 264 from conveyor sections 820B, 820C, 820D.

As seen in FIGS. 2, 3A, 4, and 7B, the break pack product interface 263 connects at least each product deck level 130DG1, 130DG2, 130DG3 (of product deck 130DG, for example) to form a put wall 263W. has a plurality of break pack product interface locations or break pack product container stations 263L arranged along substantially the entire edge of the break pack product container station 263L, where each break pack product interface location 263L is associated with a respective break pack product container 264. is configured to hold. As described herein, the put wall or multi-level break pack goods container fill array 263W has a plurality of levels PWL, each level PWL has a container fill station area CFA, and a break pack goods interface. The locations 263L are arranged along the container fill station area CFA, and each level PWL has a corresponding break pack product transfer deck 130DG1-130DG3 juxtaposed along the break pack product interface locations 263L of the container fill station area CFA. Here, put wall 263W is different and separate from array of storage shelves 130SA of storage structure 130. The put wall 263W provides at least two degrees of freedom (e.g., multi-axis transfer) for the transfer of goods to/from the break pack goods interface location 263L, e.g., the two degrees of freedom are the length of the goods transfer deck 130DG. , spanning/between levels 130DG1-130DG3 of put wall 236W, and spanning/between a group of levels 130DGL. Here, the put wall 263W corresponds to the corresponding product transfer deck 130DG at each level of the put wall 263W (e.g., each level of the put wall 263W corresponds to a respective level 130DG1-130DG3 of the group of levels 130DL). and multiple levels of break pack product interface locations 263L distributed along each storage structure level 130L. Transfer of goods between different levels 130DG1-130DG3 and/or a group of levels 130DGL is performed by a goods bot 262 passing through a ramp of the goods deck 130DG between different levels 130DG1-130DG3 and/or a group of levels 130DGL. a break-packed product (BPG) lift that transports break-packed products PBG between various levels, and/or any other It can be brought about by any suitable method.

When the container bot 110 transfers one or more (supply) containers to the break pack handling station 140, the container bot 110 transfers one or more (supply) containers from the respective break pack product interface location 263L (to storage or outbound lift 150B). specified) Break Pack product container 264 , opportunistically (i.e., the container bot 110 was not planning to take out the Break Pack product container 264 but accidentally moves by the Break Pack product container 264 , For efficiency, the control server 120 may pick (in the sense that the control server 120 may send a command to the container bot 110 to opportunistically remove the break pack product container 264). In other aspects, the break-pack goods container 264 in storage may be placed in the same picking aisle 130A as the supply container 265, where both the break-pack goods container 264 and the supply container 265 are in the same break-pack module 266. designated (eg, by control server 120) to be transported. Container bots 110 that have been previously commanded to pick supply containers 265 may be instructed to pick supply containers 265 by control server 120 (if break pack goods containers 264 are specified to be transferred after the initial command is issued to container bots 110). etc.) may be commanded to opportunistically pick break pack product containers 264 while moving along the same picking path. Here, the container bot 110 moves with both the break pack goods container 264 and the supply container 265, transports the supply container 265 to the break pack operation station 140 of the break pack module 266, and then transfers the break pack goods container 264 to the same break pack goods container 264. The break pack module 266 may be transferred to a predetermined break pack product interface location 263L.

1A, 1C, 2, 3A, 3B, 4, 6A, 6B, 7A, 7B, 7C, 7D, 8A, and 8B, each break pack operation station 140 is coupled to a respective product deck 130DG. be done. The break pack product transfer deck 130DG is separate and distinct from the transfer loop 233BP formed by the containerbot transfer surface 266RS and is separate from the container autonomous transfer transfer loop 233 of the containerbot transfer surface 266RS and described herein. It has a break pack product interface 263 that connects the edges of each of the moving loops DG1L, DG2L, DG3L (see FIG. 4) of the product transfer deck 130DG. Each product deck level 130DG1, 130DG2, 130DG3 at each level of the put wall 263W is separate and distinct from each container bot transfer deck 130EXT coupled to a respective break pack operation station 140. Here, the break pack product transfer deck 130DG is configured such that at least one product bot 262 passes through the break pack product transfer deck 130DG for transportation by at least one container bot 110 on the container transfer deck 130DC. The BPG is configured to be conveyed from the break pack handling station 140 to the corresponding break pack merchandise container 264 . The product bot(s) 262 transport one or more break pack products (unpacked from supply containers) along the break pack product autonomous transport movement loops DG1L, DG2L, DG3L formed by the product transfer deck 130DG. breakpack product BPG between the breakpack operation station 140 and the breakpack product interface 263 . Container bot(s) 110 may also autonomously (e.g., from operator stations 801, 802, 803, 804).

For example, as seen in FIG. 1B, automated storage and retrieval system 100 may be provided with multiple break pack modules 266, where each break pack module includes a respective put wall 263W. Here, the common portions and transfer areas (e.g., at least the picking aisle 130A and the container transfer deck 130DC) of the multi-level container storage array (e.g., storage structure 130) are connected to multiple It is communicatively connected to the put wall 263W of. Each put wall 263W is independent from each other put wall 263W. Each put wall 263W is filled (eg, with containers and/or break pack merchandise) independently of each other put wall 263W. As a further example, each put wall 263W results in the output of an independent break pack product container 264, and each put wall 263W is accessed by the container bot(s) 110 to The output of the break pack product container 264 is orthogonal to each other (e.g., separately and differently/independently) to provide the output break pack product container 264 filled with the break pack of each other put wall 263W. It is independent from the output of the product container 264. As an example, the orthogonal filling of break pack container 264 is such that filling of break pack container 264 is completed without interfering with any other inputs (e.g., to other break pack containers 264) or outputs from put wall 263W. filling the break pack containers 264 with break pack goods BPG in the order defined by the break pack goods containers 264 so that Here, the break-packed products BPG for any given order are grouped together to form independent batches of break-packed products defined by the break-pack container 263, where the break-packed products BPG for any given order are Grouped break pack items for orders are arranged for delivery directly to a customer (eg, a business customer or e-commerce customer) or to a distribution center. Each independent put wall 263W holds a respective break pack product container 264, each different, filled independently with respect to each other break pack product container 264 of each other independent put wall 263W. have various break-pack product container stations or interface locations 263L arranged to place the filled break-pack product container(s), such that each different filled break-pack product container(s) 264 is located at an independent put wall 263W. Define the output of an independent breakpack product container.

In one aspect, the merchandise transfer deck 130DG is configured such that merchandise is picked from one container (such as a supply container 265 or any other suitable normalized container) at the break-pack operations station 140 and another at the break-pack merchandise interface 263. (e.g., outbound as described below) in a supply container 265 or a normalized container with goods (generally of the same type), where other supply containers 265 or normalized The converted container is returned to storage. Generally, supply containers 265 inbound to break pack module 266 are picked until empty, but only some (but not all) of the goods from the inbound supply container may be decanted. Here, an outbound (i.e., outbound from the break pack module 266) container 265 or what is referred to as a normalized container (tote, tray, etc.) is also used with respect to the break pack product container 264 to facilitate the decanting process. It may be placed on the break pack product interface 263 by the container bot(s) 110 in a manner similar to that described herein. In the decant process, merchandise is removed from the supply container 265 (which may be the original product/case packaging of the merchandise(s)) at the breakpack handling station 140 and located on the breakpack merchandise interface 263 ( for example, into an outbound supply container 265 or a normalized container (having the same type of product as that being removed at the break pack handling station 140). Products of the same type are consolidated from multiple supply containers 265 into a smaller number of supply containers 265 (and then returned to storage by container bot(s) 110) for storage in storage racks. The storage density of the automated storage and retrieval system 100 increases as the supplied supply containers 265 can be maintained substantially "full" (rather than having multiple containers that are not full of the same type of product). can be increased. In some aspects, the decanted goods (in a normalized container or an outbound supply container) are output from the storage and retrieval system 100 via the lift 150 and output to a palletized load (such as at an output station 160UT). They may be palletized as parts or shipped individually (such as at output station 160EC).

Merchandise bot 262 may be any suitable type of autonomously guided bot with a payload configured to hold break pack merchandise rather than a product container (eg, case unit, pick face, etc.). The product bot 262 passes through the product decks 130DG, along the corresponding/each product deck 130DG, and between product decks 130DG at different levels of the putwall 263W (e.g., of a group of levels 130DGL). The break pack product BPG is configured to transport the break pack product BPG to each break pack product interface location 263L at each level of the break pack product interface location 263L. Also referring to FIG. 25, each product bot 262 raises or lowers at least one autonomously guided break pack product transport vehicle longitudinally along a path (e.g., along a product deck 130DG, etc.) and between levels. of wheel odometry 2590, dead reckoning 2591, distance measurement and detection of fiducials by electromagnetic distance sensor or vision 2592 and by two-dimensional or three-dimensional camera 2593, informing the vehicle pose and localization in both the Z direction. At least one, alone or in combination, provides for posing and locating the merchandise bot 262 within the Break Pack module 266 through one or more of the Break Pack merchandise transfer decks 130DG1-130DG and at least one interlevel diversion. configured to provide free transitions of vehicle movement at substantially constant travel speeds in transitions to and from paths (e.g., ramps and lifts of the break pack module 266 described herein); . Each of the product bots 262 has a payload hold/support 262PS configured not similar to the payload hold of the container bot 110. The product bots 262 carry break pack product unit payloads BPGPL (including at least one break pack product BPG - FIGS. 7A and 7B) carried thereon from respective payload supports 262PS, as described herein. 7B) into the break pack product container 264 at each break pack product interface location 263L at each level of the put wall 263W. Product bot 262 is configured to autonomously move along and across break pack product autonomous transport movement loops DG1L, DG2L, DG3L formed by product decks 130DG. Product bot 262 is configured to automatically unload one or more break pack products BPG (removed from break pack operation station 140 ) from product bot 262 into break pack product container 264 at break pack product interface 263 . ing.

In one or more aspects, also referring to FIGS. 21 and 22, the product bot 262 may be a non-holonomic autonomous vehicle or a non-holonomic product bot 262NH generally similar to the container bot 110, but with payload retention as described above. The payload holding section of the container bot 110 is configured differently. For example, each product bot 262 may include a frame or chassis 262F1, a drive system 2100, a controller 262C, and one or more sensors 2110. Drive system 2100 includes any suitable drive motor(s) configured to drive a pair of drive wheels 262DW disposed at or adjacent one end of chassis 262F1. The drive wheels 262DW may rotate at the same rotational speed (e.g., for substantially linear movement of the product bot 262) and at different speeds (e.g., for rotation of the product bot 262 along an arcuate path of travel). , and may be differentially driven in opposite directions (eg, to pivot the merchandise bot 262 about a pivot axis located substantially midway between the drive wheels 262D). One or more caster wheels 262CW are located at the other end of chassis 262F1, opposite drive wheel 262DW.

Chassis 262F1 includes any suitable payload holding portions 2120A, 2120S (integrated or coupled to chassis 262F1 in any suitable manner) configured to hold one or more break pack products BPG. . The payload holding portions 2120A, 2021S are open containers, bins, trays, or other suitable structures configured to contain/hold the break-packed product BPG for transportation by the product bot 262, where the payload The holding parts 2120A, 2020S lack grippers, position adjustments, etc. that can grip the break pack product BPG and prevent movement within the payload holding parts 2120A, 2120S.

As an example (see FIG. 21), payload retainer 2120A is an asymmetric payload retainer that extends longitudinally along longitudinal axis LAX of chassis 262F (e.g., a longitudinally extending side surface of payload retainer 2120A). LS1 and LS2 are longer than the laterally extending side surfaces LS3 and LS4 of the payload holding part 2120A). In this example, the break pack product BPG may be ejected from the payload holding portion 2120A (e.g., into a container located at the break pack product interface location 263L) along the longitudinal direction/axis LAX of the product bot 262 (see also FIG. reference). In other aspects, the break-pack product BPG may be ejected from the payload holding portion 2120A (e.g., into a container located at the break-pack product interface location 263L) in the lateral/axial LAT of the product bot 262 (see also FIG. 25). ). As another example (see FIG. 22), the payload holding section 2120S has side surfaces LS1 and LS2 extending in the longitudinal direction of the payload holding section 2120A that are substantially the same as side surfaces LS3 and LS4 extending in the horizontal direction of the payload holding section 2120A. The length is the symmetrical payload holder. In this example, the break-pack product BPG may be ejected from the payload holding portion 2120S (e.g., into a container located at the break-pack product interface location 263L) along the lateral/axial LAT of the product bot 262 (see also FIG. reference). In other aspects, the break pack product BPG may be ejected from the payload holding portion 2120S (e.g., into a container located at the break pack product interface location 263L) in the longitudinal direction/axis LAX of the product bot 262 (see also FIG. 25). ).

The sensor 2110 may be configured to provide any suitable navigation and/or navigation system that facilitates passage of the product bot 262 along the product deck 130DG and ejection of the break pack product BPG at the break pack product interface location 263L under the control of the controller 262C. Contains an object detection sensor. Sensors 2110 may include, but are not limited to, fiducials located on the structure of storage and retrieval system 100, guide tape located on product deck 130DG, indoor GPS, navigation beacons, and/or any other suitable navigational aids. of each product bot 262 along the product deck 130DG by utilizing/configured to detect any suitable navigation aid 2510 (see FIG. 25), including one or more of the following: Can provide navigation.

In one or more aspects, referring also to FIGS. 23 and 24, the product bot 262 is a holonomic autonomous vehicle or holonomic product bot 262H whose payload holding portion is configured differently than the container bot 110, as described above. It can be. For example, each product bot 262 may include a frame or chassis 262F2, a drive system 2100, a controller 262C, and one or more sensors 2110. Drive system 2100 includes any suitable drive motor(s) configured to drive a pair of drive wheels 262DW disposed substantially midway between the longitudinal ends of chassis 262F1. . The drive wheels 262DW may rotate at the same rotational speed (e.g., for substantially linear movement of the product bot 262) and at different speeds (e.g., for rotation of the product bot 262 along an arcuate path of travel). and may be differentially driven in opposite directions (eg, to pivot the merchandise bot 262 about a pivot axis located substantially in the center of the chassis 262F2 between the drive wheels 262DW). One or more caster wheels 262CW are located at each longitudinal end of chassis 262F2.

Chassis 262F2 includes any suitable payload holding portions 2120A, 2120S (integrated or coupled to chassis 262F1 in any suitable manner) configured to hold one or more break pack products BPG. . The payload holding portions 2120A, 2021S are open containers, bins, trays, or other suitable structures configured to contain/hold the break-packed product BPG for transportation by the product bot 262, where the payload The holding parts 2120A, 2020S lack grippers, position adjustments, etc. that can grip the break pack product BPG and prevent movement within the payload holding parts 2120A, 2120S.

As an example (see FIG. 23), payload retainer 2120A is an asymmetric payload retainer that extends longitudinally along longitudinal axis LAX of chassis 262F (e.g., a longitudinally extending side surface of payload retainer 2120A). LS1 and LS2 are longer than the laterally extending side surfaces LS3 and LS4 of the payload holding part 2120A). In this example, the break pack product BPG may be ejected from the payload holding portion 2120A (e.g., into a container located at the break pack product interface location 263L) along the longitudinal direction/axis LAX of the product bot 262 (see also FIG. reference). In other aspects, the break-pack product BPG may be ejected from the payload holding portion 2120A (e.g., into a container located at the break-pack product interface location 263L) in the lateral/axial LAT of the product bot 262 (see also FIG. 25). ). As another example (see FIG. 24), the payload holding section 2120S has side surfaces LS1 and LS2 extending in the longitudinal direction of the payload holding section 2120A that are substantially the same as side surfaces LS3 and LS4 extending in the horizontal direction of the payload holding section 2120A. A symmetrical payload holder, which is of length. In this example, the break-pack product BPG may be ejected from the payload holding portion 2120S (e.g., into a container located at the break-pack product interface location 263L) along the lateral/axial LAT of the product bot 262 (see also FIG. reference). In other aspects, the break pack product BPG may be ejected from the payload holding portion 2120S (e.g., into a container located at the break pack product interface location 263L) in the longitudinal direction/axis LAX of the product bot 262 (see also FIG. 25). ).

The sensor 2110 may be configured to provide any suitable navigation and/or navigation system that facilitates passage of the product bot 262 along the product deck 130DG and ejection of the break pack product BPG at the break pack product interface location 263L under the control of the controller 262C. Contains an object detection sensor. Sensors 2110 may include, but are not limited to, fiducials located on the structure of storage and retrieval system 100, guide tape located on product deck 130DG, indoor GPS, navigation beacons, and/or any other suitable navigational aids. of each product bot 262 along the product deck 130DG by utilizing/configured to detect any suitable navigation aid 2510 (see FIG. 25), including one or more of the following: Can provide navigation.

The product bot 262 (as either a non-holonomic product bot 262NH or a holonomic product bot 262H) can be mounted on either an asymmetric payload holder 2120A or a symmetric payload holder depending on the configuration of the break pack product container 264 with which the product bot 262 interfaces. It is composed of For example, the orientation (e.g., longitudinal ejection of break-packed goods BPG or lateral ejection of break-packed goods BPG) and/or shape (symmetrical or asymmetrical) of payload retention portions 2120A, 2120S of break-packed goods container 264 Matched to the orientation/shape of the break pack merchandise container 264 to maximize cargo fill. As described herein, the cargo fill of a break-packed goods container is maximized when the break-packed goods BPG therein occupies at least about 30% of the container volume or at least about 50% of the container volume. It can be considered that For example, as seen in FIG. 25, when filling a break-pack product container 264, the product bot 262 maintains the payload so that the orientation of the payload holding portion 2120A matches the orientation of the break-pack product container 264 being filled. portion, particularly the asymmetric payload holding portion 2120A. As seen in FIG. 25, when the longitudinally extending sides 264S1, 264S2 of the longitudinally extending break pack product container 264 extend away from the sides of the product deck 130DG, the product bot 262 The longitudinally extending side surfaces LS1 and LS2 of the payload holding portion 2120A are aligned with the longitudinally extending side surfaces 264S1 and 264S2 of the break pack product container 264 for longitudinal ejection of the break pack product PBG into the container 264. may orient itself on the merchandise deck 130DG substantially transverse to the travel lanes L1, L2, L3. As also seen in FIG. 25, when the longitudinally extending side surfaces 264S1, 264S2 of the longitudinally extending break pack product container 264 extend along the sides of the product deck 130DG, the product bot 262 The longitudinally extending side surfaces LS1, LS2 of the payload holding portion 2120A are aligned with the longitudinally extending side surfaces 264S1, 264S2 of the break pack product container 264 for lateral ejection of the break pack product PBG into the product container 264. may orient itself on the merchandise deck 130DG substantially along one of the travel lanes L1, L2, L3.

Automated storage and retrieval system 100 may include non-holonomic product bots, holonomic product bots, or both non-holonomic product bots and holonomic product bots passing through product deck 130DG. A suitable example of a product bot 262 is one manufactured by Tompkins International of Raleigh, North Carolina (USA - see, e.g., U.S. Pat. No. 10,248,112, issued April 2, 2019). , Seattle Washington on Amazon. com Inc. Pegasu drive robots available from Pegasu (USA), and Hikrobot Technology Co. of Hangzhou, China. , Ltd. A mobile robot (such as the Latent Mobile Robot) available from Other suitable examples of goods bots 262 and container bots 110 can be found in the article “Warehousing System for Storing and Retrieving Goods In Containers”, June 26, 2020, the entire disclosure of which is incorporated herein by reference. No. 17/358,383, filed on June 25, 2021, which is a non-provisional application of U.S. Provisional Patent Application No. 63/044,721, filed on June 25, 2021. .

As described herein, the break pack product autonomous transport movement loops DG1L, DG2L, DG3L formed by the product deck 130DG are any of the respective groups of product deck levels 130DGL on which the product bots 262 operate. and provides the product bot 262 with random access to any and each of the break pack product interface locations 263L of the break pack product interface 263 on each product deck level 130DG1, 130DG2, 130DG3.

Each product deck 130DG includes a group of product deck levels 130DGL. For example, each product deck 130DG (there may be multiple product decks stacked one above the other - see FIG. 3B) includes operator station deck level 130DG0 and a group of product deck levels 130DGL (which in the illustrated example (including product deck levels 130DG1, 130DG2, 130DG3 substantially stacked one above the other). Here, the operator station deck level 130DG0 is common to each product deck level 130DG1, 130DG2, 130DG3 of the group of product deck levels 130DGL, where the product bot 262 operates on multiple product decks as part of a transport task. Navigate and/or move products on levels 130DG0, 130DG1, 130DG2, 130DG3 (e.g., where the tasks are to pick break pack products BPG, place break pack products BPG, . ).

In aspects of the disclosed embodiment, each group of product deck levels 130DGL includes three product deck levels 130DG1, 130DG2, 13DG3 substantially stacked one above the other, but in other aspects, the group of product decks Any suitable number of product deck levels at level 130DGL may be included. The break pack product BPG (FIG. 7B) is transferred from the break pack operation station 140 to the break pack product container 264 on one of the product deck levels 130DG1, 130DG2, 130DG3 of the group of product deck levels 130DGL from the break pack module. 266 to the product bot 262.

As seen in FIG. 4, each of the product deck levels 130DG1, 130DG2, 130DG3 in combination with the operator station deck level 130DG0 form a break pack product autonomous movement loop DG1L, DG2L, DG3L (e.g., operator station deck Level 130DG0 forms a common/shared loop portion for each break pack product autonomous moving loop DG1L, DG2L, DG3L). The product bot 262 connects the breakpack product autonomous movement loop DG1L, DG2L, between the breakpack product interface 263 and the operator stations 801, 802, 803, 804 (e.g., at different product deck levels 130DG1, 130DG2, 130DG3). It circulates along DG3L.

In the illustrated example, operator station deck level 130DG0 is at the same level (i.e., substantially in the same plane) as merchandise deck level 130DG2 (where there is a deck transition between merchandise deck level 130DG2 and operator station deck level 130DG0). In other aspects, the operator station deck level 130DG0 may be at the same level as any one of the product deck levels 130DG1, 130DG2, 130DG3. In yet other aspects, a ramp may be provided between the operator station deck level 130DG0 and each of the product deck levels 130DG1, 130DG2, 130DG3 (e.g., the operator station deck level is coplanar with any of the product deck levels). (It doesn't have to be on top). In the illustrated example, lamps 130DG1R, 130DG3R are provided between operator station deck level 130DG0 and product deck levels 130DG1, 130DG3. Although ramps 130DG1R, 130DG3R are illustrated, any suitable lifts, escalators, elevators, ladders, etc. may be provided, and the product bot 262 is located at operator station deck level 130DG0 and product deck levels 130DG1, 130DG2, 130DG3. configured to be walked/climbed to transition between.

Ramps 130DG1R, 130DG3R and deck transition 130DG2R extend from output end 130DG0E1 of operator station deck level 130DG0. One or more of the product deck levels 130DG1, 130DG2, 130DG3 extend back to the input end 130DG0E2 of the operator station deck level 130DG0. In the illustrated example, merchandise deck level 130DG1 includes a return ramp 455 that communicates with input end 130DG0E2 of operator station deck level 130DG0. The return ramp 455 is common to each of the product deck levels 130DG1, 130DG2, and 130DG3, where the product bots 262 from the product deck levels 130DG2 and 130DG3 access the return ramp 455 from the product deck level 130DG2. , 130DG3 to product deck level 130DG1 (described below) are provided.

According to the disclosed embodiments, product bot 262 does not need to travel to operator station deck level 130DG0 to transition between product deck levels 130DG1, 130DG2, 130DG3. For example, the one or more ramps 451, 452, 453, 454 allow the product bot 262 to transition substantially directly between product deck levels 130DG1, 130DG2, 130DG3 without passing through operator station deck level 130DG0. It is provided between the product deck levels 130DG1, 130DG2, and 130DG3 so as to be able to do so. In some aspects, the product bot 262 moves bi-directionally on one or more ramps 451, 452, 453, 454 to transition between various product deck levels 130DG1, 130DG2, 130DG3 while In other aspects, movement along one or more ramps 451, 452, 453, 454 is such that the item bot 262 is at one of the item deck levels 130DG2, 130DG3 in order to return to the operator station 801, 802, 803, 804. It may be unidirectional, such as from one or more to the product deck level 130DG1.

One or more (or each) of the product deck levels 130DG1, 130DG2, 130DG3 are provided with one or more shunts 461, 462, 463. The shunts 461, 462, 463 substantially reduce the size of the break-pack goods autonomous movement loops DG1L, DG2L, DG3L, respectively, in which the goods bots 262 move. Provide a transition between opposing sides. For example, shunt 461 on product deck level 130DG1 is a break pack product autonomous movement loop with shunt that provides circulation of product bots 262 on product deck level 130DG1 without passing product bots on operator station deck level 130DG0. Form DG1LS. The shunt 462 on the product deck level 130DG2 connects the break pack product autonomous movement loop DG2LS with a shunt that provides circulation of the product bots 262 on the product deck level 130DG2 without passing product bots on the operator station deck level 130DG0. Form. The shunt 463 on the product deck level 130DG3 connects the break pack product autonomous moving loop DG3LS with a shunt that provides circulation of the product bot 262 on the product deck level 130DG3 without passing the product bot on the operator station deck level 130DG0. Form. Although one shunt is illustrated for each of the product deck levels 130DG1, 130DG2, 130DG3 for illustrative purposes only, break pack products autonomous with any suitable number of shunts on each product deck level 130DG1, 130DG2, 130DG3 There may be multiple shunts at each of the product deck levels 130DG1, 130DG2, 130DG3 to form mold movement loops.

It is noted that at least some of the lanes of the mobile loops DG1L, DG2L, DG3L, DG1LS, DG2LS, DG3LS are separated from each other by physical barriers. In the example shown, operator station deck level 130DG0 may have multiple travel lanes similar to the lanes of container deck 130D, but with ramps 130DG1R, 130DG3R, 451, 452, 453, deck transition 130DG2R, and product deck level. 130DG1, 130DG2, 130DG3 are single lanes that are physically separated (e.g., form at least part of a movement loop) to prevent product bots 262 from moving from one lane to another. (excluding in certain locations such as the shunts described herein, where the shunts also provide a respective single lane of bot movement). Here, physical separation is provided by a "void" at the center of the moving loop, although in other embodiments physical separation may be provided by a wall or other suitable structural barrier.

In other aspects, the movement surfaces of ramps 130DG1R, 130DG3R, 451, 452, 453, deck transition 130DG2R, and product deck levels 130DG1, 130DG2, 130DG3 as well as operator station deck level 130DG0 are arranged around the respective movement loops. may have multiple lanes providing one-way and/or two-way movement of the product bot. For example, referring also to FIG. 25, one or more of the above-described portions of the product deck 130DG (FIG. 25 includes ramps 130DG1R, 130DG3R, 451, 452, 453, deck transition 130DG2R, product deck levels 130DG1, 130DG2, 130DG3, Operator station deck level 130DG0 (note that it represents one or more of the travel surfaces of DG0) includes a plurality of travel lanes L2, L2, L3. Although three travel lanes L1, L2, L3 are illustrated in FIG. 25, it should be understood that the number of travel lanes may be more or less than three. For example, in FIGS. 3A, 4, 7A, and 7C, at least some of the product deck levels 130DG1, 130DG2, 130DG3 include multiple lanes L1, L2. The multiple lanes L1, L2, L3 allow one product bot 262 to pass through or around another product bot 262 in any suitable manner (e.g., obstacle avoidance). navigation).

As an example of obstacle avoidance navigation for the product bot, the product bot 262 may, for example, via the controller 262C and the sensor 2110, navigate the product bot 262 through a substantially smooth curved bot passage path on the transport surface of the product deck 130DG. Drive system 2100 may be configured to effect movement of the product bot to transition between travel lanes L1, L2, L3 along 2550 (see FIG. 25). The substantially smooth curved bot travel path 2550 is a predetermined optimal trajectory of the product bot 262 along the substantially smooth curved bot travel path 2550 determined based on a dynamic model of the product bot. , connects waypoint LW1 at one of the travel lanes L1, L2, L3 to waypoint LW2 at one of the travel lanes L1, L2, L3. A suitable example of obstacle avoidance navigation is, for example, U.S. Pat. , No. 117,743.

Still referring to FIGS. 3A, 4, 7A, 7C, and 25, a plurality of lanes (such as lane L2 in FIGS. 3A, 4, 7A, and 7C or any one of lanes L1, L2, L3 in FIG. 25) One is based, at least in part, on the movement of lane L2 such that a product bot in need of maintenance is removed from the break pack module 266 (such as by a product bot lift module 490 or a human operator as described herein). may be a disabled product bot lane (e.g., a failure lane) stored in a dynamically variable portion. For example, a disabled (or requiring maintenance) product bot 262D (see FIG. 7A) located in lane L2 (or lanes L1 or L3 in other aspects) indicates that product bot 262D is disabled. may be sent to controller 120 indicating its location within break pack module 266 . Controller 120 may locate disabled product bot 262 anywhere along lane L1, such as lane L2, or in other aspects, where disabled product bot 262D is located. route the operational product bot 262 around the dynamically designated failure zone 777 (where re-routing is one of the bypass lanes). effected by reorientation through one or more or shunts/ramps). If two or more travel lanes L1, L2, L3 are present, the designation of at least a portion of one of the travel lanes L1, L2, L3 by the controller 120 as a failure zone 777 (or bypass lane) , controller 120 controls a portion of any one or more of travel lanes L1, L2, L3 for a period of time corresponding to the presence of a disabled bot in one or more of travel lanes L1, L2, L3. may be dynamically designated as a failure zone 777 (or bypass lane) (e.g., based on a signal sent to controller 120 by one or more disabled bots 262). . Suitable examples of bypass lanes include, for example, U.S. Pat. Specification, and US Pat. No. 9,561,905, entitled "Autonomous Transport Vehicle," issued February 7, 2017.

As described herein, one or more barriers 766A, 766B (FIG. 7C) close off access to the dynamically designated failure zone 777 in a manner described herein. may be deployed to effect retrieval of disabled product bots 262 from break pack module 266 at .

One of the plurality of lanes (e.g., lane L2 of FIG. 7A or, e.g., any one or more of lanes L1, L2, L3 of FIG. 25) is at least partially connected to the break pack product interface of the put wall 263W. 263 (e.g., breakpack order classification 188) (and thus any of the breakpack product containers 264 located in the breakpack product interface 263 of the put wall 263W). for a product bot 262 that provides a sequence of break-packed product BPGs placed in a given one or more (sequencing may also be provided by cycling the product bot 262 around a moving loop) buffer 778. Here, the controller 120 is configured to specify a predetermined order of mixed break pack products BPG (e.g., a predetermined order may include more durable/larger break pack products or other products such as those described herein). Different break pack products BPG in the same (i.e. common) break (in any suitable order such as the more fragile/smaller break pack products are placed in the break pack product container BPG after proper sequencing) lane L2 (or lane L1, if there are two lanes L1, L2 L1, or lanes L1, L2, L3,...Ln (where n is an integer indicating the maximum number of lanes) if more than two lanes are present, or Product bot 262 may be instructed to buffer itself. As described herein, sequencing may be effected on a single item deck level 130DG1, 130DG2, 130DG3 or across/between multiple item deck levels 130DG1, 130DG2, 130DG3, where the item Bot 262 transitions between product deck levels 130DG1, 130DG2, 130DG3 to pick and place break pack products BPG and return them to break pack operation station 140.

Referring also to FIG. 7B, it is noted that one or more of the break pack product containers 264 at the put wall 263W may be partitioned break pack product containers 264PP. Although the partitioned break pack product container 264PP is illustrated here as having two partitions P1, P2, in other embodiments more than two partitions may be provided. Generally, each break pack product container 264 corresponds to an order for any given (eg, one) customer (i.e., store, e-commerce customer, distribution center, etc.). The partitioned break pack product container 264PP provides for or otherwise effects batch processing of two or more customer break pack product orders. For example, the customers (e.g., referred to as joint customers) of a distribution center that hold goods and ship those goods to their own customers (referred to herein as sub-customers) each correspond to a sub-customer. Two separate break pack product orders may be placed. The storage and retrieval system 100 may combine two separate break pack merchandise orders (corresponding to two sub-customers) into a single partitioned break pack merchandise container 264PP for shipment to a common customer.

Still referring to FIGS. 3A, 4, 7A, 7C, and 25, as discussed above, one of the plurality of lanes (such as L2) is at least partially in need of maintenance (or otherwise disabled). A disabled product bot lane (e.g., failure lane). where product deck levels 130DG1, 130DG2, 130DG3 (and/or product deck level 130DG0) close (or otherwise restrict access to) the portion of the deck level where the disabled product bot is located. and/or affected product bots 262 (if they are able to exit the affected area or stop the product bots remaining in the affected area). configured to instruct the user to exit the area. For example, product deck levels 130DG0, 130DG1, 130DG2, and 130DG3 are listed in "Automated Storage and Retrieval System with Integral Secured," published August 11, 2020, the entire disclosure of which is incorporated herein by reference. Personnel Access U.S. Pat. entitled “Al Systems”. It includes a deployable physical barrier substantially similar to that described in U.S. Pat. No. 10,507,988. For example, referring to FIG. 7C, one or more portions of the product deck 130DG are deployed to close (or otherwise block) access to respective portions of the product deck 130DG; Includes retractable barriers (eg, gates, nets, fences, etc.) that are retracted to allow access to respective portions of the 130DG. As seen in FIG. 7C, for example, at least one barrier 766A, 766B is provided at product deck level 130DG1 (similar barriers may be provided at other product deck levels). Barriers 766A, 766B are positioned adjacent to shunt 461 alongside (eg, blocking or closing) respective portions L1A, L1B of lane L2. Barriers 766A, 766B shunt 761 when one or more of barriers 766A, 766B are deployed such that product bot 262 continues to operate within an open (e.g., unblocked) portion of break pack module 266. is positioned on the product deck level 130DG1 to allow access to the product deck level 130DG1. In one or more aspects, the break pack product autonomous movement loops DG1L, DG2L, DG3L are generally described as having a common direction of movement (i.e. movement of the product bot in a single circulation direction) However, when the barriers 766A, 766B are deployed, one or more portions of the break pack goods autonomous mobile loops DG1L, DG2L, DG3L (e.g., under the traffic management control of the controller 120) transport the goods bots interactively. 262 movements may be possible.

If any of the product deck levels 130DG1, 130DG2, 130DG3 (and/or product deck level 130DG0) are closed, the operation of the break pack module 266 may include: By orienting/reorienting the product bots to different product deck levels 130DG1, 130DG2, 130DG3 (and/or product deck level 130DG0) or using ramps 451-453, 130DG1R-130DG3R and shunts 461 (FIGS. 2 and 4) by orienting/reorienting the product bot around the closed part(s) of the product deck level 130DG1, 130DG2, 130DG3 (and/or product deck level 130DG0) without interruption. Can be continued. Controller 120 controls product bot 262 on the fly to avoid closed portions of product deck levels 130DG1, 130DG2, 130DG3 (and/or product deck level 130DG0) and maintain uninterrupted operation of break pack module 266. on the fly (e.g., during the execution of a product bot task) along different travel routes (other than the pre-planned route) or to different break-pack product containers 264 (other than the pre-determined break-pack product containers). The bot may be configured to reorient (i.e., during performance of a bot task).

As also seen in FIGS. 4 and 10, the product deck 130DG includes at least one product bot lift module for inputting product bots 262 into and/or retrieving product bots 262 from the break pack module 266. 490 included. In one or more aspects, at least one product bot lift module 490 facilitates retrieval of disabled product bots 262D and/or transfer of product bots 262 to break pack module 266 for any suitable reason. Provides input and retrieval of product bot 262 from break pack module 266. For example, product bots 262 may be entered or removed depending on load balancing (e.g., predetermined throughput), product bot density/traffic, product bot maintenance, and/or any other suitable criteria. obtain. Product bot lift module 490 is disclosed in U.S. Pat. No. 10,221, entitled "Storage and Retrieval System Rover Interface," issued March 5, 2019, the entire disclosure of which is incorporated herein by reference. It may be substantially similar to that described in the '013 specification. By way of example, at least one merchandise bot lift module 490 may interface with merchandise deck(s) 130DG. As seen in FIGS. 4 and 10, at least one merchandise bot lift module 490 is interfaced with merchandise deck levels 130DG1, 130DG2, 130DG3 of a stack of merchandise deck levels 130DGL, while in other aspects: It is interfaced with one or more (stacked) operator station deck levels 130DG0 (see FIG. 4) in a manner generally similar to that illustrated in FIG. 10. The interface between the at least one product bot lift module 490 and the product decks 130DG provides that the input and ejection of product bots 262 to each product deck 130DG is substantially decoupled from the throughput of the break pack module 266 (e.g., each The inputs and outputs of the product bot 262 at the product deck level may be placed in place in the product deck 130DG such that the inputs and outputs of the product bot 262 do not affect throughput. In one aspect, at least one merchandise bot lift module 490 is connected to, or forms part of, merchandise deck 130DG for each merchandise deck level 130DG1, 130DG2, 130DG3 and/or operator station deck level 130DG0. It may interface with a spur or staging area 491 (eg, a product bot loading platform - see FIG. 4). In other aspects, at least one goods bot lift module 490 may interface substantially directly with operator station deck level 130DG0 and/or one or more of goods deck levels 130DG1, 130DG2, 130DG3.

Product deck 130DG and/or staging area 491 may include any suitable barrier 1032 that substantially prevents product bot 262 from moving away from product deck 130DG and/or staging area 491 at the lift module interface. should be kept in mind. In one aspect, the barrier 1032 has a deployed position and a lift of the product bot lift module 490 to substantially prevent the product bot 262 from moving away from the product deck 130DG and/or the staging area 491. It may be a movable barrier that may be movable between a retracted position to allow transition between platform 1031 and product deck 130DG and/or staging area 491.

In addition to inputting product bots 262 to and retrieving product bots 262 from break pack module 266, in one aspect, each product bot lift module 490 also retrieves product bots 262 from break pack module 266. between product deck levels 130DG0, 130DG1, 130DG2, 130DG3 of a group of product deck levels 130DGL and/or between product deck levels 130DG0, 130DG1, 130DG2, 130DG3 of a different (e.g., stacked) group of product deck levels 130DGL. The product bot 110 can be transported by the bot 110. The controller 120 is configured to introduce a product bot 262 from outside the break pack module 266 into a predetermined product deck level 130DG0, 130DG1, 130DG2, 130DG3 and/or a predetermined group of product deck levels 130DGL, and to introduce a product bot 262 from the break pack module 266 into a predetermined set of product deck levels 130DGL. 262 and/or by transferring the product bot 262 between product deck levels 130DG0, 130DG1, 130DG2, 130DG3 and/or the group of product deck levels 130DGL without retrieving the product bot 262 from the break pack module 266. A product bot lift module 490 may be utilized to provide product bot balancing, where the workload is balanced between product deck levels 130DG1, 130DG2, 130DG3 and/or between different sets of product deck levels 130DGL. In one aspect, the transfer of the product bot 262 between different product deck levels 130DG0, 130DG1, 130DG2, 130DG3 and/or the group of product deck levels 130DGL using the product bot lift module 490 is independent of the product bot payload transfer. (e.g., the break pack product BPG is not placed on the product bot 262 when it is transferred between a deck level or group of deck levels using the product bot lift module 490. ). In other aspects, the merchandise bot 262 may carry a payload (eg, break pack merchandise BPG) while being transferred between storage deck levels or group of deck levels using the merchandise bot lift module 490.

For purposes of example only, each product bot 262 lift module 490 may include a substantially rigid frame 1030 and a lift platform 1031 movably coupled to the frame 1030. The frame 1030 may have any suitable configuration to allow the lift platform 1031 to move between deck levels 130DG1, 130DG2, 130DG3 and/or deck level 130DG0. Rover lift module 190 may include any suitable drive system 1019M coupled to lift platform 1031 to move lift platform 1031 in the direction of arrow Z between deck levels 130DG1, 130DG2, 130DG3 and/or deck level 130DG0. may include.

Lift platform 1031 includes a frame 1031F forming product bot support 1051 having at least one opening 1052 to allow product bot 262 to transition to/from product bot support 1051. Frame 1031F may have any suitable configuration and may be movably coupled to frame 1030 and drive system 1019M in any suitable manner. The movable connection between frame 1031F and frame 1030 may also include any suitable guide member to substantially prevent movement of lift platform 1031 in the XY plane. For illustrative purposes, frame 1031F substantially supports product bot support 1051 to substantially prevent product bot 262 from being driven or moved away from lift platform 1031, such as during transport of product bot 262. One or more surrounding fences 1050A-1050C may further be included. At least one of fences 1050A-1050C moves to frame 1031F to allow merchandise bot 262 to transition between rover support 1051 and, for example, merchandise deck 130DG (and/or staging area 491). can be attached. In one aspect, the frame 1031F includes a first end 1031E1 and a second end 1031E2 longitudinally separated from the first end 1031E1. The product bot 262 allows one or more of the fences 1050B, 1050C located at the first end 1031E1 and the second end 1031E2 to allow the product bot 262 to enter or exit the lift platform 1031. on the lift platform 1031 along the longitudinal axis LA such that it can be moved between a first position for holding the product bot 262 on the lift platform 1031 and a second position for holding the product bot 262 on the lift platform 1031. and may move away from it. Fence 1050A may be used to load or retrieve product bots 262 onto or from lift platform 1031, for example, from the warehouse floor (or other "ground" level) where automated storage and retrieval system 100 is located. It may likewise be pivotable to allow. In other aspects, product bots 262 may be loaded onto lift platform 1031 in any suitable manner.

It may be desirable to have the ability for any product bot 262 to begin operating virtually anywhere within the break pack module 266. To do so, it is advantageous for the starting position of the product bot to be determined in a substantially autonomous manner. In one aspect, the registration station(s) 1013R enables the controller 262C (FIG. 1A) of the product bot 262 to determine where the product bot 262 is within the automated storage and retrieval system 100. may be distributed throughout the break pack module 266 to provide sufficient location data to a product bot 262 that lacks product bot pre-positioning data (FIG. 11, block 1100). Registration station 1013R provides a location and/or automatic registration system for product bots 262, such as cold start of product bots (if the product bot lacks pre-positioning data), and optionally throughout automated storage and retrieval system 100. may enable product bot onset, offset, and updated registration for product bot introduction/withdrawal updates at a desired location of the product bot. The location of each registration station 1013R is a reference frame (e.g., an overall three-dimensional reference space) of the structure of the automated storage and retrieval system 100; in other aspects, the overall reference space may be any suitable number of may have dimensions). When the product bot 262 and the registration station interface, the location of the registration station that the product bot 262 is interfacing with is sent to both the product bot 262 and the controller 120 to control autonomous product bot control and control of the product by the controller 120. It is noted that one or more of the controls of bot 262 may be enabled.

The product transfer deck(s) 130DG of the break pack module 266 facilitate the physical introduction and withdrawal of the product bots 262 on each deck level 130DG0, 130DG1m, 130DG2, 130DG3 of the break pack module 266. The product bot 262 may be arranged with any suitable rover entry/exit features, such as the lift module 490 or any other structural features (eg, ports, openings, platforms). In one aspect, registration station 1013R may be located and associated with a particular entry/exit station in a manner generally similar to that described above with respect to lift module 490 of product bot 262. Registration station 1013R may be initialized and mapped to a storage three-dimensional reference space (FIG. 11, block 1110) using any suitable controller, such as control server 120. Each registration station 1013R may interface or otherwise interface with one or more product bots 262 (which may lack bot pre-positioning data) within a predetermined proximal and/or orientation relative to the registration station 1013R. Otherwise, they may communicate (FIG. 11, block 1120). In one aspect, the item bot 262 is positioned when the item bot 262 lacks pre-positioning data, such that the item bot 262 may perform pick, place, and return operations (FIG. 11, block 1132). It may communicate with registration station 1013R to provide data to product bot 262 (FIG. 11, block 1131). As mentioned above, the registration station 1013R also includes a device, such as a lift module 490 of the product bot 262, to inform the product bot 262 from which position the product bot 262 is being inserted or removed. It may be used at the point of introduction and withdrawal of the product bot 262. In another aspect, the registration station 1013R may collect data from the product bot 262 (FIG. 11, block 1130) and send the data to the controller 120 (FIG. 11, block 1140), where the data is transferred to the controller 120. may be sufficient for autonomous product bot registration by (FIG. 11, block 1150) (i.e., the data includes a unique product bot identification and the product bot's location in the overall three-dimensional reference space of the automated storage and retrieval system 100). ). This allows controller 120 to effect the introduction of product bot 262 into, for example, break pack module 266, which may be associated with an overall three-dimensional reference space. Conversely, withdrawal of a product bot 262 causes the product bot 262 to deregister from the automated storage and retrieval system 100 when the product bot 262 exits the break pack module 266 in a manner substantially similar to that described above (FIG. 11). , block 1151). Registration and deregistration of product bots is based on deployment or withdrawal information (e.g., which product bots 262 are inserted into which break pack modules 266 and on which deck levels 130DG0, 130DG1, 130DG2, 130DG3, or retrieved). In addition to automatically updating the system software using the system's software, other configuration settings of the automated storage and retrieval system 100 may be automatically checked.

In one aspect, registration station 1013R may also function as a location update (e.g., product bot 262 has prior location data), where registration station 1013R provides positioning data to product bot 262 to break The location of product bot 262 within pack module 266 is updated or otherwise modified (FIG. 11, block 1133). In one or more aspects, registration stations 1013R may be located throughout break pack module 266 to provide continuous updates of product bot locations. Communicator 262T of product bot 262 may also be configured to obtain data from registration station 1013R in any suitable manner. Registration station 1013R may be used by product bot 262 to determine where product bot 262 is during normal operation if product bot 262 needs to reset itself.

Referring to FIGS. 3A, 4, 6A, 6B, 7A-7D, 8A, and 8B, the product bot 262 operates at the operator stations 801, 802, 803 of the break pack operation station 140, as described herein. 804 and a break pack product container 264 located at the break pack product interface 263. For example, the controller 120 may pick up a break pack product BPG from any one of the operator stations, such as operator station 802 (illustrated in FIG. 8B), and transfer the break pack product BPG to a product The product bot 262 may be instructed to deliver to a predetermined break pack product container 264 located at a predetermined break pack product interface location 263LP located along the deck level 130DG1. Here, an operator such as human operator HUM (or robot operator ROB) places a break pack product BPG on product bot 262 located in queue 844 on product deck 130DG. From operator station 802, product bot 262 traverses operator station deck level 130DG0 to ramp 130DG1R to enter product deck level 130DG1. As described herein, if there is an obstruction, such as a closed portion of the product deck level 130DG1, the controller 120 controls the operation of the other product deck levels 130DG2, 130DG3, shunts 461, and/or ramps 451-454. The merchandise bot 262 may be rerouted around obstacles on the fly, such as by reorienting the merchandise bot along a travel path, including passing through one or more.

In one or more aspects, the product bot 262 is configured to verify the identity of the break pack product container 264 located at the predetermined break pack product interface location 263LP. It is configured with an appropriate sensor 733. The sensor(s) 733 may be an optical sensor (e.g., a barcode reader), a radio frequency identification (RFID) tag reader, or any suitable identification mark/tag on the break pack merchandise container 264. and one or more other suitable sensors. Once the product bot 262 is located at the predetermined break pack product interface location 263LP, the product bot 262 verifies the identity of the break pack product container 264 located at the predetermined break pack product interface location 263LP. If the correct break pack product container 264 is located at the predetermined break pack product interface location 263LP, the product bot 262 is configured to transfer the break pack product BPG to the break pack product container 264. If the product bot 262 determines that an erroneous break pack product container 264 is placed in the predetermined break pack product interface location 263LP, the product bot 262 is configured to communicate it to the controller 120, and the controller 120 , reorienting the product bot 262 to another break pack product container (e.g., at the same or a different level) in the break pack product interface 263, reorienting the product bot 262 to the buffer area of the product deck 130DG to ensure the correct break. Waiting for delivery of a pack product container (or supply container from which the break pack product was removed or containing the same SKU as the break pack product BPG) and/or reorienting the product bot 262 back to the break pack operation station 140 As such, tasks for product bots 262 may be reassigned on the fly.

When a break-packed product BPG is delivered to a break-packed product container 264 for transport by container bot 110 to a warehouse or from automated storage and retrieval system 100, product bot 262 transfers another break-packed product BPG to a break-packed product BPG. It may be returned to the break pack handling station 140 for transport. In other aspects, the product bot 262 may be passed to and removed from the break pack module 266 or transferred to another break pack module by the product bot lift module 490.

As described above, the break-pack product(s) BPG delivered (e.g., from one product bot 262 or from multiple break-pack products from number of product bots 262) are placed in The broken-packed product containers 264 are picked from deck level 130DG by container bots 110 moving along container bot movement surfaces 266RS1, 266RS2, 266RS3 corresponding to product deck level 130DG for storage or automated storage and storage. 3A, for example, container bot transfer surface 266RS1 corresponds to and serves product deck level 130DG1, and container bot transfer surface 266RS2 provides transfer of break pack product containers 264 from retrieval system 100. The container bot movement surface 266RS3 corresponds to and functions at the product deck level 130DG3.) In one aspect, the container bot(s) 110 are described in "Warehousing System for Storage and Retrieving Goods In Containers", the disclosure of which is incorporated herein by reference in its entirety and filed June 26, 2020. The break-pack product container 264 is opened for ejection of the break-pack product container 264 in a manner similar to that described in U.S. Provisional Patent Application No. 63/044,721 entitled The break pack product container 264 is configured to transport from the break pack product interface 263 to a container storage location 130S, which is the break pack product container storage location 130SB, for storage. ing.

Referring to FIGS. 2, 3A, 4, 7B, 8B, and 27, exemplary operation of the break pack module or automated order fulfillment system 266 will be described. A multi-level break pack product container filling array or put wall 263W is provided (FIG. 27, block 2700). Each level PWL of put wall 263W has a container filling station area CFA, and break pack merchandise container stations 263L are arranged along container filling station area CFA (e.g., along merchandise deck 130DG), and each level PWL has a container filling station area CFA. It has corresponding break-pack product transfer decks 130DG1-130DG3 juxtaposed along the break-pack container station 263L in the container filling station area (see FIG. 4). The method uses at least one product bot 262 to move break-pack products along corresponding break-pack product transfer decks 130DG1-130DG3 and at different levels PWL of a multi-level break-pack product container filling array 263W. 27, block 2710, between the break pack product transfer decks 130DG1-130DG3 to each break pack product container station 263L at each level PWL. Each break pack product container station 263L is accessed by at least one product bot 262 and is arranged to hold a break pack product container 264 filled with a predetermined break pack product filling payload BPGFP, and is accessed by at least one product bot 262. has a payload support 262PS (see, eg, FIG. 7B) for holding at least one breakpack product BPG unit until delivery by at least one product bot 262.

The corresponding transfer decks 130DG1-130DG3 at each level PWL are connected to the corresponding break-pack product transfer decks 130DG1-130DG3 at each level PWL and other break-pack product transfer decks 130DG1-130DG3 corresponding to each other level PWL. The inter-level transition autonomously guided break pack goods transport vehicle path ITPS passing between the levels is communicatively joined to the other transfer decks 130DG1-130DG3 corresponding to each other level PWL of the put wall 263, thereby At least one product bot 262 transfers each other break pack corresponding to each other level PWL from the corresponding break pack product transfer deck 130DG1-130DG3 via an interlevel autonomous guided break pack product transfer vehicle path ITPS. Transitioning to the pack product transfer decks 130DG1-130DG3 to transport a given break pack product BPG fill payload loaded in at least one product bot 262 on one level PWL to each break pack product container station at a different level PWL. Fill break pack product container 264 at 263L. Here, the corresponding break-pack goods transfer decks 130DG1-130DG3 at each level PWL and the inter-level transition autonomously guided break-pack goods transport vehicle path ITPS include at least one inter-level detour (e.g., as described herein). at least a two-dimensional matrix of autonomously guided break pack goods vehicle detours including at least one intra-level detour (e.g., a bypass or shunt as described herein); , whereby the at least one product bot 292 connects the initial break pack product container station designation on the fly via at least one of the at least one inter-level detour and the at least one inter-level detour. From CSD1, there is a free detour to a detour break pack goods container station destination CSD2 above at least one of a common level PWL and a different level PWL with the initial container station destination CSD1 (see FIG. 4). Here, the corresponding break pack product transfer decks 130DG1-130DG3 at each level are non-deterministic, and at least one inter-level detour path is non-deterministic, so that the at least one product bot 262 It is possible to freely transition between packed product transfer decks 130DG1-130DG3 and at least one interlevel detour.

2, 3A, 4, 7B, 8B, and 26, exemplary operation of automated storage and retrieval system 100 with respect to storage and retrieval of merchandise will be described. Storage structure 130 is provided as described herein (Figure 26, block 2600). Containers (e.g., break pack merchandise containers and/or supply containers) are accessed to/from container storage locations/spaces 130S on each of the storage shelves in the array of storage shelves 130SA at each level of the storage structure 130, at least The container bots 110 are transported to the break pack operation station 140 (FIG. 26, block 2610), where at least one container bot 110 navigates the container transfer decks 130DC and picking aisles 130A at each level to Separate from the transfer deck 130DC, at least one container bot 110 is located at each level of the storage structure 130. A put wall 263W is provided (FIG. 26, block 2620) that includes a plurality of break pack product interface locations 263L distributed along each level with a corresponding break pack product transfer deck 130DG at each level of the put wall 263W. Including levels of. Break-pack products BPG are transferred by at least one product bot 262 along corresponding break-pack product transfer decks 1230DG and between corresponding break-pack product transfer decks 130DG (eg, 130DG1-130DG3) at different levels of put wall 263W. and to each break pack product interface location 263L at each level of put wall 263W (FIG. 26, block 2630). Operation of the container bot 110 is effected using a controller 120 between a container storage location 130S, a break pack operating station 140, and a break pack product container 264 located at a put wall 263W break pack product interface location 263L (see FIG. 26, block 2640).

With reference to FIGS. 2, 3A, 4, 7B, 8B, 9, 9A, and 9B, exemplary operation of the break pack module will be described. As discussed above, the container bot 110 can store containers (e.g., supply container 265, empty break pack goods container 264E, partially filled break pack goods container 264PF, and/or any suitable state/level of fill). to the break pack module 266. These supply containers 265 and break pack merchandise containers 264 are delivered to one or more of operator station 140 and break pack merchandise interface 263. For example, container bot 110 is configured to deliver supply containers 265 (or break pack containers 264) to operator stations 801-804 of break pack handling station 140 in the manner described above (e.g., container bot 110 delivering supply containers substantially directly to break pack operation station 140 or to lifts 310A, 310B and sorting/sequencing supply containers 265 for delivery to break pack operation station 140 (FIG. 9B, block 19150) ). In one aspect, after placing the supply container 265 on the conveyor 500A, for example, the container bot 110 moves to the empty break pack container lift 222, which is placed adjacent to the conveyor 500A and/or in communication with the container output conveyor 820. An empty break pack container 264E (or partially filled break pack container 264PF) may be picked from the empty break pack container lift 222 (FIG. 9B, block 19100), where the container bot picks the empty break pack container 264E (or partially filled break pack container 264PF) from the empty break pack container lift 222. picking an empty break pack container 264E directly or from the container output conveyor 820, where the empty break pack container is removed from the lift 222 in any suitable manner, such as by a multi-directional drive/conveyor unit/section 370; 820). Thereafter, the empty break pack container 264E may be placed in a predetermined empty break pack product interface location 263L of the break pack product interface 263 (FIG. 9B, block 19110).

After delivering/placing the empty break pack container 264E to the predetermined empty break pack product interface location(s) 263L, the container bot 110 transfers it to the break pack product container storage location 19000. or from one or more other different break pack item interface locations 263L of the put wall 263 for transfer from the storage and retrieval system 100 (e.g., filled, partially filled, or empty). ) picking one or more other different break pack containers 264 (FIG. 9B, block 19120) (e.g., according to a predetermined order-out sequence corresponding to the break pack output classification 189, as described herein); (such as part of a palletized load or other outbound container). Here, container bot 110 places one or more other various break pack containers 264 at storage location 130S, transfer station TS, buffer station BS, or substantially directly on lift 150 (FIG. 9B, block 19130). Container bot 110 may pick another supply container (FIG. 19140) and place it into break pack product module 266 in the manner described above (eg, return to FIG. 9B, block 19150). Here, the container bot 110 replaces the supply container 265 with an empty break pack product container 264E at a location between the operator station 140 and the break pack product interface 263, and then exchanges the empty break pack product container 264E at the break pack product interface 263. Replace merchandise container 264E with a filled or partially filled break pack merchandise container.

In another aspect, the container bot 110 may facilitate decantation of break-packed goods or supply containers, as described herein. For example, a partially filled supply container 265 or a partially filled break pack merchandise container 264 may be delivered from operator station 140 to container output conveyor 820. Container bot 110 may pick partially filled supply container 265 or partially filled break pack goods container 264 after placing the supply container at operator station 140 (FIG. 9B, block 19150). 9B, block 19100). Container bot 110 partially fills supply containers 265 or partially fills break pack merchandise containers 264 such that they are filled with SKU merchandise as described herein. The filled supply container 265 or partially filled break pack product container 264 is placed at the predetermined break pack product interface location 263L (FIG. 9B, block 19110).

After delivering/placing a partially filled supply container 265 or a partially filled break pack product container 264 to a predetermined empty break pack product interface location(s) 263L, the container bot 110 , from one or more other different break-pack product interface locations 263L (e.g., filled, or partially filled or empty) (FIG. 9B, block 19120) (e.g., palletized loads or other outbound containers following a predetermined order-out sequence). (e.g. part of). Here, container bot 110 places one or more other different break pack containers 264 at storage location 130S, transfer station TS, buffer station BS, or substantially directly on lift 150 (FIG. 9B, block 19130). ). Container bot 110 may pick another supply container (FIG. 9B, block 19140) and place it into break pack product module 266 in the manner described above (eg, return to FIG. 9B, block 19150). Here, the container bot 110 replaces the supply container 265 with a partially filled supply container 265 or a partially filled break pack product container 264 at a location between the operator station 140 and the break pack product interface 263. and then connect the partially filled supply container 265 or the partially filled break pack product container 264 with the filled or another partially filled break pack product container at the break pack product interface 263. Exchange.

In yet another aspect, container bot 110 is configured to deliver empty break pack goods containers 264 substantially directly from any suitable empty break pack container lift 222 to break pack goods interface 263. . Empty break-pack container lift 222 may be located adjacent to container deck 130DC at the entrance to break-pack goods module 266 and/or adjacent to conveyor 500A, as described above. The container bot 110 is commanded by the controller 120 (or other suitable controller) to pick a break pack goods container 264 from an empty break pack goods container lift 222 or any suitable break pack goods container storage location 19000. (FIG. 9B, block 19100). Break pack product container storage locations 19000 are located on one or more of storage deck levels 130L and are accessible by container bot 110 from one or more of container decks 130DC and picking aisles 130A. For example, break pack product container storage location 19000 includes a dedicated location for the storage of break pack product containers 264, a storage space 130S located alongside (or along) picking aisle 130A, and a transfer station TS or buffer station BS. may be one or more of the container holding positions. In other aspects, container bot 110 may pick empty break pack containers 264 from lift 150 without break pack containers 264 entering storage.

Container bot 110 removes one or more empty break pack goods containers 264 from break pack goods container lift 222 and/or break pack goods container storage location 19000 in the manner described above with respect to supply containers 265, e.g. Transfer to break pack product interface 263, such as break pack product interface location 263L (see FIG. 9A), or otherwise to break pack operator station 140 (FIG. 9A, block 19110). In one aspect, the container bot 110 places the empty break pack container(s) 264E into the predetermined empty break pack product interface location(s) 263L, as illustrated in FIG. 9A. delivery, while in other aspects the partially filled break pack product container 264PF is delivered to the empty break pack product interface location(s) 263L by the container bot(s) 110. Delivered. As can be appreciated, the ability of the container bot 110 to sort containers onboard the container bot 110 as described herein allows the container bot 110 to initially fill from a predetermined break pack product interface location 263L. By picking a filled or partially filled break pack container 264, an empty break pack product interface location(s) 263L may be created, and then an empty break pack container (carried by the container bot) (e.g., a filled BreakPack product container is replaced with an empty BreakPack product container at a given BreakPack product interface location 263L) at the breakPack product interface location 263L that was just created. ).

After delivering an empty Break Pack container 264E and/or a partially filled Break Pack container 264PF to a predetermined empty Break Pack item interface location(s) 263L, the container bot 110 (filled or From the exchange of a partially filled Break Pack container with an empty Break Pack container, with or without a filled or partially filled Break Pack container carried on it), the Break Pack goods from one or more other different break pack merchandise interface locations 263L (e.g., filled or partially Picking (FIG. 9B, block 19120) one or more other different break pack containers 264 (filled or empty) (e.g., part of a pallet load or other outbound container according to a predetermined order-out sequence) ). In other aspects, after delivering the empty break pack container 264E and/or the partially filled break pack container 264PF to the predetermined empty break pack product interface location(s) 263L, the container bot 110 may leave BreakPack station 266 without picking a BreakPack container from BreakPack product interface 263. In yet other aspects, after delivering the empty break pack container 264E and/or the partially filled break pack container 264PF to the predetermined empty break pack product interface location(s) 263L, the container bot 110 may pick empty or partially filled supply containers 265 from container output conveyor 820 for transfer to storage or transfer from a storage and retrieval system in the manner described above. Container bot 110 may then pick another empty break pack product container or supply container for transfer to break pack product module 266.

Referring again to supply container 265, at operator stations 801-804, supply container(s) 265 is scanned by sensor suite 899 to verify that the supply container is the expected supply container. (Figure 9, block 9000). The operator (human operator HUM or robot operator ROB) opens the supply container 265 (FIG. 9, block 9010) so that the inventory keeping unit SKU of the break pack item BPG in the supply container 265 is stored in any suitable location in the sensor suite 899. correctness using the appropriate sensor or instruction information presented on the display 899D of the operator station 801-804 (FIG. 9, block 9020). The operator picks the desired number of break pack products BPG from the supply container 265 (FIG. 9, block 9030) and places the break pack products BPG into the break pack product container 264 or onto the product bot 262 (FIG. 9, Block 9031). The sensor suite 899 may determine changes in the bin weight of the container 264/product bot 262 in any suitable manner (e.g., through any suitable vision system that tracks break-packed product and/or operator hand movements, (e.g., by doing so), the system is configured to confirm the picked amount of break pack items placed by the operator (FIG. 9, block 9040).

When break pack product(s) BPG is placed in break pack product container 264, break pack product container 264 is conveyed from the operator station to container output conveyor 820 as described above. Container bot 110 picks break pack product containers 264 from container output conveyor 820 and transfers break pack product containers 264 to transfer station TS to output break pack product containers 264 to storage or from automated storage and retrieval system 100. Alternatively, it is transported to buffer station BS. If the break pack product BPG(s) is placed on the product bot 262 (e.g., waiting in queue 844 at operator station deck level 130DG0 adjacent to operator stations 801-804); The product bot 262 passes the product deck 130DG to a predetermined break pack product container 264 in the break pack product interface 263 on a predetermined product deck level 130DG1, 130DG2, 130DG3 (eg, in the manner described above) (FIG. 9, block 9050). In one or more aspects, the product bot 262 waits in a buffer 778 (see FIG. 7C) or in one or more moving loops DG1L, DG2L, DG3L, DG1LS, DG2LS, (such as by cycling around the DG3LS (FIG. 4)) (FIG. 9, block 9055). In one or more aspects, when the product bot 262 is at a given break pack product interface location 263L of the break pack product interface 263 (e.g., corresponding to a given break pack product container 264), the product The bot 262 scans the break pack product container 264 to verify that the break pack product container 264 at the predetermined break pack product interface location 263L is the expected predetermined break pack product container 264 (FIG. 9). , block 9060). Once the predetermined break pack product container 264 is verified, the product bot 262 places the break pack product(s) BPG in the predetermined break pack product container 264 (FIG. 9, block 9070) and the product bot 262 (or any other suitable sensor of the break pack product module 266 configured to identify the placement of the break pack product at the break pack product interface location 263L). The placement of the break pack product BPG within the break pack product container 264 is confirmed (FIG. 9, block 9080). In the manner described above, the container bot 110 picks a given break pack product container 264 from a given break pack product interface location 263L and moves the break pack product container 264 to any suitable destination (e.g., to a storage warehouse, etc.). or from the automated storage and retrieval system 100 to a transfer station TS or buffer station BS for output of the break pack product container 264 (FIG. 9, block 9090).

12A and 12B, the rack module array RMA of storage structure 130 includes vertical support members 1212 and horizontal support members (herein referred to as (also called rails) 1200. Rails 1200S (also referred to as aisle decks or decks) may be attached to one or more of vertical support members 1212 and horizontal support members 1200 in picking aisle 130A, for example, so that container bots 110 can move through picking aisle 130A onto rails 1200S. It may be configured to rest along. At least one side of at least one of the picking aisles 130A of the at least one storage level 130L may have one or more storage shelves (eg, formed by rails 1210, 1200 and slats 1210S). In one aspect, the one or more shelves are arranged in a variety of ways to form a plurality of shelf levels 130LS1-130LS3 between storage or deck levels 130L defined by transfer deck 130B (and rails 1200S forming an aisle deck). It can be provided at a height. Accordingly, there are multiple rack shelf levels 130LS1-130LS3 corresponding to each storage level 130L extending along one or more picking aisles 130A that communicate with the container transfer deck 130DC of the respective storage level 130L. As can be appreciated, the plurality of rack shelf levels 130LS1-130LS3 contain stacks and/or stacks of stored case units/supply containers 265 (or case tiers) that are accessible from a common deck 1200S of each storage level 130L. Each storage level 130L is provided with a stack of stored break-pack merchandise containers 264 (or break-pack layers) (eg, stacks of stored cases are disposed between the storage levels).

As can be appreciated, a container bot 110 passing through a picking aisle 130A at a corresponding storage level 130L has access to each storage space 130S (e.g., case units and/or break packs) available at each shelf level 130LS1-130LS3. for picking and placing product containers), where each shelf level 130LS1-130LS3 has an adjacent shelf on one or more sides PAS1, PAS2 (see, e.g., FIG. 1B) of the picking aisle 130A. located between vertically stacked storage levels 130L. As described above, each of storage shelf levels 130LS1-130LS3 is accessible by container bot 110 from rails 1200 (e.g., from a common picking aisle deck 1200S corresponding to container transfer deck 130DC at each storage level 130L). be. As seen in FIGS. 12A and 12B, vertically ( There are one or more intermediate shelf rails 1210B, 1210C spaced apart (eg, in the Z direction). As can be appreciated, horizontal support member 1200 also forms a shelf rail (in addition to shelf rail 1210) on which the case unit is placed.

Each stacked shelf level 130LS1-130LS3 of the corresponding storage level 130L (and/or each single shelf level described below) is arranged (e.g., along the length of an aisle or by a picking aisle). The pick face (e.g., supply container 265 ) and/or an open and non-deterministic two-dimensional storage surface (e.g., having a case unit/break-pack product container support surface CUSP as shown in FIG. 12B) to facilitate dynamic allocation of break-pack product containers 264. Define. Dynamic assignment of pick faces and the case units that make up the pick faces is described, for example, in U.S. Pat. provided in the manner described in the book. Although supply containers 265 are illustrated in FIG. 12A as being stored on side PAS2 of picking aisle 130A and break pack product containers 264 are shown as being stored on side PAS1 of picking aisle 130A, in other embodiments , a combination of supply containers 265 and break pack product containers 264 stored on common sides PAS1, PAS2 (e.g., one or both sides PAS1, PAS2) of picking aisle 130A and/or supplies stored on a common shelving surface. There may be a combination of containers 265 and break pack product containers 264.

In one aspect, with reference to FIGS. 12C and 13B, each of the storage levels 130L includes a single level of storage shelves for storing a single level of case units (e.g., each storage level includes a single level of case units). case unit support surface CUSP), the container bot 110 is configured to transfer case units to/from the storage shelves of the respective storage level 130L. For example, the container bot 110' illustrated in FIG. Sufficient Z movement of transfer arm 110PA is not provided to place case units in multiple storage shelf levels 130LS1-130LS3 (accessible from 1200S). Here, a transfer arm drive 250 (which may be substantially similar to one or more of drives 250A, 250B) lifts a case unit from a case unit support surface CUSP of a single level of a storage shelf to a payload area 110PL. / includes only sufficient Z movement to transfer the case unit from / to transfer arm 110PA and between fingers 273 of transfer arm 110PA and payload bed 110PB. Suitable examples of container bots 110' can be found, for example, in U.S. patent application Ser. can.

Referring again to FIG. 1B, each container transfer deck 130DC or storage level 130L includes one or more lift pick face interface/handoff stations TS (referred to herein as interface stations TS), where (1 The case units (e.g., individual case units, pick faces, supply containers, etc.), totes and/or break pack merchandise containers 264 are transported between the lift load handling equipment LHD and the container bot 110 on the container transfer deck 130DC. transferred between. The interface station TS is located on the side of the container transfer deck 130DC opposite the picking aisle 130A and the rack module RM, such that the container transfer deck 130DC is interposed between the picking aisle and each interface station TS. . As mentioned above, each container bot 110 at each pick level 130L has access to each storage location at each storage level 130L such that each container bot 110 also has access to each interface station TS at each pick level 130L. 130S, each picking aisle 130A, and each lift 150 (via a respective container transfer deck 130DC). In one aspect, the interface station is arranged along the container transfer deck 130DC in a high-speed bot travel path such that access of the container bot 110 to the interface station TS is non-deterministic to the bot speed on the high-speed bot travel path HSTP. Offset from HSTP. In this way, each container bot 110 can store case units (e.g., individual case units, pick faces (built by the bot), supply containers, etc.), totes, and/or break pack items. Containers 264 can be moved from all interface stations TS to all storage spaces 130S corresponding to deck level 130L and vice versa.

In one aspect, the interface station TS includes case units (e.g., individual case units, pick faces, supply containers, etc.) between the container bot 110 and the load handling device LHD of the lift 150, which will be described in more detail below. Configured for passive transfer (e.g., handoff) of totes and/or break pack merchandise containers 264 (e.g., interface station TS has no moving parts to transfer case units) . For example, referring also to FIG. 14, the interface station TS and/or buffer station BS may be connected to a container bot 110 (as described herein) and a storage space 130S where case units or totes are transferred to/from shelves. In one aspect, the storage shelves described above (each with rails 1210, 1200 and slats 1210S one or more stacked levels TL1 of the transfer rack shelf RTS (e.g., such as to take advantage of the lifting capabilities of the container bot 110 for the stacked rack shelf RTS); Contains TL2. In one aspect, the buffer station BS at one or more of the stacked levels TL1, TL2 also serves as a handoff/interface station for the load handling device LHD of the lift 150. In one aspect, a bot, such as container bot 110', loads case units (e.g., individual case units, pick faces, supply containers, etc.), totes, and/or break pack merchandise containers to a single level 130L of storage shelves. When configured for H.264 transfers, the interface station TS and/or the buffer station BS may also serve as a unit of transfer rack shelf (eg, generally similar to the storage rack shelf of storage level 130L described above with respect to FIG. 12B). Contains one level. As can be appreciated, the operation of a storage and retrieval system in which the container bot 110' serves a single level storage and transfer shelf is generally similar to the operation described herein. As can also be appreciated, case units (e.g., individual case units, pick faces, supply containers, etc.), totes, and/or to stacked rack shelves RTS (and/or single level rack shelves) The handoff (e.g., picking and placement) of the load handling device LHD (or lift) of the break pack merchandise container 264 is performed by the handoff (e.g., picking and placement) of the break pack merchandise container 264 as the case unit, tote, and/or break pack merchandise container 264 is transferred to/from the shelf (hereinafter referred to as This is done in a passive manner substantially similar to that between the container bot 110 and the storage space 130S (as described in 1999). In other aspects, shelves are provided for picking and placing case units, totes, and/or break pack merchandise containers 264 from one or more of the container bots 110 and the load handling devices LHD of the lifts 150 (as shown in FIG. 13A). The transfer arm 110PA of the container bot 110 shown in FIG. Suitable examples of interface stations using active transfer arms include, for example, U.S. Patent Application No. 12/757,354, filed April 9, 2010, the entire disclosure of which is incorporated herein by reference. It is written in the book.

In one aspect, the position of the container bot 110 relative to the interface station TS occurs in a manner generally similar to the position of the bot relative to the storage space 130S. For example, in one aspect, the location of the container bot 110 relative to the storage space 130S and the interface station TS is determined by the position of the container bot 110 in U.S. patent application Ser. ,035 (now U.S. Pat. No. 9,008,884) and U.S. Patent Application No. 13/608,877 (now U.S. Pat. No.) occurs in a manner substantially similar to that described in the specification. For example, with reference to FIGS. 1A and 12B, containerbot 110 uses one or more sensors to detect slats 1210S or positioning features 130F (openings, reflective surfaces, RFID tags, etc.) located on/in rails 1200. 110S included. The slats and/or positioning features 130F are arranged to locate the container bot 110 within the storage and retrieval system, eg, relative to the storage space and/or the interface station TS. In one aspect, container bot 110 includes a controller 110C that at least partially determines the position of container bot 110 within storage and retrieval system 100, for example, by counting slats 1210S. In other aspects, positioning feature 130F may be arranged to form an absolute or incremental encoder that, when detected by container bot 110, provides position determination of container bot 110 within storage and retrieval system 100. .

As can be appreciated, with reference to FIG. 14, the transfer rack shelves RTS at each interface/handoff station TS are arranged on a common transfer rack shelf RS (e.g., for holding a corresponding number of case units or totes). defining a multi-load station (having one or more storage case unit holding locations); As mentioned above, each load at a multi-load station is picked and placed by either the container bot 110 or the load handling device LHD (e.g., multiple case units/totes/break packs moved as a single unit). single case unit/tote/break pack product container or multi-case pick face. As can also be appreciated, by the above bot position, the container bot 110 is directed to the multi-load station for picking and placing case units/totes and pick faces from predetermined positions in the holding position of the multi-load station. It becomes possible to position itself. The interface/handoff station TS may include multi-place buffers (e.g., one or more cases located along the X-axis of the container bot 110 when the container bot 110 interfaces with the interface station TS). 13B), where the inbound and/or outbound case unit/tote/break pack goods containers and pick faces are connected to the container bot 110 and the load handling equipment LHD of the lift 150. It is temporarily stored when transported between.

In one aspect, one or more peripheral buffer/handoff stations BS (generally similar to interface station TS and referred to herein as buffer stations BS) are also located opposite picking aisle 130A and rack module RM. It is arranged on the side of the container transfer deck 130DC, so that the container transfer deck 130DC is interposed between the picking aisle and each buffer station BS. Peripheral buffer stations BS are interspersed between interface stations TS or otherwise aligned therewith, as shown in FIGS. 1B and 14, in one aspect. In one aspect, the peripheral buffer station BS is formed by rails 1210, 1200 and slats 1210S and is a continuation (but a separate section) of the interface station TS (e.g., the interface station and the peripheral buffer station share a common rail 1210, 1200). Thus, the peripheral buffer station BS also includes, in one aspect, one or more stacked levels TL1, TL2 of transfer rack shelves RTS as described above with respect to the interface station TS; in other aspects, the peripheral buffer station BS also includes a buffer station BS. The transfer rack includes a single level of shelving. The peripheral buffer station BS is used to transfer case units/totes/break pack goods containers and/or pick faces from one container bot 110 to another different container bot 110 on the same storage level 130L, as described in more detail below. Defines a buffer to be temporarily stored when being transported to As can be appreciated, in one aspect, the peripheral buffer station is located at any suitable location of the storage and retrieval system, including anywhere within the picking aisle 130A and along the container transfer deck 130DC.

Still referring to FIGS. 1B and 14, in one aspect at least the interface station TS is located on an extension or pier 130BD extending from the container transfer deck 130DC, while in other aspects the length of the interface station TS is , can be placed and extended along the container transfer deck. In one aspect, the pier 130BD resembles a picking path along which the container bot 110 moves along a rail 1200S secured to the horizontal support member 1200 (in a manner generally similar to that described above). In other aspects, the movement surface of pier 130BD may be substantially similar to the movement surface of container transfer deck 130DC. Each pier 130BD is located on a side of the container transfer deck 130DC, such as the opposite side from the picking aisle 130A and the rack module RM, such that the container transfer deck 130DC is interposed between the picking aisle and each pier 130BD. It will be done. The pier(s) 130BD extend from the transfer deck at a non-zero angle relative to at least a portion of the high speed bot 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. As can be appreciated, a peripheral buffer station BSD (generally similar to peripheral buffer station BS described above) may also be located along at least a portion of pier 130BD.

15A, 15B, 13B, and 16, as noted above, in one aspect, the interface station TS is a passive station, and therefore the load transfer device LHD of the lift 150A, 150B is an active transfer arm. Or it has a pick head 4000A. In one aspect, the inbound lift module 150A and the outbound lift module 150B are different (as described in U.S. Pat. No. 9,856,083, previously incorporated by reference herein in its entirety). In other aspects, inbound lift module 150A and outbound lift module 150B have the same type of pick head similar to pick head 4000A. The pick heads of lifts 150A, 150B may at least partially define a Y throughput axis as described herein. In one aspect, both the inbound lift module 150A and the outbound lift module 150B have a vertical mast 4002 along which a slide 4001 is configured to raise and lower the slide (and the pick head 4000A attached thereto). 120 (eg, connected to control server 120). The inbound lift module(s) 150A includes a pick head 4000A mounted to the slide 4001 such that as the slide moves vertically, the pick head 4000A moves vertically with the slide 4001. In this aspect, pick head 4000A includes one or more tines or fingers 4273 attached to base member 4272. Base member 4272 is movably attached to one or more rails 4360S of frame 4200, which in turn is attached to slide 4001. Any suitable drive unit 4005, such as a belt drive, chain drive, screw drive, gear drive, etc. (generally similar in shape to drive 4002D, but because drive 4005 is smaller than drive 4002D) portion 4002D) is attached to frame 4200 and drives base member 4272 (with finger(s)) in the direction of arrow 4050 (e.g., extension direction 4050A and retraction direction 4050B). The base member 4272 is connected to the base member 4272 in order to perform the operation. Outbound lift module(s) 150B may be generally similar to inbound lift module(s) 150A.

As can be appreciated, the lift modules 150A, 150B allow the pick head 4000A to interface with the interface station at a predetermined storage level 130L when picking and placing case unit(s) and/or break pack goods containers. It is under the control of any suitable controller, such as control server 120, to be raised and/or lowered to a predetermined height corresponding to the TS. As can be appreciated, the lift modules 150A, 150B provide the Z throughput axis (for both the bot reference frame REF and the rack reference frame REF2) of the storage and retrieval system as described herein. , where output lift module 150B sorts case units on the fly for delivery to output station 160US. At the interface station TS, the pick head 4000A or an individual portion thereof (e.g., an effector or a load handling device) corresponds to one or more case unit holding positions of the interface station TS where the one or more case units are being picked. LHD) that fingers 4273 interfit between slats 1210S (as illustrated in FIG. 15B) under the case unit(s) (and/or break pack goods container) being picked. Stretched so that it is The lifts 150A, 150B raise the pick head 4000A to lift the case unit(s) from the slats 1210S and transfer the case unit(s) to one or more of the output stations 160UT, 160EC. The pick head 4000A is retracted for transport, such as transport, of the case unit(s) and/or break pack merchandise container to another level of the storage and retrieval system. Similarly, in order to place one or more case units, the pick head 4000A or its The individual portions (eg, effector or load handling device LHD) are extended such that fingers 4273 are above the slats. The lifts 150A, 150B lower the pick head 4000A to place the case unit(s) on the slats 1210S, such that the fingers 4273 pick the case unit(s) being picked. are interfitted between the lower slats 1210S.

Referring now to FIG. 13A, as described above, the container bot 110 includes a stacked storage space 130S, an interface station, at least partially defined in the Z direction by one or more of the rails 1210A-1210C, 1200. TS, and a transfer arm 110PA that provides for picking and placing case units from peripheral buffer stations BS, BSD (e.g., a storage space, an interface station, and/or a peripheral buffer station that provides for movement of case units as described above). (can be further defined in the X and Y directions via target assignment, relative to either the rack reference frame REF2 or the bot reference frame REF). As can be appreciated, the bot defines an X throughput axis (e.g., relative to the bot's reference frame REF) and at least partially a Y throughput axis, as described further below. Container bot 110 transports case units between each lift module 150 and each storage space 130S at a respective storage level 130L, as described above. Container bot 110 includes a frame 110F having a drive section 110DR and a payload section 110PL. Drive section 110DR is configured to drive each drive wheel(s) 202 to propel container bot 110 along the X direction (with respect to the bot's reference frame REF to define the X throughput axis). including one or more drive wheel motors connected to the drive wheel motor. As can be appreciated, the X-axis of bot movement coincides with the storage position as the container bot 110 moves through the picking aisle 130A. In this aspect, the container bot 110 is positioned on opposite sides of the container bot 110 at an end 110E1 (e.g., a first longitudinal end) of the container bot 110 to support the container bot 110 on a suitable drive surface. In other aspects, the container bot 110 is provided with any suitable number of drive wheels, including two drive wheels 202 . In one aspect, each drive wheel 202 is independently controlled such that the container bot 110 may be steered by differential rotation of the drive wheels 202, but in other aspects, the rotation of the drive wheels 202 is substantially the same. It may be coupled to rotate at a speed. Any suitable wheels 201 are attached to the frame on opposite sides of the container bot 110 at the end 110E2 (e.g., the second longitudinal end) of the container bot 110 to support the container bot 110 on the drive surface. . In one aspect, the wheels 201 are caster wheels that are free to rotate and allow the container bot 110 to pivot by differential rotation of the drive wheels 202 to change the direction of movement of the container bot 110. . In other aspects, the wheel 201 is configured to control the bot controller 110C (configured to provide control of the container bot 110 as described herein), for example, to change the direction of movement of the container bot 110. It is a steerable wheel that changes direction under control. In one aspect, container bot 110 includes one or more guide wheels 110GW positioned at one or more corners of frame 110F, for example. The guide wheel 110GW is connected to the container bot 110, for example, as described in U.S. patent application Ser. and/or on the container transfer deck 130DC and/or to position the container bot 110 at a predetermined distance from the location where one or more case units are to be placed and/or picked. An interface or transfer station for interfacing with module 150 may interface with storage structure 130, such as a guide rail (not shown) in picking aisle 130A. As mentioned above, the container bot 110 may enter the picking aisle 130A with different facing directions for accessing the storage spaces 130S located on both sides of the picking aisle 130A. For example, container bot 110 may enter picking aisle 130A with end 110E2 leading in the direction of travel, or the bot may enter picking aisle 130A with end 110E1 leading in the direction of travel.

Payload section 110PL of containerbot 110 includes payload bed 110PB, fence or datum member 110PF, transfer arm 110PA, and pusher bar or member 110PR. In one aspect, the payload bed 110PB is configured such that one or more case units and/or break pack goods containers carried within the payload section 110PL may, for example, The longitudinal axis of the bot in order to position it in place and/or relative to other case units and/or break pack merchandise containers within the payload section 110PL (e.g., longitudinal forward/backward positioning of the case unit). to the frame 110F (e.g., the container bot 110 including one or more rollers 110RL mounted laterally (with respect to the longitudinal axis LX of ). In one aspect, rollers 110RL may be driven by any suitable motor (e.g., may be rotated about their respective axes) to move case units and/or break pack goods containers into payload section 110PL. ). In other aspects, the container bot 110 is configured to move the case unit(s) and/or break pack product container(s) onto the rollers 110RL to move the case unit(s) and/or break pack product container(s) into position within the payload section 110PL. one or more longitudinally movable pusher bars (not shown) for urging the case unit and/or break pack product container onto the container. Vertically movable pusher bars are described, for example, in U.S. patent application Ser. No. 13/326,952, filed December 15, 2011, the entire disclosure of which is incorporated herein by reference. It can be almost similar to something. The pusher bar 110PR may be attached to a fence in the manner described in U.S. Provisional Patent Application No. 62/107,135, filed January 23, 2015, previously incorporated herein by reference in its entirety. 110PF and/or transfer arm 110PA along the pick head 270 of the payload area 110PL for lateral positioning of the case unit(s) and/or break pack goods container(s) within the payload area 110PL. It is movable in the Y direction with respect to the reference frame REF of the container bot 110 so as to bring the container bot 110 to the reference frame REF.

Still referring to FIG. 13A, case units and/or break pack product containers are placed on payload bed 110PB and removed from payload bed 110PB with transfer arm 110PA along the Y-throughput axis. Transfer arm 110PA may be configured, for example, as described in U.S. Provisional Patent Application No. 62/107,135, filed January 23, 2015, previously incorporated herein by reference in its entirety. , including a lift mechanism or unit 200 disposed substantially within payload section 110PL. Lift mechanism 200 moves into position in storage structure 130 for picking and/or placing pickfaces and/or individual case units into storage spaces 130S (e.g., at respective storage levels 130L where containerbots 110 are located). of the rough and fine positioning of the pick face (which may include either a case unit or a break pack goods container, or both a case unit and a break pack goods container) carried by the container bot 110 that is lifted vertically into the Provide both. For example, the lift mechanism 200 may include a plurality of elevated storage shelf levels 130LS1-130LS3, TL1, TL2 accessible from a common picking aisle or a break pack goods interface accessible from the containerbot transfer surface(s) 266RS. Pick and place the case unit at location 263L (see, eg, FIGS. 2, 12A, and 14).

Lift mechanism 200 includes a combination of robot axis movement (e.g., pusher bar 110PR, such as the longitudinally movable pusher bar described above), lift mechanism 200, pick head extension, and forward/ A combined and substantially simultaneous movement of the rear positioning mechanism) is configured to be performed such that different/multi-SKU or multi-pick payloads are processed by the container bot 110. In one aspect, operation of lift mechanism 200 is independent of operation of pusher bar 110PR, as described below. The decoupling of the lift mechanism 200 and the pusher bar 110PR shaft provides a combined pick/place sequence, as described above, which reduces pick/place cycle time, increases storage and retrieval system throughput, and/or or provide storage density for storage and retrieval systems. For example, lift mechanism 200 picks and places case units at multiple elevated storage shelf levels accessible from a common picking aisle and/or interface station deck 1200S, as described above.

The lift mechanism may be configured in any suitable manner such that the pick head 270 of the container bot 110 moves bidirectionally along the Z axis (e.g., reciprocates in the Z direction (see FIG. 13A)). . In one aspect, the lift mechanism includes a mast 200M, and the pick head 270 is movably attached to the mast 200M in any suitable manner. The mast is movably attached to the frame in any suitable manner such that it is movable along the transverse axis LT of the containerbot 110 (e.g., in the Y direction to define the Y throughput axis). In one aspect, the frame includes guide rails 210A, 210B to which the mast 200 is slidably attached. Transfer arm drives 250A, 250B may be attached to the frame to provide at least movement of the transfer arm 110PA along the transverse axis LT (eg, Y axis) and the Z axis. In one aspect, transfer arm drives 250A, 250B include an extension motor 301 and a lift motor 302. Extension motor 301 is attached to frame 110F and attached to mast 200M in any suitable manner, such as by belt and pulley transmission 260A, screw drive transmission (not shown), and/or gear drive transmission (not shown). Can be linked. Lift motor 302 is attached to mast 200M by any suitable transmission, such as a belt and pulley transmission 271, a screw drive transmission (not shown), and/or a gear drive transmission (not shown), and pick head 270 can be connected to By way of example, mast 200M includes guides, such as guide rails 280A, 280B, along which pick head 270 is mounted for guided movement in the Z direction along guide rails 280A, 280B. In other aspects, the pick head is attached to the mast in any suitable manner for guided movement in the Z direction. Regarding the transmission 271, the belt 271B of the belt and pulley transmission 271 is such that when the belt 271 moves (e.g., driven by the motor 302), the pick head 270 moves with the belt 271 and moves along the guide rail 280A in the Z direction. It is fixedly coupled to the pick head 270 so as to be driven bidirectionally along 280B. As can be appreciated, if a screw drive is utilized to drive the pick head 270 in the Z direction, the engagement between the nut and the screw will cause the pick head 270 to move as the screw is rotated by the motor 302. A nut may be attached to pick head 270 for movement. Similarly, if a gear-driven transmission is utilized, a rack and pinion or any other suitable gear drive may drive pick head 270 in the Z direction. In other aspects, any suitable linear actuator is used to move the pick head in the Z direction. Transmission 260A for extension motor 301 is generally similar to that described herein with respect to transmission 271.

Still referring to FIG. 13A, the pick head 270 of the containerbot 110 transfers the case unit to the containerbot 110, e.g., the storage space 130S, the peripheral buffer stations BS, BSD, the interface station TS (see FIGS. 1B and 14), case units, such as guided conveyors 500A, 500B, 500C (see FIGS. 5A and 5C) and/or break pack merchandise interface 263 (see FIG. 6D) for transfer of supply containers 265 to break pack handling station 140; and/or a break pack product container picking/placement location, and in other aspects substantially directly between the container bot 110 and the lift module(s) 150. In one aspect, pick head 270 includes a base member 272, one or more tines or fingers 273A-273E, and one or more actuators 274A, 274B. Base member 272 is attached to mast 200M, as described above, so as to ride along guide rails 280A, 280B. The one or more tines 273A-273E are attached to the base member at the proximal ends of the tines 273A-273E such that the distal ends (eg, free ends) of the tines 273A-273E are cantilevered from the base member 272. 272. Referring again to FIG. 12B, the tines 273A-273E are connected to the slats 1210S forming the case unit support surfaces CUSP of the storage shelves (and peripheral buffer stations BS, BSD, interface stations TS, and/or (e.g., guided conveyors 500A-500C). , the container output conveyor 820, and similar slats of the container support surface of the break pack module 266 (such as the break pack product interface location 263L).

One or more of tines 273A-273E are movably mounted to base member 272 (such as on a slide/guide rail similar to those described above) so as to be movable in the Z direction. In one aspect, any number of tines may be attached to base member 272, but in the illustrated aspect, for example, five tines 273A-273E are attached to base member 272. Any number of tines 273A-273E may be movably attached to base member 272, but in the embodiment illustrated in the figures, for example, the outermost tines 273A, 273E (with respect to centerline CL of pick head 270) While movably attached to base member 272, remaining tines 273B-273D are immovable relative to base member 272.

In this embodiment, the pick head 270 utilizes only three tines 273B-273D to transfer smaller sized case units (and/or groups of case units/break pack product containers) to/from the container bot 110. However, as many as five tines 273A-273E are utilized to transfer larger size case units (and/or groups of case units/break pack product containers) to/from container bot 110. In other aspects, fewer than three tines are utilized to transport smaller sized case units (eg, where more than two tines are movably attached to base member 272). For example, in one aspect, the smallest case unit being transferred to/from container bot 110 without disturbing other case units, e.g., on a storage shelf, is approximately the distance between slats 1210S (see FIG. 12B). Only one tine 273A-273E is movably attached to the base member to have a width of X1.

The stationary tines 373B-373D define a pick plane SP of the pick head 270 and are useful when transferring case units, break pack goods containers (and/or pick faces of case units and/or break pack goods containers) of all sizes. The movable tines 373A, 373E are used for transporting larger case units (and/or pick faces) relative to the stationary tines 373B-373D (e.g., in the Z direction with actuators 274A, 274B). Can be selectively raised and lowered. Still referring to FIG. 13A, an example is shown in which all of the tines 273A-273E are positioned such that the case unit support surface SF of each tine 273A-273E is aligned with the pick plane SP of the pick head 270. , as can be appreciated, the two end tines 273A, 273E are movable to be positioned lower (e.g., in the Z direction) relative to the other tines 273B-273D, thereby causing the tines 273A, 273E to 273E does not contact the one or more case units or break pack goods containers carried by the pick head 270 (and/or the pick face of the case units and/or break pack goods containers) and the storage space 130S on the storage shelf. The case unit support surfaces SF of tines 273A, 273E are Offset from (eg below) the pick plane SP.

Movement of tines 273A-273E in the Z direction is effected by one or more actuators 274A, 274B mounted at any suitable location on transfer arm 110PA. In one aspect, one or more actuators 274A, 274B are attached to base member 272 of pick head 270. The one or more actuators are any suitable actuators, such as linear actuators, that can move one or more tines 273A-273E in the Z direction. For example, in the embodiment illustrated in FIG. 13A, there is one actuator 274A, 274B for each movable tine 273A, 273E such that each movable tine is independently movable in the Z direction. In other aspects, one actuator may be coupled to multiple movable tines such that the multiple movable tines move as a unit in the Z direction.

As can be appreciated, by movably mounting one or more tines 273A-273E on the base member 272 of the pick head 270, large case units, break pack merchandise containers, and/or For example, storage spaces (as described herein), interface stations, peripheral buffer stations, and The ability to pick and place small case units or break pack goods containers without interfering with other case units or break pack goods containers positioned on/on the container holding area of the break pack module 266 is also provided. By the ability to pick and place case units of variable size without interfering with other case units on/at storage spaces, interface stations, peripheral buffer stations, break pack handling stations, and/or break pack merchandise interfaces. , the size of the gap GP between the case units on the storage shelf is reduced (see FIG. 12A). As can be appreciated, since the tines 273B-273D are fixed to the base member 272, raising and lowering of the case unit and/or pick face to/from the case unit holding position is effected solely by the lift motors 301, 301A. , no redundant movements occur when picking/placing case units.

Referring again to FIG. 13A, it is again noted that pusher bar 110PR is movable independently of transfer arm 110PA. Pusher bar 110PR is movably attached to the frame in any suitable manner, such as by a guide rod and slide arrangement, and is movably mounted along the Y direction (e.g., generally parallel to the extension/retraction direction of transfer arm 110PA). ) activated. In one aspect, at least one guide rod 360 is mounted within payload section 110PL to extend transversely to longitudinal axis LX of frame 110F. Pusher bar 110PR may include at least one slide member 360S configured to engage and slide along a respective guide rod 360. In one aspect, at least the guide rod/slide arrangement captures and retains the pusher bar 110PR within the payload section 110PL. Pusher bar 110PR is actuated by any suitable motor and transmission, such as motor 303 and transmission 303T. In one aspect, motor 303 is a rotary motor and transmission 303T is a belt and pulley transmission. In other aspects, pusher bar 110PR may be actuated by a linear actuator having substantially no rotating components.

Pusher bar 110PR is positioned within payload section 110PL so that it is substantially perpendicular to roller 110RL and does not interfere with pick head 270. As seen in FIG. 17C, container bot 110 is in a transport configuration in which at least one case unit/break pack goods container is supported on rollers 110RL (eg, the rollers collectively form a payload bed). In the transport configuration, the tines 273A-273E of the pick head 270 are interdigitated with the roller 110RL and are disposed (along the Z direction) below the case unit support surface RSP (see FIG. 17A) of the roller 110RL. The pusher bar 110PR is configured with slots 351 (FIG. 17D) through which the tines 273A-273E pass, with sufficient clearance within the slots 351 to allow the tines to align with the case unit support surface. This allows the pusher bar 110PR to move under the RSP and allows the pusher bar 110PR to move freely without interference from the tines 273A-273E. Pusher bar 110PR also includes one or more apertures through which rollers 110RL pass, where the apertures are configured to allow free rotation of the rollers about their respective axes. is sized to. As can be appreciated, the independently operable pusher bar 110PR does not interfere with the lateral (eg, Y-direction) extension of the roller 110RL, the transfer arm 110PA, and the raising/lowering of the pick head 270.

As mentioned above, the pusher bar 110PR is a separate, stand-alone axis of the container bot 110 that operates without interference from the extension and lift axes of the pick head 270, so that it does not interact with the extension and/or lift of the transfer arm 110PA. They can be operated almost simultaneously. Combined axis movement (e.g., simultaneous movement of the extension and/or lift axis of transfer arm 110PA and pusher bar 110PR) results in increased payload processing throughput in and along the Y throughput axis, resulting in increased Ordered (e.g., at least partially A multi-pick 140 is provided (according to a break-pack sequence), which may be based on a predetermined ejection sequence. For example, with reference to FIGS. 17A-17B, during a multi-pick/place sequence of transfer arm 110PA, pusher bar 110PR has contact depth X3 (e.g., when picked/placed from a storage space or other holding location). , the case unit(s), the break pack goods container(s), and/or the depth of the tine occupied by the pick face CU). one or more case units, break pack product container(s), and/or pick face are pre-positioned (FIG. 18, block 1100) when picked and transferred to payload section 110PL. . Distance A plurality of case units/break pack product container(s) can be seated on roller 110RL. As the case unit(s) CU and/or break pack product container(s) 264 are lowered onto the rollers 110RL (FIG. 18, block 1110), the case(s) The distance that pusher bar 110PR has traveled to contact unit CU and/or break pack product container(s) 264 is the distance X4 by the conventional conveyance vehicle of payload section 110PL (to the side of payload section 110PL). direction and relative to the access side 401) compared to moving from the rear (eg, rear) side 402, a shorter distance X2. Case unit(s) CU and/or break pack goods container(s) 264 are lowered by transfer arm 110PA and transferred to roller 110RL so as to be supported solely by roller 110RL. and the pusher bar 110PR is actuated (with respect to the lateral and access side 401 of the payload section 110PL) to move the case unit(s) CU and/or the break pack goods container(s) 264 forward (FIG. 18, block 1120). For example, the pusher bar 110PR may be configured such that the case unit(s) is connected to the fence 110PF with the case unit reference datum being the case unit(s) CU/break pack product container(s) 264 and the fence 110PF. the case unit(s) CU and/or the case unit(s) CU and/or the fence 110PF (located on the access side 401 of the payload section 110PL) such that the ) The break pack product container 264 may be pushed laterally in the Y direction. In one aspect, the pusher bar 110PR connects the case unit(s) CU and/or the break pack product container(s) 264 to each other and to the reference frame REF of the container bot 110 (FIG. 13A). The case (e.g., to hold the case unit(s) and/or break pack merchandise container(s) 264 against the fence 110PF to maintain a predetermined spatial relationship) may engage or otherwise grip case unit(s) CU and/or breakpack product container(s) 264 during transport of the unit/breakpack product container; (FIG. 18, block 1130). When placing the case unit(s) and/or the break pack product container(s) 264, the pusher bar 110PR pushes the case unit(s) CU and/or the break pack product container(s) 264. from contact with the case unit(s) CU and/or the break-pack product container(s) 264 after positioning the break-pack product container(s) 264 relative to the fence 110PF. (e.g., in the Y direction) (FIG. 18, block 1140). Substantially immediately after pusher bar 110PR disengages case unit(s) CU and/or break pack product container(s) 264, transfer arm 110PA (eg, in the Z direction) One or more of the lift axes and extension axes (e.g., in the Y direction) of ) are actuated substantially simultaneously with the pull-apart movement of pusher bar 110PR (FIG. 18, block 1150). In one aspect, when the pusher bar is pulled out of contact with case unit(s) CU and/or break pack product container(s) 264, both the lift and extension axes are actuated. However, in other embodiments, one of the lift axis and the extension axis is actuated. As can be appreciated, in addition to the simultaneous movement of the lift and/or extension axes of the transfer arm 110PA by pulling apart the pusher bar 110PR, the pusher moves the case unit(s) CU and/or the case unit(s) CU and/or By reducing the distance traveled to reposition the break pack product containers 264, the case unit(s) CU and/or break pack product container(s) 264 can be moved to the container bot 110. The time required to transfer to/from is reduced and the throughput of the storage and retrieval system 100 is increased.

As an example of case manipulation on the container bot 110, see also FIGS. 17C-17F, the container bot 110 may be a supply container 265 (e.g., pick face, case unit(s), etc.) or a break pack goods container 264. ) The container(s) CUA are located at a holding location (e.g., a storage space 130S in a common picking aisle for bringing ordered multi-picks, and in other aspects a lift interface station TS, a break pack goods interface 263 break pack item interface location(s) 263L and/or case unit buffer station BS located in a picking aisle or on a transfer deck) and transferred to payload section 110PL. When the container(s) CUA is transferred to the payload section 110PL, the pusher bar 110PR is activated when the container(s) CUA(s) are lowered for transfer to the rollers 110RL. or a plurality of containers CUA) and the fence 110PF, such that the container CUA and the fence 110PF can be pre-positioned adjacent to the fence 110PF. Pusher bar 110PR (roller 110RL) contacts alignment surface 273JS (FIG. 17A) of tines 273A-273E and is aligned with rear surface 402 of payload section 110PL. is actuated to push the container(s) CUA (resting thereon) in the Y direction toward the rear (eg, rear) 402 of the payload section 110PL.

In one aspect, the container bot 110 performs a common pick (e.g., such that the container bot 110 moves in one direction so that all of the case units in the ordered multi-pick are picked in a common path of the picking aisle). Continue to traverse the aisle in the same direction XC, according to a predetermined break-pack sequence (which break-pack sequence may be determined, at least in part, by the order-out sequence of items from the automated storage and retrieval system 100 for order fulfillment). It stops at another predetermined storage space 130S. As mentioned above, the pusher bar 110PR is configured such that the container CUA remains in place (and/or in a longitudinal position) at the back side 402 of the payload section 110PL with respect to the reference frame REF of the container bot 110. Remains in contact with (eg, grips) the container(s) CUA during transport of the case unit(s) between case unit holding positions. For example, to pick a subsequent container from another storage space in a common picking aisle, pusher bar 110PR is moved in the Y direction to disengage container(s) CUA and transfer arm 110PA The lift and extension axes of are actuated to move another container(s) CUB from the other storage space 130S2 (or in other aspects, e.g., at the lift/handoff interface station TS, as described above). (from one or more break pack product interface locations 263L and/or buffer/handoff station BS). While the container(s) CUB is being picked, the pusher bar 110PR is arranged between the container(s) CUA and the positioning surface 273JS of the tines 273A-273E. It is positioned in the Y direction adjacent to the back side 402 of payload section 110PL. The container(s) CUB is transferred to the payload section and lowered/positioned onto the rollers 110RL such that the containers CUA, CUB are positioned relative to each other along the Y-axis. The pusher bar 110PR is actuated in the Y direction to push the containers CUA, CUB toward the fence 110PF, position the containers CUA, CUB forward, and grip/grasp the containers CUA, CUB for transport to the break pack module 266. Hold. As can be appreciated, in one aspect the containers CUA, CUB are placed together in a holding position as a unit, while in other aspects the containers CUA, CUB are separated from each other, e.g. and placement of a container CUA on a lift 150B or other holding location (such as another break pack handling station 140 in another break pack module 266), such as a common support surface 140S of a break pack handling station 140. For example, the case units are transported and placed in separate positions of holding positions or in different case unit holding positions. For example, and referring also to FIGS. 1B and 16, the container bot 110 carrying the multi-pick payload transfers the multi-pick payload containers CUA, CUB to one or more interface stations TS (including buffer shelves) corresponding to the output lift 150B. Transfer to.

As can be appreciated, in one aspect where the container bots 110 turn to the pier 130BD (FIG. 16), the spacing between the bots traveling on the high speed bot travel path HSTP of the container transfer deck 130DC (FIG. 1B) is A bot interfacing with station TS decelerates and redirects to interface station TS substantially without interference from and/or by another container bot 110 moving along container transfer deck 130DC. It is something that can be done. In other aspects, the container bot 110 moving on the container transfer deck 130DC is configured such that the container transfer deck 130DC is substantially open and the container bot 110 moves across and along the container transfer deck 130DC as described above. Configured for targeted traffic, it can be driven around container transfer deck 130DC and turned to interface station TS. If multi-pick containers CUA, CUB are placed, for example, at different positions on a common buffer shelf BS of the interface/handoff stations 7000A, 7000B of the lifts 150B1, 150B2, the container bot 110 picks the first of the containers. A second container CUB of the containers is placed in the first position of the buffer shelf 7000A, and a second container CUA of the containers is placed in the second position of the buffer shelf 7000A. When multi-pick containers are placed at a common container holding position, the container bot 110 places both containers CUA, CUB as a unit (eg, pick face) at a common position on the buffer shelf 7000A, for example.

The containers CUA, CUB may be located in separate locations in a common holding location (such as that described in U.S. Pat. No. 9,856,083, the entire disclosure of which is hereby incorporated by reference) or When sorted for placement in different holding positions, the containers CUA, CUB are separated from each other in the payload section 110PL. For example, referring to FIGS. 13A, 13B, and 17A-17F, pick head 270 of transfer arm 110PA moves in the Z direction enough to allow pusher bar 110PR to pass under the container. The containers CUA, CUB may be lifted off the rollers 110RL by the amount (FIG. 19, block 1250A). When the containers CUA, CUB are lifted, the pusher bar 110PR is positioned along the Y direction to be located between the containers CUA, CUB (see FIG. 17F) (FIG. 19, block 1250B). The pick head 270 is lowered so that the containers CUA, CUB are transferred to the rollers 110RL and the pusher bar is inserted between the containers CUA, CUB (FIG. 19, block 1250C). The pusher bar 110PR is moved in the Y direction (e.g., to separate the containers) to move the container CUA toward the rear surface 402 of the payload section 110PL (e.g., to align the alignment surfaces 273JS of tines 273A-273E or any other suitable While moving (with respect to a fixed position), the container CUB remains in front of the payload section 110PL adjacent to the fence 110PF (eg, as shown in FIG. 17D) (FIG. 19, block 1250D). As can be appreciated, when the container is held against the alignment surface 273JS of the tine during transport, the pusher bar is moved in the Y direction (e.g., to separate the container) to move the container CUB to the payload. While moving toward the front surface 401 of section 110PL (eg, relative to fence 110PF or any other suitable location), container CUA remains on the rear surface of payload section 110PL adjacent alignment surface 273JS. Pusher bar 110PR may be moved in the Y direction to reposition container CUB relative to fence 110PF to position the container on tines 273A-273E to place the container in a container holding position (FIG. 19, block 1250E). As can be appreciated, when the container CUA is positioned relative to the alignment surface 273JS of the tines 273A-273E (e.g., pick head 270), the container moves the CUB substantially away from the container CUA. (FIG. 19, block 1250F), eg, the container CUA does not come into contact with other containers placed in the container holding position. Container CUA is lowered/transferred back to payload section 110PL (eg, by retracting and lowering transfer arm 110PA) (FIG. 19, block 1250G). The pusher bar 110PR, which is positioned in advance between the position adjustment surface 273JS and the container CUA, pushes the container CUA placed on the roller 110RL against the fence 110PF, and moves the container CUA (for example, from the holding position where the container CUB is placed) to the fence 110PF. (different) position forward to place in another container holding position (FIG. 19, block 1250H). Pusher bar 110PR remains pressed against container CUA to grip the container (eg, at a fence) during transport to another container holding position (FIG. 19, block 1250I). Pusher bar 110PR is moved away from container CUA and the transfer arm is actuated to lift and extend pick head 270 and place container CUA into another container holding position (FIG. 19, block 1250J).

Similarly, referring to FIGS. 1A, 1B, and 2, in one aspect where the container bot 110 turns from the transfer deck (see FIG. 1B) to the break pack module 266, the high speed of the container transfer deck 130DC (see FIG. 1B) The spacing between bots moving on the bot movement path HSTP is such that a bot interfacing with the interface station TS is free from interference from and/or due to another container bot 110 moving substantially along the container transfer deck 130DC. It is such that it is possible to slow down and turn to the interface station TS without any delay. In other aspects, the container bot 110 moving on the container transfer deck 130DC is configured such that the container transfer deck 130DC is substantially open and the container bot 110 moves across and along the container transfer deck 130DC as described above. Configured for target traffic, it can be driven around the container bot 110 and redirected to the break pack module 266. If the containers CUA, CUB of the multi-pick are placed, for example, at different positions on a common support surface of the guided conveyor 500A, 500B, 500C (FIG. 3A), the container bot 110 picks the first one of the containers CUB is placed in a first position on the support surface, and a second one of the containers CUA is placed in a second position on the support surface of the guiding conveyor 500A, 500B, 500C. When multi-pick containers are placed in a common container holding position, the container bot 110 uses both containers CUA, CUB as a unit (e.g. pick face), e.g. place in position.

The containers CUA, CUB may be located in separate locations in a common holding location (such as that described in U.S. Pat. No. 9,856,083, the entire disclosure of which is hereby incorporated by reference) or When sorted for placement in different holding positions, the containers CUA, CUB are separated from each other in the payload section 110PL. For example, referring to FIGS. 13A, 13B, and 17A-17F, pick head 270 of transfer arm 110PA moves in the Z direction enough to allow pusher bar 110PR to pass under the container. The containers CUA, CUB may be lifted off the rollers 110RL by the amount (FIG. 19, block 1250A). When the containers CUA, CUB are lifted, the pusher bar 110PR is positioned along the Y direction to be located between the containers CUA, CUB (see FIG. 17F) (FIG. 19, block 1250B). The pick head 270 is lowered so that the containers CUA, CUB are transferred to the rollers 110RL and the pusher bar is inserted between the containers CUA, CUB (FIG. 19, block 1250C). The pusher bar 110PR is moved in the Y direction (e.g., to separate the containers) to move the container CUA toward the rear surface 402 of the payload section 110PL (e.g., to align the alignment surfaces 273JS of tines 273A-273E or any other suitable While moving (with respect to a fixed position), the container CUB remains in front of the payload section 110PL adjacent to the fence 110PF (eg, as shown in FIG. 17D) (FIG. 19, block 1250D). As can be appreciated, when the container is held against the alignment surface 273JS of the tine during transport, the pusher bar is moved in the Y direction (e.g., to separate the container) to move the container CUB to the payload. While moving toward the front surface 401 of section 110PL (eg, relative to fence 110PF or any other suitable location), container CUA remains on the rear surface of payload section 110PL adjacent alignment surface 273JS. Pusher bar 110PR may be moved in the Y direction to reposition container CUB relative to fence 110PF to position the container on tines 273A-273E to place the container in a container holding position (FIG. 19, block 1250E). As can be appreciated, when the container CUA is positioned relative to the alignment surface 273JS of the tines 273A-273E (e.g., pick head 270), the container moves the CUB along the guided conveyors 500A, 500B, 500C can be placed in a container holding position substantially without interference from the container CUA (FIG. 19, block 1250F); Do not come into contact with other containers. Container CUA is lowered/transferred back to payload section 110PL (eg, by retracting and lowering transfer arm 110PA) (FIG. 19, block 1250G). The pusher bar 110PR positioned in advance between the position adjustment surface 273JS and the container CUA pushes the container CUA placed on the roller 110RL against the fence 110PF, and pushes the container CUA onto the support surface of the same guide conveyor 500A, 500B, 500C. or forward positioning of another guiding conveyor 500A, 500B, 500C to another container holding position (e.g., different from the holding position in which the container CUB was placed) on another support surface (FIG. 19, block 1250H). ). Pusher bar 110PR remains pressed against container CUA to grip the container (eg, at a fence) during transport to another container holding position (FIG. 19, block 1250I). Pusher bar 110PR is moved away from container CUA and the transfer arm is actuated to lift and extend pick head 270 and place container CUA into another container holding position (FIG. 19, block 1250J). Referring again to FIGS. 1A-1C, 1E and to FIGS. 28 and 30A, the automated storage and retrieval system 100 can store and retrieve items (e.g., pallets, cases, containers, packages of items, individual (unpacked) items). orthogonal classification transport echelons 15000, 15100, 15200 (also referred to herein as classification echelons) that distinguish between classifications (e.g., herein referred to as units or each). The distinction in the classification of the goods results in or otherwise creates a classification of the goods that is separate and distinct from the conveyance of the goods through the automated storage and retrieval system 100 (e.g., results in a further distinction in the classification of the goods). . The Orthogonal Classification Echelon 15000, 15100, 15200 performs classification by decomposing product components (e.g., pallets, cases, packs, units) into the smallest necessary product components and classifying the smallest necessary product components individually. provides a recursive classification of goods, such that the minimum necessary goods component(s) are then reassembled into larger groups (e.g. into one or more of pallets, cases, packs). reassemble). Each of these reassembled larger groups is sorted by reassembly iteration. As an example, referring to FIG. 30A, if the smallest required product component is a unit (also referred to herein as an individual), the incoming pallet is disassembled into cases, the cases containing the units are disassembled into packs, Packs are broken down into units. The desired number of units are sorted at the unit level and reassembled into sorted packs. The desired number of sorted packs are sorted at pack level and reassembled into sorted cases. A desired number of sorted cases are sorted at the case level and assembled into sorted pallet loads PAL. Here, the classification is drilled down to the desired classification level and the classified items are reassembled and classified in a recursive manner resulting in the construction of a pallet load PAL.

Orders for filled goods (e.g., pallets, cases, containers, packages of goods, individual (unpacked) goods, etc.) may be placed on a probabilistic basis (e.g., the goods ordered and the time to receive the order are substantially automated storage as a function of time (e.g. sorting of goods ordered at a predetermined scheduled time prior to the time the order is shipped/fulfilled or sorting of goods just in time) and may be implemented by retrieval system 100. These probabilistic orders determine the pick order of sorted items, such as to build a pallet load or pallet PAL, as described herein with respect to FIG. 1D (e.g., throughout the disclosure). No. 8,965,559, entitled "Pallet Building System," issued February 24, 2015, incorporated herein by reference). Although the pallet of FIG. 1D is illustrated and described as a mixed case pallet, such illustration also represents palletized loads having mixed cases, mixed totes, mixed packs, mixed units per tote, etc. . Here, the sorted items are picked from a common storage array (eg, the storage array formed by storage spaces 130S of storage structure 130). Automated storage and retrieval system 100 processes orders by utilizing one or more of orthogonal classification echelons 15000, 15100, 15200, or otherwise processes orders by utilizing one or more of orthogonal classification echelons 15000, 15100, 15200. required to bring a given order from a common storage array independent of order type (e.g., pallet order, case order, pack order, mixed order, etc.), order order, and order time through By processing down to the classification level (e.g., the controller 120 drills/drives down the orthogonal classification echelon to a given order, i.e., case level classification, pack level classification, unit/individual level classification, or a combination thereof). the desired level of classification required), resulting in the maximum throughput of merchandise for each order (e.g., received for processing by automated storage and retrieval system 100).

The Orthogonal Classification Echelon 15000, 15100, 15200 provides maximum throughput of goods through the automated storage and retrieval system 100 by differentiating the classification of goods at various levels of classification from the conveyance of goods. , controlled by controller 120 to provide maximum flexibility in order fulfillment. Correspondingly, orthogonal classification echelons 15000, 15100, 15200 result in minimized filling costs for each order processed through automated storage and retrieval system 100.

The different classification echelons described herein may be provided by the asynchronous transport system and/or break pack module 266 of the storage and retrieval system 100. As described herein, the autonomous storage and retrieval system 100 includes at least one asynchronous transport system for transporting cases/products at a given storage structure level 130L (e.g., level transport). including automated conveyance systems (e.g., bots, break pack modules, and other suitable level conveyances as described herein). Here, as described herein, the storage and retrieval system 100 moves along one or more physical paths of the storage and retrieval system to provide at least one level of asynchrony. The container bot 110 includes a non-deterministic container bot 110. For example, at least another level of asynchrony is provided (as described herein) such that the number of locations holding cases/products is greater than the number of bots transporting cases/products. As can be appreciated, the controller 120 includes the container bot 110 and the product bot 262 (both of which implement at least a portion of the asynchronous transport system) for assembling orders of break-packed products BPG from the supply container 265 into the break-packed product container 264. forming) and ejecting the break pack goods container 264 via the container ejecting station TS. For example, the controller 120 may operate between (1 (one or more) container bots 110; As another example, the controller 120 may perform unit/piece level classification (e.g., a break pack Order sorting 188 ) is configured to effect the operation of the product bot(s) 262 to sort the break pack products BPG into corresponding break pack product containers 264 . As a further example, the controller 120 may cause the container bot(s) 110 to access the corresponding break-pack product container 264 on the product transfer deck 130DG and transfer the break-pack product container to the break-pack product container 264, as described herein. and ( (e.g., break pack output classification 189).

Still referring to FIG. 30A, with respect to recursive classification of products via the orthogonal classification echelon 15000, 15100, 15200, the configuration of the controller 120 (e.g., non-transitory computer program code therein) determines that the solution is the orthogonal classification echelon 15000. , 15100, 15200 so that controller 120 approaches a solution to recursive classification in the same way as provided by the physical components of orthogonal classification echelons 15000, 15100, 15200. For example, the controller 120 may be configured to disassemble a larger product unit(s) into smaller product units, and to categorize smaller product units into categorized larger product units, as described herein. a case-level classification echelon control module 120M1, a pack-level classification echelon, which alone or in combination (e.g., depending on the level of classification required to effect order fulfillment) provides subsequent recursively classified assembly of product units; A control module 120M2, and a unit/individual level classification echelon control module 120M3.

As described herein, with reference to FIGS. 28 and 30A, automated storage and retrieval system 100 includes multiple sorting (or transport) echelons 15000, 15100 formed by an asynchronous transport system and at least one lift 150B. , 15200. Each sorting echelon 15000, 15100, 15200 is communicatively connected to a common portion of the storage array (eg, storage space 130S of respective storage level 130L) and an output (eg, output station 160UT). As described herein, classification echelons 15000, 15100, 15200 result in orthogonal classifications of product units distributed into intersections, corresponding to classification echelons 15000, 15100, 15200, thereby providing corresponding The classified mixed output product units of classification echelons 15000, 15100, 15200 are in a predetermined sequence. The orthogonal classification of product units by each classification echelon 15000, 15100, 15200 means that each classification echelon 15000, 15100, 15200 is a mixed individualized product unit, each classified in a predetermined sequence (e.g., individualized pack PCK (FIG. 29C) -29E)), a mixed pack group (e.g. pack PCK and/or unit UNT arranged in a common container (see Figures 29D-29E)), and one or more output product units of the mixed case. The plurality of classification echelons 15000, 15100, 15200 such that they are orthogonal classification echelons with respect to each other classification echelon 15000, 15100, 15200 of the plurality of classification echelons 1500, 15100, 15200, combined at the output. Each of the other classification echelons is orthogonal to the orthogonal classification. As described herein, the orthogonal classification of each classification echelon 15000, 15100, 15200 that results in an output of product units in a predetermined sequence is independent of one or more of order sequence and order time.

Referring to FIGS. 28 and 29B-29E, case-level sorting echelon 15000 includes at least transfer decks 130BC, 130DC, container bot 110, picking aisle 130A, storage location 130S, and unloading lift 150B. In some aspects, case-level classification echelon 15000 also includes input lift 150A. At least part 15010 of case-level classification echelon 15000 is classified in a manner substantially similar to that described in U.S. Pat. No. 10,947,060, previously incorporated by reference in its entirety. A vertical sequencer is formed that arranges the case/container SCUs in a predetermined sequence, resulting in the construction of a sorted pallet PAL. As illustrated in FIG. 29B, case-level classification echelon 15000 receives cases CU from storage arrays formed at least in part by storage spaces 130S at respective storage structure levels 130L and places cases on predetermined pallets PAL. Classify into.

The pack level sorting echelon 15100 includes at least a container bot 110, a portion 130DCP of a container transfer deck 130DC, and a break pack manipulation station 140. Now, as seen in FIGS. 29C and 29E, the case CU is transferred from the storage space 130S to the pick-level sorting echelon 15100, broken down to the pack level, and sorted at the pack level. The sorted pack SPCK is transported by the container bot 110 to part 15010 of the case-level classification echelon 15000 for recursive sorting into pallets PAL, and is transferred to a break pack goods container 264 (which is generally referred to as 29C and 29E (denoted as “cases”) or one of them is made to form a classified mixed pack group with other classified packs SPCK or classified units SUNT . Breakpack product containers 264 are transported by container bot 110 to part 15010 of case-level classification echelon 15000 for recursive classification into pallets PAL. Placement of a pack PCK in a break pack product container 264 or on a support surface of, e.g., a staging area of a break pack handling station 140 (e.g., for picking by a container bot 110) may occur at the break pack handling station. performed in any suitable manner, such as by an operator at a computer. Placement of pack PCKs into break pack product containers 264 (such as interface locations 263L for grouping with other pack PCKs or units UNT) may also be performed by product bot 262, thereby allowing pack-level classification echelons 15100 can be formed.

The unit/individual level classification echelon 15200 includes at least a product deck 130DG, a product bot 262, and an interface location 263L. Here, as illustrated in FIGS. 29D and 29E, the case CU is transferred from the storage space 130S to the unit/piece level classification echelon 15200, decomposed to the unit level, and classified at the unit level by the product bot 262. . The product bot 262 places the sorted unit SUNT (again, generally represented as a "case" in FIGS. 29E and 29E) into a break pack product container 264 along with other sorted units SUNT to the pallet PAL. Mixed individualized product units (as described herein) that are transferred in break pack product container 264 to portion 15010 of case-level classification echelon 15000 by container bot 110 for recursive classification (see FIG. 30A) of form).

Referring to FIG. 28, the multiple classification echelons 15000, 15100, 15200 are dynamic such that temporary assets of one classification echelon may migrate to form temporary assets of another classification echelon. For example, a container bot 110 that transports/transfers cases/containers between echelons may migrate from assets in the case-level classification echelon 15000 to assets in the pack-level classification echelon, and vice versa. The product bot 262 can migrate any given product bot 262 from assets in the pack-level classification echelon 15100 to assets in the unit-level classification echelon 15200 depending on the transportation task assigned to the given product bot 262. It is configured to carry/transport both packs and units so that they can be carried and vice versa.

Still referring to FIGS. 28 and 30A, and FIGS. 29A-29E, the automated storage and retrieval system 100 includes sorting (FIG. 29A) of pallets PALs (such as for placement in a transport vehicle), placement on sorted pallet PALs, Classification of case CUs for placement (FIG. 29B), classification of pack PCKs (e.g. retrieved from case CUs) for placement in classified container SCUs (FIGS. 29C and 29E), placement in classified container SCUs. 29E and 29E). Here, each of the classification echelons 15000, 15100, 15200 provides an orthogonal classification informed by recursive classification decisions. For example, as illustrated in Figures 29B-29E, classifying products by the case-level classification echelon decomposes product components (e.g., pallets, cases, packs, units) into the smallest necessary product components to informed by the classification performed by one or more of the pack-level classification echelon 15100 and the unit/individual-level classification echelon 15200 such that the classification is effected by separately classifying the required product components of the product; Reassembling the minimum required product component(s) into a larger group (e.g., reassembling into one or more of pallets, cases, packs). Each of these reassembled larger groups is sorted by reassembly iteration.

Controller 120 is configured (eg, includes appropriate non-transitory programming and memory) to determine a recursive classification that informs the orthogonal classification of each classification echelon 15000, 15100, 15200. Again, the controller 120 includes a case-level classification echelon control module 120M1, a pack-level classification echelon control module 120M2, and a unit/individual level classification echelon control module 120M3, which may be used alone or in combination (e.g., to (depending on the level of classification required to effect fulfillment), the disaggregation of the larger product unit(s) into smaller product units, and the classified larger product units as described herein. resulting in a subsequent recursive sorted assembly of smaller sorted merchandise units into merchandise units. By way of example, each classification echelon 15000, 15100, 15200 may be configured to classify ordered items at the respective classification level necessary to effect order fulfillment (e.g., case level, pack level, unit/piece level). It is configured. The multiple sorting echelons 15000, 15100, 15200 retrieve from an automated storage and retrieval system each sorted goods unit/piece, one or more sorted goods packs, one or more sorted cases, and one Alternatively, it is configured to output at least one of a plurality of classified palettes. Each of the classification echelons 15000, 15100, 15200 operates independently (ie, decoupled) from each other classification echelon 15000, 15100, 15200 under the control of the controller 120. Here, the controller 120 is configured to separate the throughput of cases CU through the automated storage and retrieval system 100 from the classification of items (eg, pallets, cases, packs, units/pieces). Controller 120 is configured to receive one or more product fulfillment orders and to determine demand for cases ordered by the product fulfillment order(s). The controller 120 is configured to (one or more ) Determine/resolve the product classification and level of classification required to fulfill product fulfillment orders. Batch processing efficiency is increased by resolving the level of classification and product classification for one or more fulfillment orders, and by batching/grouping transfers of products that are common to multiple fulfillment orders. , the work performed by the automated storage and retrieval system 100 is minimized (extra movements are virtually eliminated).

Controller 120 is communicatively coupled to the asynchronous transport system and configured to use classification echelons 15000, 15100, 15200 to generate orthogonal classifications for each classification echelon 15000, 15100, 15200, as described herein. It is composed of Here, the controller 120 considers the existing/available physical paths through the automated storage and retrieval system 100 that the items may move, such as items, bots, lifts, etc., within the automated storage and retrieval system 100. (collectively referred to as objects). The resolution of object movement is performed by controller 120 as a function of time for a predetermined time when an order is to be fulfilled. Here, the controller 120 (e.g., provided with the physical path, the required product classification level(s), and the classified products combined from the prior classification) is classified by the classification echelons 15000, 15100, 15200. (e.g., pallets, cases, packs, units/pieces) are transported through the storage and retrieval system 100 in close proximity to each other in time and space ( For example, between and within classification echelons 15000, 15100, 15200) are configured to optimize release of items (e.g., from a common storage array formed by storage space 130).

The controller 120 also manages the transportation of goods along the physical path so that a single node of the autonomous storage and retrieval system's transport equipment (e.g., lift, break pack station, bot, etc.) is not overloaded. For example, it is configured to balance Here, the passage of goods through the automated storage and retrieval system 100 provides control over and during production (e.g., the transfer of goods through the storage and retrieval system 100) and directs the goods along a lower cost path. Balance is taken along the available physical paths to minimize the cost by sending .

The classification echelons 15000, 15100, 15200 described herein are modular, where the modularity of the classification echelons 15000, 15100, 15200 extends to storage and retrieval system assets (e.g., transfer decks, bots, breaks, etc.). bot interface station) on the deck, such as a pack module 266 or other suitable location of a given storage level 130L. By way of example, and referring to FIGS. 1B, 2-4, and 31, break pack module 266 is configured such that additional product transfer decks 130DGE1-130DGE3 can be stacked on product transfer decks 130DG1-130DG3, and transfer deck 130B or communicatively coupled to picking aisle 130A, where each of item transfer decks 130DG1-130DG3, 130DGE1-130DGE3 is accessible from break pack operation station 140. The addition of the product transfer decks 130DGE1-130DGE3 increases the number of product transfer decks 130DG by increasing the number of break pack product interface locations 263L and product bots 262 (e.g., at their respective elevated levels 130DGL1-130DGL3, 130DGLE1-130DGLE3). Expand the capacity of. In a similar manner, additional container transfer decks 130DCE may be stacked above (or below) container transfer deck 130DC to provide container bot 110 access to additional product transfer decks 130DGE1-130DGE3. Ramps similar to ramps 222, 222C, 222R are provided to effect the transition of container bots 110 between stacked product transfer decks 130DG, 130DGE, but in other aspects, additional product transfer decks 130DGE, respectively may be communicatively coupled to the decks of different (stacked) storage levels 130L such that they are accessible by container bots 110 of the different storage levels 130L. An additional asset provided by the modularity of the classification echelon is that the physical path through the storage and retrieval system 100 is minimized to minimize the cost of moving products through the storage and retrieval system 100 for any fulfillment order. Provides a scalable increase in throughput by increasing the number.

With reference to FIGS. 1A, 1B, 2-4, 28, 29A-29E, 30A, 30B, and 31, exemplary operation of orthogonal classification echelons 15000, 15100, 15200 will be described. In operation, a pallet is received into automated storage and retrieval system 100 at input station 160IN (Figure 30B, block 17000). The pallet cases CU are depalletized by depalletizer 160PA (FIG. 30B, block 17005) and transferred to a common storage array by input lift module 150A and container bot 110. The controller 120 is configured to direct the assets of the automated storage and retrieval system 100 to fulfill orders, where, for example, the order includes cases CU, packs PCK, and units/individuals UNT (collectively products). may include one or more of the following: Products are commonly stored by controller 120 in temporal and spatial proximity and relative to each other to move along one or more physical paths through storage structure 130 of automated storage and retrieval system 100. Released from storage array. Here, the orthogonal classification echelons 15000 , 15100 , 15200 are utilized in parallel to classify ordered products, where the classification is distinct from the transport of the products through the storage and retrieval system 100 . As described herein, the controller 120 sorts the ordered products to release the products in batches from a common storage and to effect the batch sorting through the orthogonal sorting echelons 15000, 15100, 15200. Solve. Once the product classification is resolved, the controller resolves the movement of the product along different physical paths of the automated storage and retrieval system. Here, ordered cases, packs, and units for any given order are released close to each other in time and space.

The ordered cases are transported to the case-level sorting echelon 15000 by the container bot 110 and processed in any suitable manner, such as ordered placement at buffer station BS or transfer station TS and/or vertical sequencing by lift 150B. (Figure 30B, block 17030). The classified case SCU is output by the case-level classification echelon 15000 (FIG. 3B, block 17035) and transported (as described herein) for placement on a pallet 17050 (FIG. 30B, block 17050).

If a pack PCK is ordered, the case CU containing the pack PCK is conveyed by the container bot 110 to, for example, the break pack product module 266 (forming at least part of the pack-level classification echelon 15100), where the case CU contains the pack PCK. The pack PCK is retrieved (eg, de-cased) from the case CU (FIG. 30B, block 17010) and classified in the manner described herein (FIG. 30B, block 17025). The sorted pack SPCK is output to a break pack product container 264 (FIG. 30B, block 17040), or in some aspects is not included and is conveyed to a pallet PAL or case level sorting echelon 15000 to be processed as described above. For placement on a pallet PAL such as, ordered cases CU are arranged.

If a unit UNT is ordered, the case CU containing the unit UNT is conveyed by the container bot 110 to, for example, the break pack product module 266 (forming at least part of the unit-level classification echelon 15200), where: The unit UNT is removed from the case CU and any pack PCK (e.g., case disassembled and/or de-packed), the unit is placed in the pack (FIG. 30B, block 17015), and the unit is removed from the case CU and any pack PCK. It is classified in the manner described in the specification (Figure 30B, block 17020). The sorted units SUNT are included in a pack PCK with other units for sorting according to the pack-level sorting echelon 15100 as described above, and one or more of them are transported to a break pack goods container 264 on a pallet PAL. is output (FIG. 30B, block 17045) and conveyed to the case-level classification echelon 15000 to be arranged in the ordered case CU for placement on the pallet PAL, as described above.

The output of the plurality of sorting echelons 15000, 15100, 15200 is a pallet PAL, each containing one or more of mixed individualized product units, mixed packaging groups, and mixed cases sorted in a predetermined sequence.

Although the recursive classifications of the classification echelons 15000, 15100, 15200 are described with respect to the transfer of products from the storage and retrieval system 100, in other aspects the recursive classifications may be applied to the products being input into the storage and retrieval system 100. It is noted that it can be performed for For example, a fulfillment order may be known to controller 120 at any given time, but any given one of the fulfillment orders may not be scheduled to be fulfilled until a predetermined period of time. When products for a given fulfillment order are entered into storage and retrieval system 100, controller 120 uses classification echelons 15000, 15100, 15200 to classify the products in a manner substantially similar to that described herein. may be opportunistically sorted, but the sorted packs, sorted units, and/or sorted cases may be classified opportunistically until the time that the classified products are requested to fill the fulfillment order (output from the system). storage array).

In accordance with one or more aspects of the disclosed embodiments, a warehouse system for storing and retrieving merchandise in containers is provided. The warehouse system is a multi-level container storage array, each level of the multi-level storage array having a transport area and a storage area, the storage area including an array of storage shelves configured to hold containers. , a transfer area is substantially continuous and arranged to communicatively connect the storage shelves of the array of storage shelves to each other, and the transfer area includes a picking aisle and a container transfer deck connecting the picking aisle. a multi-level container storage array, the at least one autonomously guided container transport vehicle being separate from the container transfer deck, the at least one autonomously guided container transport vehicle being located at each level of the multi-level storage array; and at least one autonomously guided container transport vehicle passes through the container transfer deck and the picking aisle at each level to access/from container storage locations on each of the storage shelves at each level of the multi-level storage array. at least one autonomously guided container transport vehicle configured to transport containers to a break pack handling station; and a put wall, with a corresponding break pack goods transfer deck at each level of the put wall. a plurality of levels of put walls of BreakPak goods container stations distributed along each level and at least one autonomously guided BreakPack goods transport vehicle, the at least one autonomously guided BreakPak goods transport vehicle comprising: Passing break-pack merchandise along corresponding break-pack merchandise transfer decks and between corresponding break-pack merchandise transfer decks at different levels of the put wall to each break-pack merchandise container station at each level of the put wall. at least one autonomously guided break pack goods transport vehicle configured to transport between the break pack goods container located at the container storage location, the break pack operating station, and the break pack goods container station of the put wall; and a controller configured to effect operation of the at least one autonomously guided container transport vehicle.

According to one or more aspects of the disclosed embodiments, the put wall is distinct and separate from the multi-level container storage array.

In accordance with one or more aspects of the disclosed embodiments, at least one autonomously guided container transport vehicle is configured to transport supply goods containers and break pack goods containers, respectively.

In accordance with one or more aspects of the disclosed embodiments, the break-pack merchandise transfer deck at each level of the put wall is such that the respective put wall level is connected to each container transfer deck coupled to a break-pack operating station. is separate and distinct from each container transfer deck, such as having a separate and different break pack product transfer deck.

In accordance with one or more aspects of the disclosed embodiments, a break pack merchandise transfer deck includes at least one autonomously guided break pack product transfer deck for transport by at least one autonomously guided container transport vehicle on the container transfer deck. A packed goods transport vehicle is configured to pass through the break pack goods transfer deck and transport break pack goods from the break pack operating station to a corresponding break pack goods container.

In accordance with one or more aspects of the disclosed embodiments, an autonomously guided break pack goods transport vehicle has a payload support and transports a break pack goods unit payload conveyed thereon to the payload support. The break pack product container is configured to output from and to a break pack product container at each break pack product container station at each level of the put wall.

In accordance with one or more aspects of the disclosed embodiments, the common portion and transfer area of the multi-level container storage array is configured to provide a plurality of containers, each independent of the other, via one or more of the break pack handling stations. put walls, each put wall is filled independently from each other put wall, each put wall results in an output of an independent break pack commodity container, and each put wall is autonomous. Accessed by a guided container transport vehicle, the output of each put wall's independent break pack goods container is independent of each other put wall so as to provide output break pack goods containers that are filled orthogonally to each other. are doing.

In accordance with one or more aspects of the disclosed embodiments, each independent put wall has a different break-pack merchandise container station, and each different break-pack merchandise container station has a The put wall is arranged to hold a different respective break pack goods container filled independently with respect to each other break pack goods container, such that each different filled break pack goods container , defining the output of an independent break pack commodity container of an independent put wall.

In accordance with one or more aspects of the disclosed embodiments, the warehouse system further comprises an intervening sorter positioned to communicatively couple the multi-level array transfer area and the break pack handling station; The sorter is configured to sort supply goods containers from the autonomous guided container transport vehicle and upstream of the break pack handling station.

In accordance with one or more aspects of the disclosed embodiments, the sorting of supplied goods containers by an intervening sorter upstream of a break pack operation station ranges from a lower optimized order of goods to a higher optimized order of goods. a predetermined sequence of supply goods containers input into the break pack operation station, arranged to facilitate the sequencing of the supply goods containers into the order, and the release of goods from the supply goods containers, and filling the put wall; effecting the dispatch of at least one autonomously guided BreakPak goods conveyance vehicle from a BreakPack operating station for delivery.

In accordance with one or more aspects of the disclosed embodiments, an intervening classifier upstream of the break pack manipulation station is configured to define a plurality of mutually orthogonal classification axes.

According to one or more aspects of the disclosed embodiments, the at least one classification axis in one direction has parallel classification axes.

In accordance with one or more aspects of the disclosed embodiments, at least one autonomously guided break-pack goods transfer vehicle along a corresponding break-pack goods transfer deck and between corresponding break-pack goods transfer decks of a put wall. The passage of each break-pack goods container from a lower optimized order of goods to a higher optimized order results in a predetermined order of filling of break-pack goods into break-pack goods containers at the put wall. A break pack product sorter is defined downstream of the break pack handling station to facilitate sequencing of the break pack products delivered to each of the break pack product containers at the station.

In accordance with one or more aspects of the disclosed embodiments, a break-pack product sorter downstream of the break-pack operating station is configured to define a plurality of mutually orthogonal sorting axes.

According to one or more aspects of the disclosed embodiments, the at least one classification axis in one direction has parallel classification axes.

According to one or more aspects of the disclosed embodiments, a method for storing and retrieving merchandise in a container is provided. The method includes providing a multi-level container storage array, each level of the multi-level container storage array having a transport area and a storage area, the transport area configured to hold a container thereon. the transport area is substantially continuous and arranged to communicatively connect the storage shelves of the array of storage shelves with each other, and the transport area includes a picking aisle and a picking aisle. a container transfer deck connecting the containers to and from the container storage locations on each of the storage shelves of each level of the multi-level storage array using at least one autonomously guided container transfer vehicle; , to a break pack handling station, the at least one autonomously guided container transport vehicle navigating through a container transfer deck and a picking aisle at each level, the container transfer deck being separate from the container transfer deck, and the at least one At least one autonomous guided container transport vehicle is located at each level of the multi-level storage array, with breaks distributed along each level along with a corresponding breakpack goods transfer deck at each level of the process and put wall. providing a multi-level put wall of the packed goods container station and using at least one autonomously guided break pack goods transport vehicle to transport break pack goods along a corresponding break pack goods transfer deck and at the put wall; The process of conveying break pack goods to each break pack goods container station at each level of the put wall between the corresponding break pack goods transfer decks at different levels of the container storage position, break pack operating station, and put effecting operation of at least one autonomously guided container transport vehicle between break-pack goods containers located at break-pack goods container stations of the wall.

According to one or more aspects of the disclosed embodiments, the put wall is distinct and separate from the multi-level container storage array.

In accordance with one or more aspects of the disclosed embodiments, at least one autonomously guided container transport vehicle transports a supply goods container and a break pack goods container, respectively.

In accordance with one or more aspects of the disclosed embodiments, the break-pack merchandise transfer deck at each level of the put wall is such that the respective put wall level is connected to each container transfer deck coupled to a break-pack operating station. is separate and distinct from each container transfer deck, such as having a separate and different break pack product transfer deck.

In accordance with one or more aspects of the disclosed embodiments, a break pack merchandise transfer deck includes at least one autonomously guided break pack product transfer deck for transport by at least one autonomously guided container transport vehicle on the container transfer deck. A packed goods transport vehicle is configured to pass through the break pack goods transfer deck and transport break pack goods from the break pack operating station to a corresponding break pack goods container.

In accordance with one or more aspects of the disclosed embodiments, an autonomously guided break pack goods transport vehicle has a payload support and transports a break pack goods unit payload conveyed thereon to the payload support. and output to break pack product containers at each break pack product container station at each level of the put wall.

In accordance with one or more aspects of the disclosed embodiments, the common portion and transfer area of the multi-level container storage array is configured to provide a plurality of containers, each independent of the other, via one or more of the break pack handling stations. put walls, each put wall is filled independently from each other put wall, each put wall results in an output of an independent break pack commodity container, and each put wall is autonomous. Accessed by a guided container transport vehicle, the output of each put wall's independent break pack goods container is independent of each other put wall so as to provide output break pack goods containers that are filled orthogonally to each other. are doing.

In accordance with one or more aspects of the disclosed embodiments, each independent put wall has a different break-pack merchandise container station, and each different break-pack merchandise container station has a The put wall is arranged to hold a different respective break pack goods container filled independently with respect to each other break pack goods container, such that each different filled break pack goods container , defining the output of an independent break pack commodity container of an independent put wall.

In accordance with one or more aspects of the disclosed embodiments, the method includes an autonomous classifier configured to communicatively couple a multi-level array transfer area and a break pack handling station. The method further includes sorting the supplied goods containers from the guided container transport vehicle and upstream of the break pack handling station.

In accordance with one or more aspects of the disclosed embodiments, the sorting of supplied goods containers by an intervening sorter upstream of a break pack operation station ranges from a lower optimized order of goods to a higher optimized order of goods. a predetermined sequence of supply goods containers input into the break pack operation station, arranged to facilitate the sequencing of the supply goods containers into the order, and the release of goods from the supply goods containers, and filling the put wall; effecting the dispatch of at least one autonomously guided BreakPak goods conveyance vehicle from a BreakPack operating station for delivery.

In accordance with one or more aspects of the disclosed embodiments, an intervening classifier upstream of the break pack manipulation station defines a plurality of mutually orthogonal classification axes.

According to one or more aspects of the disclosed embodiments, the at least one classification axis in one direction has parallel classification axes.

In accordance with one or more aspects of the disclosed embodiments, at least one autonomously guided break-pack goods transfer vehicle along a corresponding break-pack goods transfer deck and between corresponding break-pack goods transfer decks of a put wall. The passage of each break-pack goods container from a lower optimized order of goods to a higher optimized order results in a predetermined order of filling of break-pack goods into break-pack goods containers at the put wall. A break pack product sorter is defined downstream of the break pack handling station to facilitate sequencing of the break pack products delivered to each of the break pack product containers at the station.

In accordance with one or more aspects of the disclosed embodiments, a break-pack product sorter downstream of the break-pack operating station is configured to define a plurality of mutually orthogonal sorting axes.

According to one or more aspects of the disclosed embodiments, the at least one classification axis in one direction has parallel classification axes.

According to one or more aspects of the disclosed embodiments, an automated order fulfillment system is provided. The automated order fulfillment system is a multi-level break pack merchandise container filling array, each level having a container filling station area, the break pack merchandise container stations arranged along the container filling station area, and each level having: a multi-level break pack goods container filling array having corresponding break pack goods transfer decks juxtaposed along the break pack container stations in the container filling station area and at least one autonomously guided break pack goods transport vehicle; the at least one autonomously guided break pack goods transport vehicle comprises a payload support for holding at least one break pack goods unit for transport by the at least one autonomously guided break pack goods transport vehicle; At least one autonomously guided break-pack goods transfer vehicle is arranged at each level along the corresponding break-pack goods transfer deck and between corresponding break-pack goods transfer decks at different levels of the multi-level break-pack goods container filling array. and each break pack goods container station is accessed by at least one autonomously guided break pack goods conveyance vehicle and is configured to transport break pack goods to and from each break pack goods container station at a predetermined break pack goods container station. at least one autonomously guided break pack goods transport vehicle arranged to hold a break pack goods container filled with a goods filling payload, and a corresponding transfer deck at each level; A multi-level break pack goods container filling array is provided by interlevel transition autonomous guided break pack goods transport vehicle paths passing between break pack goods transfer decks and other break pack goods transfer decks corresponding to each other level. is communicatively joined to other transfer decks corresponding to each other level of the vehicle, such that the at least one autonomously guided break-pack goods transport vehicle transfers between levels via the autonomously guided break-pack goods transport vehicle path. from the corresponding break-pack product transfer deck to each other break-pack product transfer deck corresponding to each other level and loaded onto at least one autonomously guided break-pack product transfer vehicle on one level. transporting a predetermined break pack product filling payload to fill break pack product containers at each break pack product container station at a different level.

In accordance with one or more aspects of the disclosed embodiments, the corresponding break pack goods transfer deck and interlevel transition autonomously guided break pack goods transport vehicle path at each level includes at least one interlevel detour and forming at least a two-dimensional matrix of autonomously guided break-pack merchandise vehicle detours including at least one intra-level detour route, whereby the at least one autonomously guided break-pack merchandise vehicle detours on-the-fly the at least one intra-level detour route; from the initial break pack goods container station designation via at least one of an inter-level detour and at least one inter-level detour on at least one of a level common to the initial container station designation and a different level. Detour Freely take a detour to the designated destination of the break pack product container station.

In accordance with one or more aspects of the disclosed embodiments, the corresponding break pack product transfer deck at each level is non-deterministic, and the at least one inter-level detour is non-deterministic, such that at least One autonomously guided break pack goods transport vehicle may freely transition between a corresponding break pack goods transfer deck and the at least one interlevel detour.

According to one or more aspects of the disclosed embodiments, the at least one interlevel detour is a ramp.

In accordance with one or more aspects of the disclosed embodiments, the at least one autonomously guided break pack goods transport vehicle includes at least one autonomously guided break pack goods transport vehicle longitudinally along the route and between levels. Wheel odometry, dead reckoning, distance measurement and detection of references with electromagnetic distance sensors or vision, distance measurement of references with 2D or 3D cameras, informing vehicle pose and positioning in both the Z direction, raising or lowering and sensing, alone or in combination, effecting posing and locating in the transition between the break pack goods transfer deck and the at least one interlevel detour. The vehicle is configured to provide a free transition of movement of the vehicle at a substantially constant speed of movement.

In accordance with one or more aspects of the disclosed embodiments, the automated order fulfillment system further comprises a multi-level container storage array, each level of the multi-level storage array having a transport area and a storage area; The storage area includes an array of storage shelves configured to hold the containers, and the transport area is substantially continuous and arranged to communicatively connect the storage shelves of the array of storage shelves to each other. The transport area includes a multi-level container storage array, including a picking aisle and a container transfer deck connecting the picking aisle, and a multi-level container storage array and a multi-level break-packed product through the container transfer deck and the picking aisle. and at least one autonomously guided container transport vehicle configured to effect transport of containers to and from the container filling array, the multi-level break pack goods container filling array being different from the multi-level container storage array. , are separate.

In accordance with one or more aspects of the disclosed embodiments, at least one autonomously guided container transport vehicle is configured to transport supply goods containers and break pack goods containers, respectively.

In accordance with one or more aspects of the disclosed embodiments, a corresponding break pack goods transfer deck at each level of the multi-level container storage array is configured such that each level of the multi-level container storage array Each container transfer deck is separate and distinct, such as having a separate and different break pack product transfer deck.

In accordance with one or more aspects of the disclosed embodiments, a corresponding break pack merchandise transfer deck includes at least one autonomously guided container transport vehicle for transfer by at least one autonomously guided container transport vehicle on the container transfer deck. A type break pack goods transport vehicle is configured to pass through a corresponding break pack goods transfer deck and transport break pack goods from a break pack operating station to a corresponding break pack goods container.

In accordance with one or more aspects of the disclosed embodiments, the automated order fulfillment system further comprises a break pack manipulation station and an intervening sorter disposed upstream of the break pack manipulation station, the intervening classifier comprising: , configured to sort supply commodity containers inbound to the break pack operation station.

In accordance with one or more aspects of the disclosed embodiments, the sorting of supplied goods containers by an intervening sorter upstream of a break pack operation station ranges from a lower optimized order of goods to a higher optimized order of goods. A predetermined sequence of supply goods containers input into the break pack operation station, arranged to facilitate the sequencing of supply goods containers into an order, and the release of goods from the supply goods containers, and multi-level break pack goods. providing for the dispatch of at least one autonomously guided break-pack goods transport vehicle from a break-pack operating station to fill a container fill array;

In accordance with one or more aspects of the disclosed embodiments, an intervening classifier upstream of the break pack manipulation station is configured to define a plurality of mutually orthogonal classification axes.

According to one or more aspects of the disclosed embodiments, the at least one classification axis in one direction has parallel classification axes.

In accordance with one or more aspects of the disclosed embodiments, at least one autonomously guided break-pack goods transfer vehicle along corresponding break-pack goods transfer decks and between corresponding break-pack goods transfer decks at different levels. The passage of from a lower optimized order of goods to a higher optimized order results in a predetermined order of filling of break-packed goods into break-packed goods containers in a multi-level break-packed goods container filling array. , defining a break-pack merchandise sorter downstream of the break-pack handling station that facilitates sequencing of the break-pack merchandise delivered to each of the break-pack merchandise containers at each break-pack merchandise container station.

In accordance with one or more aspects of the disclosed embodiments, a break-pack product sorter downstream of the break-pack operating station is configured to define a plurality of mutually orthogonal sorting axes.

According to one or more aspects of the disclosed embodiments, the at least one classification axis in one direction has parallel classification axes.

According to one or more aspects of the disclosed embodiments, a method for order fulfillment in an automated order fulfillment system is provided. The method includes providing a multi-level break pack goods container filling array, each level having a container filling station area, the break pack goods container stations being arranged along the container filling station area, and each level having a container filling station area. , a corresponding break pack product transfer deck juxtaposed along a break pack container station in a container filling station area, and a corresponding break pack product transfer deck using at least one autonomously guided break pack product transfer vehicle. Passing break-packed goods along the pack-packed goods transfer decks and between corresponding break-packed goods transfer decks at different levels of the multilevel break-packed goods container filling array to each break-packed goods container station at each level. transporting, each break pack goods container station being accessed by at least one autonomously guided break pack goods transport vehicle to hold break pack goods containers filled with a predetermined break pack goods filling payload; the at least one autonomously guided break pack goods transport vehicle having a payload support for holding at least one break pack goods unit for transport by the at least one autonomously guided break pack goods transport vehicle; and a corresponding transfer deck at each level is an interlevel transfer deck that passes between the corresponding break pack product transfer deck at each level and the other break pack product transfer deck corresponding to each other level. The transitional autonomous guided break pack goods transport vehicle path connects the at least one autonomous guided break communicatively to other transfer decks corresponding to each other level of the multilevel break pack goods container filling array. The packed goods transport vehicle transitions from the corresponding break pack goods transfer deck to each other break pack goods transfer deck corresponding to each other level via an interlevel transition autonomous guided break pack goods transport vehicle path. , transporting a predetermined BreakPak product filling payload loaded onto at least one autonomously guided BreakPak product transport vehicle on one level and filling a BreakPak product container at each BreakPak product container station on a different level. .

In accordance with one or more aspects of the disclosed embodiments, the corresponding break pack goods transfer deck and interlevel transition autonomously guided break pack goods transport vehicle path at each level includes at least one interlevel detour and forming at least a two-dimensional matrix of autonomously guided break-pack merchandise vehicle detours including at least one intra-level detour route, whereby the at least one autonomously guided break-pack merchandise vehicle detours on-the-fly the at least one intra-level detour route; from the initial break pack goods container station designation, via at least one of an inter-level detour and at least one inter-level detour, on at least one of a level common to the initial container station designation and a different level. Detour Freely take a detour to the designated break pack product container station.

In accordance with one or more aspects of the disclosed embodiments, the corresponding break pack product transfer deck at each level is non-deterministic, and the at least one inter-level detour is non-deterministic, such that at least One autonomously guided break pack goods transport vehicle may freely transition between a corresponding break pack goods transfer deck and the at least one interlevel detour.

According to one or more aspects of the disclosed embodiments, the at least one interlevel detour is a ramp.

In accordance with one or more aspects of the disclosed embodiments, the at least one autonomously guided break pack goods transport vehicle includes at least one autonomously guided break pack goods transport vehicle longitudinally along the route and between levels. Wheel odometry, dead reckoning, distance measurement and detection of references with electromagnetic distance sensors or vision, distance measurement of references with 2D or 3D cameras, informing vehicle pose and positioning in both the Z direction, raising or lowering and sensing, alone or in combination, effecting posing and locating in the transition between the break pack goods transfer deck and the at least one interlevel detour. Provides a free transition of vehicle movement with a substantially constant speed of movement.

It is to be understood that the foregoing description is merely exemplary of aspects of the disclosed embodiments. Various alternatives and modifications may be contemplated by those skilled in the art without departing from the aspects of the disclosed embodiments. Accordingly, aspects of the disclosed embodiments are intended to cover all such alternatives, modifications, and variations that fall within the scope of any claims appended hereto. Furthermore, the mere fact that different features are recited in mutually different dependent or independent claims does not mean that a combination of these features cannot be used to advantage and that such a combination is not disclosed. This is not intended to imply that they remain within the scope of the described embodiments.

Claims (51)

A warehouse system for storing and taking out products in containers, the warehouse system comprising:
a multi-level container storage array, each level of the multi-level container storage array having a transport area and a storage area, the storage area including an array of storage shelves configured to hold containers; the transport area is substantially continuous and arranged to communicatively connect storage shelves of the array of storage shelves to each other; the transport area includes a picking aisle and a container connecting the picking aisle; a multi-level container storage array including a transfer deck;
at least one autonomously guided container transport vehicle separate from the container transfer deck, the at least one autonomously guided container transport vehicle being located at each level of the multi-level container storage array; one autonomous guided container transport vehicle passes through the container transfer deck and the picking aisle at each level and accesses to/from container storage locations on each of the storage shelves at each level of the multi-level container storage array; at least one autonomously guided container transport vehicle configured to transport containers to a break pack operation station;
a put wall with a plurality of levels of break pack merchandise container stations distributed along each level with a corresponding break pack merchandise transfer deck at each level of said put wall;
at least one autonomously guided break-pack goods transport vehicle, said at least one autonomously guided break-pack goods transport vehicle said at least one autonomously guided break-pack goods transport vehicle along said corresponding break-pack goods transfer deck and at different levels of said put wall. at least one autonomously guided break pack product configured to pass through and transport break pack products between corresponding break pack product transfer decks to each break pack product container station at each level of said put wall; A transport vehicle,
and configured to effect movement of the at least one autonomously guided container transport vehicle between break-pack merchandise containers located at the container storage location, the break-pack handling station, and the break-pack merchandise container station of the put wall. warehouse system, including a controller. The warehouse system of claim 1, wherein the put wall is different and separate from the multi-level container storage array. The warehouse system of claim 1 , wherein the at least one autonomously guided container transport vehicle is configured to transport supply goods containers and break pack goods containers, respectively. The break pack goods transfer deck at each level of the put wall is such that each put wall level has a separate and different break pack goods transfer deck from each container transfer deck coupled to the break pack handling station. 2. The warehouse system of claim 1, wherein each container transfer deck is separate and different. The break-pack product transfer deck is configured such that at least one autonomously guided break-pack product transfer vehicle moves over the break-pack product transfer deck for transport by the at least one autonomously guided container transfer vehicle on the container transfer deck. 2. The warehouse system of claim 1, wherein the warehouse system is configured to transport break-packed merchandise from the break-packed handling station to a corresponding break-packed merchandise container. The autonomously guided break pack goods transport vehicle has a payload support and transports the transported break pack goods unit payload thereon from the payload support to each break pack goods container at each level of the put wall. The warehouse system of claim 1, wherein the warehouse system is configured to output to the break pack merchandise container at a station. a common portion of the multi-level container storage array and the transfer area are communicatively connected to a plurality of put walls, each independent of one another, via one or more of the break pack handling stations;
each put wall is filled independently from each other put wall;
Each put wall results in the output of an independent break pack product container,
each put wall is accessed by the autonomous guided container transport vehicle, such that the output of the independent break pack goods containers of each put wall provides filled output break pack goods containers orthogonally to each other; The warehouse system of claim 1, wherein the warehouse system is independent of each other put wall. Each independent put wall has a different break pack merchandise container station, and each different break pack merchandise container station is independent of each other break pack merchandise container of each other independent put wall. and each filled break-pack product container is arranged to hold a different, each filled break-pack product container, such that each different filled break-pack product container defines an output of an independent break-pack product container of an independent put wall. The warehouse system according to claim 7. The warehouse system further comprises an intervening sorter positioned to communicatively couple the multi-level array transfer area and the break pack handling station, the intervening sorter including: and upstream of the break pack handling station, the warehouse system is configured to sort supply goods containers. Sorting of the supply goods containers by the intervening sorter upstream of the break pack operation station facilitates sequencing of the supply goods containers from a lower optimized order of goods to a higher optimized order. a predetermined sequence of supply goods containers input to said break pack operation station, and release of goods from said supply goods containers and said release from said break pack operation station for filling said put wall. 10. The warehouse system of claim 9, wherein the warehouse system provides for dispatch of at least one autonomously guided break pack goods transport vehicle. 10. The warehouse system of claim 9, wherein the intervening sorter upstream of the break pack handling station is configured to define a plurality of mutually orthogonal sorting axes. 12. The warehouse system of claim 11, wherein at least one sorting axis in one direction has parallel sorting axes. Traffic of the at least one autonomously guided break-pack goods transfer vehicle along the corresponding break-pack goods transfer deck and between the corresponding break-pack goods transfer deck of the put wall is controlled by the break-pack goods container at the put wall. conveying at each break-pack goods container station to each of said break-pack goods containers from a lower optimized order of goods to a higher optimized order, resulting in a predetermined order of filling of break-pack goods into 2. The warehouse system of claim 1, further defining a break-pack item sorter downstream of said break-pack handling station to facilitate sequencing of broken-pack items. 14. The warehouse system of claim 13, wherein the break-pack merchandise sorter downstream of the break-pack handling station is configured to define a plurality of mutually orthogonal sorting axes. 15. The warehouse system of claim 14, wherein at least one sorting axis in one direction has parallel sorting axes. A method for storing and retrieving goods in a container, the method comprising:
providing a multi-level container storage array, each level of the multi-level container storage array having a transport area and a storage area, the storage area being an array of storage shelves configured to hold containers; the transport area is substantially continuous and arranged to communicatively connect the storage shelves of the array of storage shelves to each other, the transport area connecting a picking path and the picking path. a process including a connecting container transfer deck;
transporting containers accessed to/from each container storage location of storage shelves at each level of said multi-level container storage array to a break pack operation station using at least one autonomous guided container transport vehicle; wherein the at least one autonomously guided container transport vehicle passes through the container transfer deck and the picking aisle at each level and is separate from the container transfer deck; at least one of the vehicles is located at each level of the multi-level container storage array;
providing a put wall with multiple levels of break pack merchandise container stations distributed along each level with corresponding break pack merchandise transfer decks at each level of the put wall;
At least one autonomously guided break-pack goods transfer vehicle is used to transport break-pack goods along said corresponding break-pack goods transfer decks and between corresponding break-pack goods transfer decks at different levels of said put wall. , conveying to each break pack product container station at each level of the put wall;
operation of the at least one autonomously guided container transport vehicle between break-pack merchandise containers located at the container storage location, the break-pack operating station, and the break-pack merchandise container station of the put wall using a controller; A method comprising: 17. The method of claim 16, wherein the put wall is different and separate from the multi-level container storage array. 17. The method of claim 16, wherein the at least one autonomously guided container transport vehicle transports a supply goods container and a break pack goods container, respectively. The break pack goods transfer deck at each level of the put wall is such that each put wall level has a separate and different break pack goods transfer deck from each container transfer deck coupled to the break pack handling station. 17. The method of claim 16, wherein each container transfer deck is separate and different. The break-pack product transfer deck is configured such that at least one autonomously guided break-pack product transfer vehicle moves over the break-pack product transfer deck for transport by the at least one autonomously guided container transfer vehicle on the container transfer deck. 17. The method of claim 16, wherein the method is configured to transport break-packed merchandise from the break-packed handling station to a corresponding break-packed merchandise container. The autonomously guided break pack goods transport vehicle has a payload support and transports the transported break pack goods unit payload thereon from the payload support to each break pack goods container at each level of the put wall. 17. The method of claim 16, wherein the method outputs to the break pack product container at a station. a common portion of the multi-level container storage array and the transfer area are communicatively connected to a plurality of put walls, each independent of one another, via one or more of the break pack handling stations;
each put wall is filled independently from each other put wall;
Each put wall results in the output of an independent break pack product container,
each put wall is accessed by the autonomous guided container transport vehicle, such that the output of the independent break pack goods containers of each put wall provides filled output break pack goods containers orthogonally to each other; 17. The method of claim 16, being independent of each other put wall. Each independent put wall has a different break pack merchandise container station, and each different break pack merchandise container station is independent of each other break pack merchandise container of each other independent put wall. and each filled break-pack product container is arranged to hold a different, each filled break-pack product container, such that each different filled break-pack product container defines an output of an independent break-pack product container of an independent put wall. 23. The method of claim 22. from the autonomously guided container transport vehicle and upstream of the break pack handling station using an intervening sorter arranged to communicatively couple the multi-level array transport area and the break pack handling station. 17. The method of claim 16, further comprising the step of sorting the merchandise containers. Sorting of the supply goods containers by the intervening sorter upstream of the break pack operation station facilitates sequencing of the supply goods containers from a lower optimized order of goods to a higher optimized order. a predetermined sequence of supply goods containers input to said break pack operation station, and release of goods from said supply goods containers and said release from said break pack operation station for filling said put wall. 25. The method of claim 24, resulting in the dispatch of at least one autonomously guided break pack goods transport vehicle. 25. The method of claim 24, wherein the intervening classifier upstream of the break pack manipulation station defines a plurality of mutually orthogonal classification axes. 27. The method of claim 26, wherein the at least one classification axis in one direction has parallel classification axes. Traffic of the at least one autonomously guided break-pack goods transfer vehicle along the corresponding break-pack goods transfer deck and between the corresponding break-pack goods transfer deck of the put wall is controlled by the break-pack goods container at the put wall. conveying at each break-pack goods container station to each of said break-pack goods containers from a lower optimized order of goods to a higher optimized order, resulting in a predetermined order of filling of break-pack goods into 17. The method of claim 16, further comprising defining a break-pack product sorter downstream of the break-pack handling station to facilitate sequencing of broken-pack products. 29. The method of claim 28, wherein the break-pack product sorter downstream of the break-pack handling station is configured to define a plurality of mutually orthogonal sorting axes. 30. The method of claim 29, wherein at least one classification axis in one direction has parallel classification axes. An automated order fulfillment system, the automated order fulfillment system comprising:
A multi-level break pack goods container filling array, each level having a container filling station area, the break pack goods container stations arranged along the container filling station area, and each level having a container filling station area; a multi-level break pack goods container filling array having corresponding break pack goods transfer decks juxtaposed along said break pack goods container stations of;
at least one autonomously guided break pack goods transport vehicle, wherein the at least one autonomously guided break pack goods transport vehicle includes at least one break pack goods transport vehicle for transport by the at least one autonomously guided break pack goods transport vehicle; the at least one autonomously guided break-pack goods transport vehicle comprising a payload support for holding packed goods units along the corresponding break-pack goods transfer deck and the multi-level break-pack goods container filling array; is configured to pass through and convey break-pack goods between corresponding break-pack goods transfer decks at different levels of the break-pack goods container station at each level, each break-pack goods container station being configured to transport break-pack goods between corresponding break-pack goods transfer decks at different levels of the at least one autonomously guided break pack goods transport vehicle, the at least one autonomously guided break pack goods transport vehicle being accessed by the one autonomous guided break pack goods transport vehicle and arranged to hold a break pack goods container filled with a predetermined break pack goods filling payload; Equipped with
Inter-level transition autonomously guided, in which a corresponding transfer deck at each level passes between said corresponding break pack goods transfer deck at each level and other break pack goods transfer decks corresponding to each other level. The at least one autonomously guided break pack product is communicatively joined by a break pack product transport vehicle path to other transfer decks corresponding to each other level of the multi-level break pack product container filling array. A transport vehicle transitions from the corresponding break pack goods transfer deck to each other break pack goods transfer deck corresponding to each other level via the interlevel transition autonomously guided break pack goods transport vehicle path. , transporting the predetermined break pack product filling payload loaded on the at least one autonomously guided break pack product transport vehicle on one level, and transporting the break pack product container at each break pack product container station on a different level. Automated order fulfillment system for filling. The corresponding break-pack product transfer deck and inter-level transition autonomously guided break-pack product transport vehicle path at each level includes at least one inter-level detour and at least one intra-level detour. forming at least a two-dimensional matrix of conveyance vehicle detours, whereby the at least one autonomously guided break-pack goods conveyance vehicle on the fly routes the at least one inter-level detour and the at least one inter-level detour; from the initial Break Pack Goods Container Station designation to a detour Break Pack Goods Container Station designation on at least one of a level common to the initial Container Station designation and a different level from the initial Break Pack Goods Container Station designation via at least one of 32. The automated order fulfillment system of claim 31. the corresponding break-pack goods transfer deck at each level is non-deterministic, and the at least one inter-level detour is non-deterministic, such that the at least one autonomously guided break-pack goods transport vehicle 33. The automated order fulfillment system of claim 32, wherein the automated order fulfillment system is freely transitionable between a corresponding break pack product transfer deck and the at least one interlevel detour. 33. The automated order fulfillment system of claim 32, wherein the at least one interlevel detour is a ramp. The at least one autonomously guided break pack goods transport vehicle is configured to pose a vehicle both longitudinally along the path and in the Z direction raising or lowering the at least one autonomously guided break pack goods transport vehicle between levels. At least one of wheel odometry, dead reckoning, distance measurement and detection of a reference by means of an electromagnetic distance sensor or vision, distance measurement and detection of a reference by means of a two-dimensional or three-dimensional camera, alone or in combination, to inform the position determination. , effecting posing and positioning of the vehicle at a substantially constant travel speed in the transition between the break pack goods transfer deck and the at least one interlevel detour path. 32. The automated order fulfillment system of claim 31, configured to provide free transition. The automated order fulfillment system includes:
a multi-level container storage array, each level of the multi-level container storage array having a transport area and a storage area, the storage area including an array of storage shelves configured to hold containers; the transport area is substantially continuous and arranged to communicatively connect storage shelves of the array of storage shelves to each other; the transport area includes a picking aisle and a container connecting the picking aisle; a multi-level container storage array including a transfer deck;
at least one autonomous guide configured to effect transport of containers through the container transfer deck and the picking aisle between the multilevel container storage array and the multilevel break pack goods container filling array; It is further equipped with a type container transport vehicle,
32. The automated order fulfillment system of claim 31, wherein the multi-level break pack merchandise container filling array is different and separate from the multi-level container storage array. 37. The automated order fulfillment system of claim 36, wherein the at least one autonomously guided container transport vehicle is configured to transport supply goods containers and break pack goods containers, respectively. The corresponding break-pack goods transfer decks at each level of the multi-level container storage array are configured such that each level of the multi-level container storage array has a separate and different break-pack goods transfer deck from each container transfer deck. 37. The automated order fulfillment system of claim 36, wherein: each container transfer deck is separate and different. The corresponding break-pack goods transfer deck is arranged such that the at least one autonomously-guided break-pack goods transport vehicle is configured to transport the break-pack goods on the corresponding break-pack goods transfer deck for transport by the at least one autonomously guided container transport vehicle on the container transfer deck. 37. The automated order fulfillment system of claim 36, wherein the automated order fulfillment system is configured to pass through a packed merchandise transfer deck and transport break packed merchandise from a break packed handling station to a corresponding break packed merchandise container. The automated order fulfillment system includes:
a break pack operating station;
an intervening classifier disposed upstream of the break pack handling station, the intervening classifier configured to classify supply goods containers inbound to the break pack handling station; 32. The automated order fulfillment system of claim 31, further comprising. Sorting of the supply goods containers by the intervening sorter upstream of the break pack operation station facilitates sequencing of the supply goods containers from a lower optimized order of goods to a higher optimized order. a predetermined sequence of supply goods containers input to said break pack operating station, and said breaks for releasing goods from said supply goods containers and filling said multi-level break pack goods container filling array; 41. The automated order fulfillment system of claim 40, wherein the automated order fulfillment system provides for dispatch of the at least one autonomously guided break pack goods transport vehicle from a pack handling station. 41. The automated order fulfillment system of claim 40, wherein the intervening sorter upstream of the break pack handling station is configured to define a plurality of mutually orthogonal sorting axes. 43. The automated order fulfillment system of claim 42, wherein the at least one sorting axis in one direction has parallel sorting axes. Traffic of the at least one autonomously guided break-pack goods transfer vehicle along the corresponding break-pack goods transfer decks and between corresponding break-pack goods transfer decks at different levels in the multi-level break-pack goods container filling array. Said break-packed goods at each break-packed goods container station from a lower optimized order of goods to an upper optimized order resulting in a predetermined order of filling of break-packed goods into said break-packed goods containers. 41. The automated order fulfillment system of claim 40, defining a break-pack item sorter downstream of said break-pack handling station to facilitate sequencing of break-pack items conveyed into each of the containers. 45. The automated order fulfillment system of claim 44, wherein the break-pack item sorter downstream of the break-pack handling station is configured to define a plurality of mutually orthogonal sorting axes. 46. The automated order fulfillment system of claim 45, wherein the at least one sorting axis in one direction has parallel sorting axes. A method for order fulfillment in an automated order fulfillment system, the method comprising:
providing a multi-level break pack goods container filling array, each level having a container filling station area, the break pack goods container stations being arranged along said container filling station area, and each level having said container filling station area; having a corresponding break-pack product transfer deck juxtaposed along said break-pack product container station in a filling station area;
using at least one autonomously guided break-pack goods transfer vehicle along said corresponding break-pack goods transfer decks and between corresponding break-pack goods transfer decks at different levels of said multi-level break-pack goods container filling array; traversing and transporting Break Pack merchandise to each Break Pack merchandise container station at each level, each Break Pack merchandise container station being accessed by the at least one autonomously guided Break Pack merchandise transport vehicle. , the at least one autonomously guided break pack goods transport vehicle being arranged to hold a break pack goods container filled with a predetermined break pack goods filling payload; having a payload support for holding at least one break-packed product unit for conveyance by the
Inter-level transition autonomously guided, in which a corresponding transfer deck at each level passes between said corresponding break pack goods transfer deck at each level and other break pack goods transfer decks corresponding to each other level. The at least one autonomously guided break pack product is communicatively joined by a break pack product transport vehicle path to other transfer decks corresponding to each other level of the multi-level break pack product container filling array. A transport vehicle transitions from the corresponding break pack goods transfer deck to each other break pack goods transfer deck corresponding to each other level via the interlevel transition autonomously guided break pack goods transport vehicle path. , transporting the predetermined break pack product filling payload loaded on the at least one autonomously guided break pack product transport vehicle on one level, and transporting the break pack product container at each break pack product container station on a different level. How to fill it. The corresponding break-pack product transfer deck and inter-level transition autonomously guided break-pack product transport vehicle path at each level includes at least one inter-level detour and at least one intra-level detour. forming at least a two-dimensional matrix of conveyance vehicle detours, whereby the at least one autonomously guided break-pack goods conveyance vehicle on the fly routes the at least one inter-level detour and the at least one inter-level detour; freely from an initial break-pack goods container station designation to a detour break-pack goods container station designation above at least one of a level common to said initial container station designation and a level different from said initial container station designation. 48. The method of claim 47, wherein the method is detoured. the corresponding break-pack goods transfer deck at each level is non-deterministic, and the at least one inter-level detour is non-deterministic, such that the at least one autonomously guided break-pack goods transport vehicle 50. The automated order fulfillment system of claim 48, wherein the automated order fulfillment system is freely transitionable between a corresponding break pack product transfer deck and the at least one interlevel detour. 49. The automated order fulfillment system of claim 48, wherein the at least one interlevel detour is a ramp. The at least one autonomously guided break pack goods transport vehicle is configured to pose a vehicle both longitudinally along the path and in the Z direction raising or lowering the at least one autonomously guided break pack goods transport vehicle between levels. At least one of wheel odometry, dead reckoning, distance measurement and detection of a reference by means of an electromagnetic distance sensor or vision, distance measurement and detection of a reference by means of a two-dimensional or three-dimensional camera, alone or in combination, to inform the position determination. , effecting posing and positioning of the vehicle at a substantially constant travel speed in the transition between the break pack goods transfer deck and the at least one interlevel detour path through one or more of the following: 48. The automated order fulfillment system of claim 47, which provides free transitions.

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