KR20230164727A - Warehouse system for storing and retrieving goods in containers - Google Patents

Abstract

The warehouse system includes a multi-level container storage array with a transfer area and a storage area at each level, and container transport vehicles located at each level to transport containers to container storage locations on each storage shelf at each level of the multi-level storage. Arranged at the breakpack operator station, corresponding to each level of the barrier. Footwall of the breakpack goods container station of one or more floors distributed along each level with a breakpack goods transfer deck, brakes for transporting breakpack goods along the corresponding breakpack goods. of container transport vehicles between the pack goods transfer vehicle goods transfer decks and the corresponding breakpack goods transfer decks at different levels of the wall, between each breakpack goods container station, container storage location, breakpack operator station and breakpack goods. The controller that executes the operation is the container located at the breakpack goods container station.

Description

Warehouse system for storing and retrieving goods in containers

This application is a continuation-in-part of U.S. Patent Application No. 17/358,383, filed June 25, 2021, which claims the benefit of U.S. Provisional Application No. 63/044,721, filed June 26, 2021, The entire disclosure is incorporated herein by reference. This application also claims the benefit of the non-provisional applications of U.S. Provisional Patent Application No. 63/170,282, filed on April 2, 2021, and U.S. Provisional Patent Application No. 63/171,465, filed on April 6, 2021. The entire contents are incorporated herein by reference.

The disclosed embodiments relate generally to material handling systems, and specifically to the transportation and storage of items within a material handling system.

It is well known that integrating automated storage and retrieval systems into the logistics chain, especially the goods-to-people system, is highly beneficial for the overall efficiency and cost of the logistics chain. Even if there is a high level of automated storage and retrieval system integration in logistics facilities, existing systems typically operate by storing product (e.g. supply) containers, which Includes cases, packs, etc. that contain products (also referred to as articles) in the form of products. Containers of goods may arrive by pallet or truck load (e.g., of conventional supply containers), and may be unpalleted or unloaded from trucks and stored in a logistics facility (e.g., a three-dimensional array of storage racks) through automated storage and retrieval systems. ) are stored in logistics facilities distributed throughout the storage space.

Particularly when mixed item containers are required (e.g., any given order container may have mixed/different items or item types held by a common container, such as when delivered directly to a consumer for fulfillment, or for retail orders). In the fulfillment of an order from a logistics facility (where the mix of ordered items in an order container is, at least in part, created at the logistics facility before being withdrawn from the logistics facility, unless delivered directly to the consumer, such as through a pick-up location, etc.); Typically, the creation of mixed commodity containers consists of one or more items of a common type, each of which is substantially the same or similar, from storage locations to manual or autonomous workstations across a three-dimensional array of storage racks. An automated storage and retrieval system is implemented to deliver goods to a given workstation according to a given fulfillment (or fill) order by an automated storage and retrieval system outputting goods/supply containers containing items, Picks up and removes pull items from different item/supply containers supplied by the retrieval system and also places other selected items (combined or common if included in a given order) into order containers. Such operator stations may be referred to as breakpack stations, where goods containers are "separated" and their contents are placed in whole or in part into order containers, or where goods containers continue to hold remaining product items after a breakpack operation, for example. In cases where it is inappropriate to do so, they may be placed in an order container, which may be referred to as a breakpack storage container (e.g., tote), and such remaining items (i.e., the remaining items contained in the “damaged” item container) may be stored in an automated storage container. and returned to storage in a three-dimensional array of storage racks by a retrieval system. To increase efficiency, order containers can be entered into a three-dimensional array of storage racks and, potentially, into storage positions in storage racks that store item containers until they are needed for order output, and can be placed in a three-dimensional array of storage racks. Both input and output from the dimensional array are carried out by an automated storage and retrieval system.

Typically, the breakpack station is located at a single common level (e.g., ground level or a level common to or close to the logistics facility fill load outlet) to execute the output of order containers filling orders from the breakpack station for release. Alternatively, or alternatively, transfer by the automated storage and retrieval system of goods containers between the storage location and the breakpack station and order containers and breakpack storage containers from the breakpack station to the storage location by the automated storage and retrieval system. The storage racks are distributed at various levels around or within a three-dimensional array of storage racks to perform input/re-input of them (collectively referred to herein as breakpack item containers). An example of an existing system and method for preparing storage devices at a picking station to fulfill orders is disclosed in U.S. Patent No. 9,988,212, issued June 5, 2018. U.S. Patent No. 9,988,212 discloses a method of ordering and/or placing an order to fulfill an order and/or making units of goods available in a storage facility in a desired order at a picking station. The storage facility includes a plurality of multi-tiered storage racks in which orders and/or product units are stored, shuttles to retrieve and store orders and/or product units, and lifts used to direct orders and/or product units to at least one storage-exit conveyor. and automated storage and retrieval equipment, each lift being connected directly to a picking station at the picking level by a bin-entry conveyor and a bin-outlet conveyor. Existing systems, such as those disclosed above, are limited to a limited exchange interface (substantially defined by the footprint of the breakpack station) between the supply container and the breakpack article container. This limits throughput through the pick-up station to that performed in the space required directly by the brakepack operator. This requires an improved system.

According to one or more aspects of the disclosed embodiments, a warehouse system for storing and retrieving items in containers is provided. The warehouse system is a multi-tier container storage array, each level of which has a transfer area and a storage area, the storage area comprising an array of storage shelves configured to support containers thereon, the transfer area being substantially continuous and the storage shelves a multi-tiered container storage array arranged to communicatively connect an array of storage shelves with one another, the transfer area comprising a picking aisle and a container transfer deck connecting the picking aisles; Distinguished from the container transfer deck, the containers that traverse the container transfer deck and the picking aisle at each level and are accessed to the breakpack workstation for each container storage location on the storage shelves at each level of the multi-tiered storage array are called breakpacks. at least one autonomously guided container transfer vehicle configured to transport to an operator station; At each level of the footwall, more than one level of breakpack article container stations distributed along each level with a corresponding breakpack article transfer deck; At least one device configured to traverse and transport breakpacks from each level of the footwall to the respective breakpack article container station, along the corresponding breakpack article transfer deck, and between the corresponding breakpack article transfer decks at different levels of the footwall. autonomously guided brakepack goods transport vehicle; and a controller configured to effect navigation of the at least one autonomously guided breakpack product transfer vehicle between the breakpack product containers located at container storage locations, a breakpack operator station, and a breakpack product container station on the footwall. .

In accordance with one or more aspects of the disclosed embodiment, the footwall is different and distinct from a multi-tier container storage array.

In accordance with one or more aspects of the disclosed embodiment, the at least one autonomous guided container transport vehicle is configured to transport a supply goods container and a breakpack goods container, respectively.

In accordance with one or more aspects of the disclosed embodiment, the breakpack product transfer deck at each level of the footwall includes a breakpack product transfer deck where each footwall level is separate and distinct from each container transfer deck coupled to a breakpack operator station. To have, it is separated and distinguished from each container transfer deck.

In accordance with one or more aspects of the disclosed embodiment, the breakpack product transfer deck includes at least one autonomously guided breakpack product transfer vehicle traversing the breakpack product transfer deck, and at least one autonomously guided container transport vehicle on the container transport deck. configured to transport a breakpack article for transport from a breakpack operator station to a corresponding breakpack article container.

In accordance with one or more aspects of the disclosed embodiment, the self-guided breakpack article transfer vehicle has a payload support and, from the payload support, a payload of breakpack article units carried thereon at each level of the footwall. It is configured to output to the breakpack product container at each breakpack product container station.

According to one or more aspects of the disclosed embodiment, the common portion and transfer area of the multi-tiered container storage array are communicatively coupled to one or more footwalls, via one or more breakpack operator stations, each footwall being connected to a respective other footwall. independent, each footwall is filled independently of each other footwall, each footwall performs an independent breakpack goods container output, each footwall is accessed by an autonomous guided container transport vehicle, and each footwall's independent The footwall article container discharges are independent of each other footwall to provide output breakpack article containers filled orthogonally to each other.

In accordance with one or more aspects of the disclosed embodiment, each independent footwall has a different breakpack article container station, each independent footwall having a different breakpack article container station each independently filled for each other breakpack article container of the respective other independent footwall. arranged to support a breakpack article container, whereby each other filled breakpack article container defines the release of an independent breakpack article container on an independent footwall.

In accordance with one or more aspects of the disclosed embodiment, the warehouse system further comprises an intervening sorter arranged to communicatively couple a multi-tier array transfer area and a breakpack operator station, the intervening sorter being configured to move from an autonomously guided container transport vehicle. , upstream of the breakpack operator station, configured to sort supply containers.

In accordance with one or more aspects of the disclosed embodiment, sorting of supply product containers by an intervening sorter upstream of the breakpack operator station includes ordering of supply product containers from a lower optimized order of the items to a higher optimized order, and breakpacks. Facilitating the execution of a predetermined sequence of supply container inputs to the operator station, disassembly of the supplies from the supply container, and dispatch of at least one autonomously guided breakpack material transfer vehicle from the breakpack operator station to fill the footwall. arranged to do so.

According to one or more aspects of the disclosed embodiment, an intervening sorter upstream of the brakepack operator station is configured to define a plurality of sorting axes orthogonal to each other.

According to one or more aspects of the disclosed embodiment, at least one sorting axis in one direction has a parallel sorting axis.

In accordance with one or more aspects of the disclosed embodiment, the at least one autonomously guided breakpack article transport vehicle traverses along a corresponding brakepack article transfer deck and between corresponding brakepack article transfer decks of the footwall, transporting a brakepack article to the footwall. A breakpack worker who facilitates the ordering of breakpack articles transported to each breakpack article container at each breakpack article container station from the lower optimized order of articles to the higher order, carrying out the prescribed order of filling the breakpack article containers of A brake pack sorter is provided downstream of the station.

In accordance with one or more aspects of the disclosed embodiment, a breakpack article sorter downstream of a breakpack operator station is configured to define a plurality of sorting axes orthogonal to each other.

According to one or more aspects of the disclosed embodiment, at least one sorting axis in one direction has a parallel sorting axis.

In accordance with one or more aspects of the disclosed embodiment, a method for storing and retrieving items in a container is provided. The method includes providing a multi-tiered container storage array, each level of which has a transfer area and a storage area, the storage area comprising an array of storage shelves configured to support containers thereon, the transfer area being substantially continuous. and are arranged to communicatively connect the storage shelves of the array of storage shelves with each other, the transfer area comprising a picking aisle and a container transfer deck connecting the picking aisles; transporting containers, by at least one autonomously guided container transport vehicle, to and from each container storage location of storage shelves at each level of the multi-tiered storage array to and from a breakpack workstation, the container transport deck and each at least one autonomously guided container transport vehicle traversing a level's picking aisle distinct from the container transfer deck, wherein at least one of the at least one autonomously guided container transport vehicles is located at each level of the multi-level storage array; providing, at each level of the footwall, more than one level of breakpack article container stations distributed along each level with corresponding breakpack article transfer decks; Each breakpack article at each level of the footwall, by means of at least one autonomously guided container transport vehicle, along the corresponding breakpack article transfer deck and between the corresponding breakpack article transfer decks at different levels of the footwall. Transferring the brake pack to the container station; and effecting, by a controller, navigation of said at least one autonomously guided breakpack product transfer vehicle between breakpack product containers located at container storage locations, a breakpack operator station, and a breakpack product container station on a footwall. do.

In accordance with one or more aspects of the disclosed embodiment, the footwall is different and distinct from a multi-tier container storage array.

According to one or more aspects of the disclosed embodiment, the at least one autonomous guided container transport vehicle transports a supply goods container and a breakpack goods container, respectively.

In accordance with one or more aspects of the disclosed embodiment, the breakpack article transfer deck at each level of the footwall is separate and distinct from each container transfer deck where each footwall level is coupled to a breakpack article operator station.

In accordance with one or more aspects of the disclosed embodiment, the breakpack goods transfer deck includes at least one autonomously guided breakpack goods transfer vehicle traversing the breakpack goods transfer deck, and at least one autonomously guided container transport vehicle on the container transfer deck. and is configured to transport a breakpack article from a breakpack operator station to a corresponding breakpack article container for transport by.

According to one or more aspects of the disclosed embodiment, an autonomously guided breakpack article transport vehicle has a payload support, from which the payload support carries a breakpack article unit payload to each brakepack article unit at each level of the footwall. Print to the break pack product container at the product container station.

According to one or more aspects of the disclosed embodiment, the common portion and transfer area of the multi-tiered container storage array are communicatively coupled to one or more footwalls, through one or more of the breakpack operator stations, each footwall being connected to a respective other footwall. independent of each other, each footwall is filled independently of each other, each footwall performs an independent breakpack goods container discharge, each footwall is accessed by an autonomously guided container transport vehicle, and each footwall's independent breakpack goods The container release is independent of each other footwall to provide output breakpack article containers filled orthogonally to each other.

According to one or more aspects of the disclosed embodiment, each independent footwall has a different breakpack article container station, each is arranged to support a different breakpack article container, and each of the different independent footwalls has a different breakpack article container station. are filled independently with respect to other independent breakpack product containers, such that each different filled breakpack product container defines the release of an independent breakpack product container from an independent footwall.

According to one or more aspects of the disclosed embodiment, a supply goods container upstream of a breakpack operator station from an autonomously guided container transport vehicle using an intervening sorter arranged to communicatively couple the multi-layer array transfer area and the breakpack operator station. It further includes a classification step.

According to one or more aspects of the disclosed embodiment, the sorting of the supply product containers by an intervening sorter upstream of the breakpack operator station comprises: ranking the supply product containers from a lower optimization order of the articles to a higher optimization order; arranged to facilitate dispatch of at least one autonomously guided breakpack material transfer vehicle from the breakpack operator station to perform a predetermined sequence of supply container inputs, dismantle materials from the supply container, and fill the footwall.

In accordance with one or more aspects of the disclosed embodiment, an intervening sorter upstream of the brakepack operator station defines a plurality of sorting axes orthogonal to each other.

According to one or more aspects of the disclosed embodiment, at least one sorting axis in one direction has a parallel sorting axis.

In accordance with one or more aspects of the disclosed embodiment, the at least one autonomously guided breakpack article transport vehicle traverses along a corresponding brakepack article transfer deck and between corresponding brakepack article transfer decks of the footwall, transporting a brakepack article to the footwall. A breakpack that facilitates the ordering of breakpack articles transported to each breakpack article container at each breakpack article container station from a lower optimized order of articles to a higher optimized order, implementing a predetermined order of filling the breakpack article containers. Provide a brake pack sorter downstream of the operator station.

In accordance with one or more aspects of the disclosed embodiment, a breakpack article sorter downstream of a breakpack operator station is configured to define a plurality of sorting axes orthogonal to each other.

According to one or more aspects of the disclosed embodiment, at least one sorting axis in one direction has a parallel sorting axis.

According to one or more aspects of the disclosed embodiment, an automated order fulfillment system is provided, the system comprising: breakpack product container stations arranged along a container fill station area, each level having a container fill station area. a multi-layer breakpack article container filling array having a corresponding breakpack article transfer deck juxtaposed along the breakpack container station in the container filling station area; and a payload support for supporting at least one breakpack article unit for transport by the at least one autonomously guided breakpack article transfer vehicle, said at least one autonomously guided brakepack article transfer vehicle. Guided breakpack product transfer vehicles are directed to each breakpack product container at each level along the corresponding breakpack product transfer deck and between corresponding breakpack product transfer decks at different levels of the multi-level breakpack product container filling array. stations, configured to traverse and transport breakpack goods, each breakpack goods container station being approached by and filled by at least one autonomously guided breakpack goods transfer vehicle with a predetermined breakpack goods filling payload. At least one autonomously guided breakpack product transfer vehicle arranged to support a breakpack product container, wherein the corresponding transfer deck at each level has a corresponding breakpack product transfer deck at each level and at each other level. communicatively connected to other transfer decks corresponding to each different level of the multi-level breakpack goods container filling array by means of an autonomously guided breakpack goods transport vehicle path for inter-level movement traversing between corresponding different breakpack goods transfer decks; At least one autonomously guided breakpack goods transport vehicle moves between levels from a corresponding brakepack goods transfer deck to each other brakepack goods transfer deck corresponding to each different level via an autonomously guided breakpack goods transfer path, transporting a predetermined load of breakpack goods loaded on at least one autonomously guided breakpack goods transport vehicle at one level, and transporting a breakpack goods container at each breakpack goods container station at another level. Make sure to fill it.

According to one or more aspects of the disclosed embodiment, the corresponding breakpack product transfer deck at each level and the interlevel moving autonomously guided breakpack product transfer path include at least one interlevel detour path and at least one intralevel ( forming at least a two-dimensional matrix of self-guided breakpack goods transfer vehicle detour routes including (intralevel) detour routes, whereby at least one autonomously guided breakpack goods transfer vehicle is configured to: from an initial breakpack container station destination to an initial container station destination; Detours in at least one of the common level and other levels are freely detoured to the breakpack product container station destination via at least one of at least one inter-level detour route and at least one intra-level detour route.

According to one or more aspects of the disclosed embodiment, the corresponding breakpack goods transfer deck at each level is non-deterministic and at least one inter-level detour route is non-deterministic, such that at least one autonomously guided breakpack goods transfer vehicle comprises: Allows free switching between the corresponding breakpack goods transfer deck and at least one inter-level bypass route (or vice versa).

According to one or more aspects of the disclosed embodiment, at least one inter-level detour path is a ramp.

According to one or more aspects of the disclosed embodiment, at least one autonomously guided breakpack goods transport vehicle, alone or in combination, uses two-dimensional or three-dimensional cameras, wheel odometry, dead reckoning, electromagnetic distance sensors, or Perform attitude determination and localization through at least one of distance measurement and reference point detection using vision, and raise or lower the at least one autonomously guided brakepack goods transport vehicle between levels in the Z direction and longitudinal direction. announces vehicle attitude and localization all along the route and performs free transitions of vehicle movement between the breakpack goods transfer deck and at least one inter-level detour (or vice versa), with a movement rate that is substantially constant in the transition; do.

In accordance with one or more aspects of the disclosed embodiment, the automated order fulfillment system comprises a multi-tiered container storage array, each level having a transfer area and a storage area, the storage area being an array of storage shelves configured to support containers thereon. wherein the transfer area is substantially continuous and arranged to communicatively connect storage shelves of the array of storage shelves with each other, the transfer area comprising a picking aisle and a container transfer deck connecting the picking aisles. storage array; and at least one self-guided container transfer vehicle configured to traverse the container transfer deck and the picking aisle, to perform transfer of containers between the multi-level storage array and the multi-level breakpack article container filling array, wherein the multi-level breakpack Article container filling arrays are different and distinct from multi-tier container storage arrays.

According to one or more aspects of the disclosed embodiment, the at least one autonomous guided container transport vehicle is configured to transport a supply goods container and a breakpack goods container, respectively.

In accordance with one or more aspects of the disclosed embodiment, a corresponding breakpack article transfer deck at each level of the multi-tier container storage array is separate and distinct from each container transfer deck, such that each level of the multi-tier container storage array is separate from each container transfer deck. and have a distinct brake pack with a material transfer deck.

In accordance with one or more aspects of the disclosed embodiment, a corresponding breakpack goods transfer deck is configured to have at least one autonomous guided breakpack goods transfer vehicle traversing the corresponding breakpack goods transfer deck, and at least one autonomous guided brakepack goods transport deck on the container transfer deck. It is configured to transport breakpack articles from a breakpack operator station to a corresponding breakpack article container for transportation by a guiding container transport vehicle.

In accordance with one or more aspects of the disclosed embodiment, the automated order fulfillment system includes: a breakpack operator station; and an intervening sorter disposed upstream of the breakpack operator station and configured to sort supply product containers entering the breakpack operator station.

In accordance with one or more aspects of the disclosed embodiment, sorting of supply product containers by an intervening sorter upstream of the breakpack operator station includes ordering of supply product containers from a lower optimized order of the items to a higher optimized order, and breakpacks. Executing a predetermined sequence of supply item containers input to the operator station, disassembly of items from the supply item container, and autonomously guiding at least one breakpack item from the breakpack operator station to fill the multi-layer breakpack item container filling array. It is arranged to facilitate dispatch of transport vehicles.

According to one or more aspects of the disclosed embodiment, an intervening sorter upstream of the brakepack operator station is configured to define a plurality of sorting axes orthogonal to each other.

According to one or more aspects of the disclosed embodiment, at least one sorting axis in one direction has a parallel sorting axis.

According to one or more aspects of the disclosed embodiment, the at least one autonomously guided breakpack goods transport vehicle traverses along a corresponding breakpack goods transfer deck and between corresponding brakepack goods transfer decks of different levels, of the breakpack articles transported to each breakpack article container at each breakpack article container station in order from the lower optimization order of the articles to the higher optimization order, carrying out a predetermined order of filling the breakpack article containers of the multi-layer breakpack article containers. Provide a breakpack item sorter downstream of the breakpack operator station to facilitate ordering.

In accordance with one or more aspects of the disclosed embodiment, a breakpack article sorter downstream of a breakpack operator station is configured to define a plurality of sorting axes orthogonal to each other.

According to one or more aspects of the disclosed embodiment, at least one sorting axis in one direction has a parallel sorting axis.

In accordance with one or more aspects of the disclosed embodiment, a method of order fulfillment in an automated order fulfillment system is provided. The method includes providing a multi-level breakpack article container filling array, each level having a container filling station zone, with breakpack article container stations disposed along the container filling station zone, having a corresponding breakpack article transfer deck juxtaposed along the breakpack container station; and by at least one autonomously guided breakpack article transport vehicle, along the corresponding breakpack article transfer deck and between corresponding breakpack article transfer decks at different levels of the multi-level breakpack article container filling array, at each level. traversing and transferring to each breakpack article container station, wherein each breakpack article container station is approached by and filled by at least one autonomously guided breakpack article transport vehicle with a predetermined breakpack article filling payload. is arranged to hold the breakpack goods container, wherein the at least one autonomously guided breakpack goods transport vehicle has a platform for supporting at least one breakpack goods unit for transport by the at least one autonomously guided breakpack goods transport vehicle. having a load support; and a corresponding breakpack article transfer deck at each level, between the corresponding breakpack article transfer deck at each level and the other breakpack article transfer deck corresponding to each different level. is communicatively connected to another transfer deck corresponding to each different level of the multi-level breakpack goods container filling array by an autonomously guided breakpack goods transport vehicle path traversing between levels, and is configured to transport at least one autonomously guided breakpack goods. allowing the vehicle to move through an inter-level autonomously guided brakepack goods transfer path from the corresponding brakepack goods transfer deck to each of the other brakepack goods transfer decks corresponding to each different level, and further: transporting a predetermined load of breakpack product filling loaded on at least one autonomously guided breakpack product transport vehicle and filling breakpack product containers at each breakpack product container station at a different level.

According to one or more aspects of the disclosed embodiment, a corresponding breakpack article transfer deck at each level and an interlevel moving autonomously guided breakpack article transfer path may include at least one interlevel detour path and at least one intralevel detour route. (intralevel) forming at least a two-dimensional matrix of autonomously guided breakpack goods transfer vehicle detour routes including detour routes, wherein at least one autonomously guided breakpack goods transfer vehicle moves from an initial breakpack container station destination to an initial container station destination. As such, the detour in at least one of the common level and the other level can be freely detoured to the breakpack product container station destination through at least one of at least one inter-level detour and at least one intra-level detour.

According to one or more aspects of the disclosed embodiment, the corresponding breakpack goods transfer deck at each level is non-deterministic and at least one inter-level detour route is non-deterministic, such that at least one autonomously guided breakpack goods transfer vehicle comprises: Allows free switching between the corresponding breakpack goods transfer deck and at least one inter-level bypass route (or vice versa).

According to one or more aspects of the disclosed embodiment, the at least one inter-level detour path is a ramp.

According to one or more aspects of the disclosed embodiment, at least one autonomously guided breakpack goods transport vehicle, alone or in combination, uses two-dimensional or three-dimensional cameras, wheel odometry, dead reckoning, electromagnetic distance sensors, or Perform attitude determination and localization through at least one of distance measurement and reference point detection using vision, and raise or lower the at least one autonomously guided brakepack goods transport vehicle between levels in the Z direction and longitudinal direction. announces vehicle attitude and localization all along the route and performs free transitions of vehicle movement between the breakpack goods transfer deck and at least one inter-level detour (or vice versa), with a movement rate that is substantially constant in the transition; do.

The foregoing aspects and other features of the disclosed embodiment are described below with reference to the accompanying drawings.
1A, 1B, and 1C are schematic diagrams of automated storage and retrieval systems in accordance with aspects of the disclosed embodiments.
1D is a schematic diagram of a mixed pallet load formed by an automated storage and retrieval system in accordance with aspects of the disclosed embodiments.
1E is a schematic diagram of an automated storage and retrieval system according to aspects of the disclosed embodiments.
2 is a schematic perspective view of a breakpack article module of the automated storage and retrieval system of FIGS. 1A, 1B, 1C, and 1E in accordance with aspects of the disclosed embodiment. ;
3A and 3B are schematic perspective and side views, respectively, of a portion of the brake pack article module of FIG. 2 according to aspects of the disclosed embodiments.
FIG. 4 is a schematic perspective view of a portion of the breakpack article module of FIG. 2 according to aspects of the disclosed embodiments.
5A, 5B, and 5C are schematic perspective views of a portion of the breakpack article module of FIG. 2 according to aspects of the disclosed embodiments.
6A, 6B, 6C, 6D, and 6E are schematic perspective views of a portion of the breakpack article module of FIG. 2 according to aspects of the disclosed embodiments.
7A, 7B, 7C, and 7D are schematic perspective views of a portion of the breakpack article module of FIG. 2 according to aspects of the disclosed embodiments.
8A and 8B are schematic perspective views of an operator station of the breakpack article module of FIG. 2 in accordance with aspects of the disclosed embodiments.
FIG. 9 is an exemplary flowchart of a method of operating a breakpack of the breakpack article module of FIG. 2 in accordance with aspects of the disclosed embodiments.
9A is a schematic diagram of breakpack article transport according to aspects of the disclosed embodiments.
9B is an example flow diagram of a method of operating a brake pack according to aspects of the disclosed embodiments.
FIG. 10 is an exemplary schematic perspective view of a Breakpack article bot guidance/removal system of the Breakpack article module of FIG. 2 in accordance with aspects of the disclosed embodiments.
FIG. 11 is an example flow diagram of a method of operating the breakpack article bot inducement/removal system of FIG. 10 in accordance with aspects of the disclosed embodiments.
12A, 12B, and 12C schematically illustrate a portion of the automated storage and retrieval system of FIGS. 1A, 1B, 1C, and 1E in accordance with aspects of the disclosed embodiment.
13A is a schematic diagram of a transportation vehicle according to aspects of the disclosed embodiments.
13B is a schematic diagram of a transportation vehicle according to aspects of the disclosed embodiments.
14 is a diagram schematically illustrating a portion of the storage and retrieval system of FIGS. 1A, 1B, 1C, and 1E in accordance with aspects of the disclosed embodiment. ;
15A and 15B schematically illustrate a portion of the storage and retrieval system of FIGS. 1A, 1B, 1C and 1E according to aspects of the disclosed embodiment.
Figure 16 schematically illustrates a portion of the storage and retrieval system of Figures 1A, 1B, 1C and 1E in accordance with aspects of the disclosed embodiment.
Figures 17A-17F schematically illustrate a portion of the transportation vehicle of Figures 13A, 13B according to aspects of the disclosed embodiment.
18 and 19 are exemplary flow diagrams according to aspects of the disclosed embodiments.
FIG. 20A is a schematic plan view of a portion of the breakpack article module of FIG. 2 according to aspects of the disclosed embodiments.
20B and 20C are schematic side illustrations of a portion of the brake pack article module of FIG. 2 according to aspects of the disclosed embodiments.
Figure 21 is a schematic diagram of a non-holonomic article bot with an asymmetric payload holding configuration in accordance with aspects of the disclosed embodiment.
Figure 22 is a schematic diagram of a non-holonomic article bot with a symmetric payload holding configuration in accordance with aspects of the disclosed embodiment.
Figure 23 is a schematic diagram of a holonomic article bot with an asymmetric payload holding configuration in accordance with aspects of the disclosed embodiment.
Figure 24 is a schematic diagram of a holonomic article bot with a symmetric payload holding configuration in accordance with aspects of the disclosed embodiment.
Figure 25 is a schematic diagram of an example portion of an article deck according to aspects of the disclosed embodiments.
Figure 26 is an example flow chart according to aspects of the disclosed embodiment.
Figure 27 is an example flow diagram in accordance with aspects of the disclosed embodiment.
FIG. 28 is a schematic block diagram of an orthogonal sorting echelon of the automated storage and retrieval system of FIGS. 1A and 1B in accordance with aspects of the disclosed embodiment.
Figures 29A-29E are illustrative diagrams illustrating example classification performed with the orthogonal classification echelon of Figure 28.
30A is a schematic diagram showing the structural configuration of an orthogonal sorting echelon of an automated storage and retrieval system and a controller structure of an automated storage and retrieval system according to aspects of the disclosed embodiments.
30B is an example flow diagram according to aspects of the disclosed embodiment.
31 schematically illustrates a portion of a storage and retrieval system according to aspects of the disclosed embodiments.

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 embodiment will be described with reference to the drawings, it should be understood that the aspects of the disclosed embodiment may be implemented in various forms. Additionally, elements or materials of any suitable size, shape or form may be used.

As disclosed herein, aspects of the disclosed embodiments provide an automated storage and retrieval system 100 that includes at least one breakpack module 266 (also referred to herein as an automated order fulfillment system). At least one breakpack module 266 is configured to support a plurality of breakpack stations (stacked, vertically distributed, or Offset) and an autonomous article bot 262 that traverses the levels. Module 266 is traversed by article bot 262 to select breakpack articles (BPGs) from operator stations 801 - 804 and to place footwalls 263W (e.g., at multiple vertical placement levels of container articles). ) (also referred to herein as a multi-tier breakpack article container filling array) places the breakpack article (BPG) in the breakpack article container 264 and returns the article bot 262 to the operator station 801-804. . Placing items at multiple vertical levels at a common or more than one common operator (breakpack) station 801-804 may allow for one or more breakpack item containers (e.g., to increase the number of locations where containers can be used), if desired (e.g. 264) increases the throughput of placing items in a container according to a predetermined/desired time and a predetermined placement order, regardless of whether it is blocked or not. Each breakpack module 266 has a separate/independent flow or stream of containers into, through, and out of the breakpack module 266. Container bot 110 and article bot 262 may be operated by a suitable controller (such as controller 120) to direct the flow of containers within automated storage and retrieval system 100, e.g. To eliminate this phenomenon, each (or more than one) breakpack module 266 may be grouped between different footwalls 236W of the breakpack modules 266 (to provide another appropriate balance of container transport). . As disclosed herein, the breakpack module 266 may be configured to store multiple components of the storage structure 130 such that the container bot 110 and/or the item bot 262 may be operated by an appropriate controller (e.g., controller 120). levels 130L, thereby providing substantially the same output rate from each (or two or more) breakpack modules 266 (e.g., eliminating any container shipping bottlenecks) , providing substantially equal output rates from each (or more than one) storage level 130L, or providing another appropriate balance of container transfers), the flow of containers within the automated storage and retrieval system 100 is directed to the storage level 130L. ) is balanced across

The operations of item bot 262 are autonomous operations under the control of any suitable controller, such as controller 120, wherein the tasks performed by item bot 262 may be performed at any time during any of the item bot tasks (as disclosed herein). ) can be reallocated on the fly. Controller 120 may also use article bots 262 to place breakpack articles (BPGs) (as described herein) into one or more breakpack article containers 264 to produce one or more breakpack articles 264 ) is configured such that placement of the breakpack articles (BPG) within the breakpack article (BPG) occurs in any suitable predetermined sequence or sorting/ordering echelon as described herein. Aspects of the disclosed embodiments also provide article bot 262 access to one or more portions of the brake pack module 266, for example, to effectuate human access to an enclosed portion of the brake pack module 266. Provided to close/restrict.

According to aspects of the disclosed embodiments, automated storage and retrieval system 100 is disclosed, for example, in U.S. Patent No. 10,822,168, issued November 3, 2020, the disclosure of which is incorporated herein by reference in its entirety. It may operate in a distribution center or warehouse to fulfill orders received from different customers for breakpack goods (BPG) and/or case units (as disclosed herein).

For example, a case unit is a case or unit of items that are not stored in (e.g., contained within) a tray, tote, or pallet. In another example, the case unit may be stored in any suitable manner, such as in a tray, tote, container (e.g., a container for items remaining after breakpack where the disassembled case unit structure is not suitable for transportation of the remaining items as a unit) or pallet. It is a case or unit of the contained goods. In another example, a case unit is a combination of non-included and included items. For example, a case unit includes a cased unit of article (e.g., soup can case, cereal box, etc.) or an individual article that can be removed from or placed on a pallet. According to aspects of the disclosed embodiments, a shipping case for a case unit (e.g., a box, bin, box, box, jug, or other suitable device for storing the case unit) can be of various sizes and be used to retain the case unit during shipping. It can also be palletized for shipping.

For example, when a bundle or pallet of case units reaches the storage and retrieval system 100, the contents of each pallet may be uniform (e.g., each pallet retains a predetermined number of identical items - one one pallet holds soup and another pallet holds cereal), when the pallets leave the storage and retrieval system, e.g., to form a mixed pallet (at least one container bot 110 and lift module 150B) Any suitable number of different case units provided with a palletizer in the sorting station (performed by at least a pallet output sorting (185) echelon) of the automated storage and retrieval system (100) transporting the case units for sorting. Combinations thereof may be included (e.g., mixed pallets where each mixed pallet holds a case unit of various types - the pallets hold a combination of soups and cereals). In aspects of the disclosed embodiments, the storage and retrieval system 100 disclosed herein can be applied to any environment in which case units are stored and retrieved.

According to aspects of the disclosed embodiments, automated storage and retrieval system 100 may be configured to store goods containers or cases (which may be generally referred to as supply goods containers or supply containers 265) for order fulfillment, as described further herein. and one or more breakpack modules 266 (see FIG. 2) configured to disassemble the units into breakpack article containers 264. One or more breakpack modules 266 may be communicatively coupled to one or more stacked (storage) levels 130L of the automated storage and retrieval system 100 . One or more levels 130L may include at least one break module 266. The break modules 266 may be plug-and-play modules that can be coupled to any suitable part of the automated storage and retrieval system 100 structure. For example, the breakpack module(s) may be coupled to a container transfer deck 130DC (see also container transfer deck 130DC2 in FIG. 1B), or an automated storage and retrieval system as described in more detail below. Pick (or peak) the passage(s) 130A of 100. The breakpack module(s) 266 may be placed in any suitable number of stacked storage levels of the automated storage and retrieval system 100.

Here, automated storage and retrieval system 100 may be configured via any suitable controller (e.g., control server 120) to cause automated storage and retrieval system 100 to have selectable operating modes. can do. The control server 120 may operate the automated storage and retrieval system 100 in various operating modes such that the pick face and breakpack article containers 264 (e.g., of the supply container 265) are configured as disclosed herein. Likewise transported to the load filling section of the automated storage and retrieval system 100 for sorting through one or more pick faces (e.g., of supply containers 265) and one or more orthogonal sort echelons 15000, 15100, 15200, as described below. The load is filled with the breakpack product container 264 having the loaded product. In one mode of operation, automated storage and retrieval system 100 is configured to output product cases, containers, and/or units to a palletizer. In other modes of operation, such as when breakpack module(s) 266 are used, automated storage and retrieval system 100 may disassemble product cases, article containers, and/or case units and breakpack article containers, product cases, etc. , sending the containers and/or case units to a palletizer, or in another aspect, breakpack (order) containers and/or remaining product cases, containers and/or case units to storage (e.g., disassembled) for later retrieval. (After the palletizer is finished), send it back to the palletizer.

As may be implemented, controller 120 is configured to perform operations of automated storage and retrieval system 100 disclosed herein. For example, the controller 120 may be configured to operate at least one container bot or autonomously guided container transport vehicle 110 (see also FIG. 5A ) and at least one item bot or autonomously guided breakpack item transport vehicle 262 (also see FIG. 5A ). For example, see FIG. 6B), as well as assembling orders of breakpack articles (BPG) from supply container 265 (see FIG. 5A) to breakpack article container 264 (see FIG. 3A), as well as a container discharge station, described below. configured to perform operation of any of the lifts 310A, 310B, 310A', 310B' described above and other components for discharging the breakpack article container 264 through (TS). For example, the controller 120 may operate on a container storage location 130S, a breakpack operator station 140, and a breakpack article transfer deck or article deck 130DG (e.g., footwall 263W as described herein). ) configured to execute operations of container bot(s) 110 between breakpack article containers 264 located along breakpack article containers 64 located at the breakpack article interface station/container station 263L. As another example, the controller 120 may configure the transport of a breakpack article (BPG) (see FIG. 7B) across the article transfer deck 130DG by the article bot 262 (e.g., as described herein). As described, the breakpack order sorting section 188 of the automated storage and retrieval system 100 is configured to sort breakpack articles (BPGs) (in echelon) into corresponding breakpack article containers 264. As a further example. , the controller 120 allows the container bot(s) 110 (to at least partially perform the breakpack output sorter 189 echelon as disclosed herein) from the footwall 263W to the goods transfer deck ( accessing a corresponding breakpack article container 264 at 130DG) and at least one of a container release/transfer station TS and a corresponding container storage location 130SB of the storage shelves of a corresponding level 130L of the multi-tiered storage array. It is configured to perform operations of the container bot(s) 110 to transport the breakpack article container 264 through a traverse along the container transfer deck 130DC.

Controller 120 also executes operation of container bot(s) 110 and lift 150 (e.g., to form a container supply system) to provide automated storage and storage of empty breakpack article containers 264. Configured for introduction into a retrieval system, the container bot(s) 110 brake along the transport/travel loop 233BP of the container transfer deck(s) 130DC and into an empty breakpack article container 264. Transfer empty breakpack article containers 264 into the breakpack module for placement at the breakpack article interface location(s) 263L of the breakpack article interface 263 for transfer of pack article (BPG), which A method similar to that disclosed in U.S. Provisional Patent Application No. 63/044,721, filed June 26, 2020, and U.S. General Patent Application No. 17/358,383, filed June 25, 2021 (both entitled “Goods in Containers”) "a warehouse system for storing and retrieving", the disclosure of which is incorporated herein by reference in its entirety).

Breakpack article interface 263 may be substantially similar to one or more of the transfer station (TS) and buffer station (BS) described herein, and may have a A deterministic interface (or alternatively, a non-deterministic surface (described herein) on which the breakpack article is positioned to form a container bot movement surface(s) 266RS that forms part of or is communicatively coupled to the container transfer deck 130DC (similar to the surface of the rack storage space 130S). In another aspect, the empty breakpack item container 264 is transported (in a manner similar to that discussed above for lifts and container bots). It can be stored in the storage space (130SB, 130S (FIG. 1B)) of the rack module (RM) or recharged at the infeed station, and the controller 120 stores the storage space (130SB, 130S) in a similar manner as disclosed above. or transfer the empty breakpack product container 264 from the buffer location to the breakpack product interface 263.

In one or more aspects, the controller 120 stores empty supply containers 265 (disclosed herein) or standardized containers into an automated storage and retrieval system. configured to effectuate the operation of container bot(s) 110 and lift 150 (e.g., forming a container supply system) to introduce (e.g., forming a container feeding system) U.S. Provisional Patent Application filed June 26, 2020 No. 63/044,721 and U.S. General Patent Application No. 17/358,383, filed June 25, 2021, both entitled "Warehouse System for Storing and Retrieving Items in Containers"; their disclosures previously incorporated herein by reference in their entirety), according to which container bot(s) 110 may transport empty supply containers 265 or standardized containers 265S to the container transfer deck ( The brake pack is transferred to the brake pack operator station 140 along the transfer/movement loops 233 and 233A of the brake pack (130DC).

As may be realized, the container bot 110, item bot 262, lift module 150, breakpack module 266, and other suitable functional parts of the storage and retrieval system 100 disclosed herein include, for example, For example, any suitable room is controlled by one or more central system control computers (e.g., control servers) 120 over any suitable network 180 to carry out the operations disclosed 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, the control server 120 is a program (e.g., non-transitory computer program code/system management software) that executes substantially simultaneously for substantially autonomous control of the automated storage and retrieval system 100 described herein. Includes a set of For example, a set of programs that run substantially simultaneously may, for illustrative purposes only, control, schedule, and monitor the activities of all active system components, manage inventory (e.g., input and removal of any case unit, order of removal and where case units are stored), pick face (one or more case units that operate and are processed as a unit by components of the storage and retrieval system 100), and a warehouse management system (2500). ) may be configured to manage the storage and retrieval system 100, including interfacing with. In one aspect, the control server 120 may be configured to control the functionality of the storage and retrieval system 100 in the manner disclosed herein.

Referring also to Figure 1D, as incoming bundles or pallets (e.g. from a manufacturer or supplier of case units) arrive at the storage and retrieval system for replenishment of the automated storage and retrieval system 100, each The contents of the pallets may be uniform (e.g., each pallet contains a predetermined number of identical items - one pallet contains soup and another pallet contains cereal). As can be seen, these cases of pallet loading may be substantially similar or otherwise homogeneous cases (e.g., similar dimensions) and may have the same SKU (otherwise, as previously mentioned, the pallets may be may be “rainbow” pallets with layers formed into homogeneous cases). When pallets (PAL) leave storage and retrieval system 100 with cases filling a replenishment order, the pallets (PAL) may include an appropriate number and combination of various case units (CU) (e.g., each A pallet can hold cases of different types, with one pellet holding a combination of canned soup, cereal, beverage packs, cosmetics and household cleaners). Cases combined on a single pallet may have different sizes and/or SKUs. In one aspect of the disclosed embodiment, the storage and retrieval system 100 generally includes an infeed section, a storage and sorting section, where storage of items in one aspect is optional and sorting is one, as described above. performed with one or more different orthogonal classifications) and an output section (e.g., classification may be provided using one or more different orthogonal classifications disclosed herein).

As may be realized, in one aspect of the disclosed embodiments, system 100, operating, for example, as a retail distribution center, may receive uniform pallet loads of cases, disassemble pallet items, or stack cases into uniform pallets. Separating the load into independent case units that are handled individually by the system, retrieving and sorting the various cases found in each order into corresponding groups, transporting and assembling the corresponding case groups into what can be referred to as a mixed case pallet load MPL. It can function to do so. Additionally, as may be realized in one aspect of the disclosed embodiments, system 100, operating, for example, as a retail distribution center, may receive a uniform pallet load of cases, disassemble pallet items, or distribute cases into a uniform distribution center. It can function to separate case units from a pallet load into independent case units that are individually handled by the system, retrieve and sort the various cases found in each order into corresponding groups, and transport and sequence corresponding groups of cases, which will be implemented in 2018. Published on January 2nd. It may be performed in the manner disclosed in U.S. Patent No. 9,856,083, filed Ser. No. 14/997,920, the disclosure of which is incorporated herein by reference in its entirety.

Automated storage and retrieval system 100 is disclosed in U.S. Provisional Patent Application No. 63/044,72, filed June 26, 2020, and U.S. General Patent Application No. 17/358,383, filed June 25, 2021 ( The title is "Warehouse system for storing and retrieving goods in containers" and the contents are incorporated herein by reference in their entirety), and the publication covers order cases that may differ in sSKU, dimensions, etc. For assembling an appropriate group of musseled case pallet loads (including one or more case units and/or breakpack containers 264). For example, when a mixed case pallet load is assembled, the output section of automated storage and retrieval system 100 creates a pallet load that can be referred to as a structured architecture of a mixed case stack. The structured architecture of the pallet load disclosed herein is representative, and 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 the structural load. The structured structure of the pallet load may be characterized as having several flat case layers (L121-L125, L12T) as previously disclosed in US Pat. No. 9,856,083, the entire contents of which are incorporated by reference. As a further example, breakpack containers 264 may be assembled and assembled by the output section of automated storage and retrieval system 100 for shipping individually to a customer or together with other breakpack containers 264 to one or more customers. It can be output.

Referring to Figures 1C and 1E. As described in more detail herein, to assemble one or more of mixed pallet loads, individual breakpack containers 264 and grouped breakpack containers 264, the controller 120 may use a container bot 110, an article bot, 262 , lift module 150 , breakpack module 266 , and other suitable functional portions of storage and retrieval system 100 may operate in different orthogonal (i.e., separate and distinct/independent) ways. Classification echelons are performed. For example, case bot 110 may perform a pallet output sort 185 echelon where case units are retrieved from storage and output for inclusion in a mixed pallet load. One or more of the case bot 110 and the breakpack module lifts 310A, 310B palletize the breakpack station input sorter 186 echelon where supply containers 265 are provided to the breakpack module 266 in a predetermined order. It can be performed orthogonally/independently of the output classification (185). Each breakpack operator station 140 of the breakpack module 266 also performs orthogonal sorting (e.g., breakpack station output sort 187 echelon) of breakpack articles (BPGs) to the article bot 262. may be configured, where item bot 262 is configured to execute other orthogonal sorting (e.g., breakpack order sorting 188 echelons) on breakpack containers 264 at footwall 263W. Case bot 110 selects breakpack container 264 from footwall 263W and places breakpack output sorting 189 echelon (i.e., sorting 185-188) in the output section of automated storage and retrieval system 100. orthogonal to ). Classification echelons 186-188 implemented by breakpack module 266 may form one or more orthogonal classification echelons 15100, 15200 as disclosed herein. The orthogonal classification of each classification echelon 186-188 that performs output of units of goods 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. Input station 160IN (including depalletizer 160PA and/or conveyor 160CA) for transporting items (inbound supply containers) to lift module 150A for entry and palletizing (e.g., palletizing from storage). Items (e.g., outbound supply containers and palletizers 160PB, operator stations 160EP, and / or an output station (160UT, 160EC) including a conveyor (160CB) for transporting filled brake pack items (order containers).

Here, the output station 160EC is an individual fulfillment (or e-commerce) output station where, for example, a filled breakpack commodity (order) container containing a single commodity item and/or a small quantity of commodities is placed (e.g., by a consumer via the Internet). Individual fulfillment orders (such as placed orders) are transferred to be fulfilled. Output station 160UT may be used by commercial entities (e.g., commercial stores, warehouse clubs, restaurants, etc.) where items such as breakpack items, case units, pick faces, etc. are held for delivery to individual customers, etc. A commercial output station where a large number of items, typically multiple items, are provided on pallets to fulfill orders from a distribution center. As may be realized, automated storage and retrieval system 100 includes both a commercial output station (160UT) and an individual fulfillment output station (160EC); In another aspect, an automated storage and retrieval system includes one or more of a commercial output station (160UT) and an individual fulfillment output station (160EC).

Automated storage and retrieval system 100 also includes input and output vertical lift modules 150A, 150B (commonly referred to as lift module 150, although input and output lift modules are shown) to lift case units from the storage structure. Note that a single lift module may be used for input and removal), storage structure 130 (which may have at least one elevated storage level and in some embodiments forms a multi-layer storage array), and (storage structure ( At least one autonomously guided container transport vehicle or container (which may be confined to each storage level of 130) and which is separate from the transfer deck 130DC (also referred to herein as a transfer area) on (or on) which they move Includes bot 110. Note that depalletizer 160PA may be configured to remove case units from the pallet so that input station 160IN can transfer the items to lift module 150 for input into storage structure 130. Should be. Palletizer 160PB may be configured to place items removed from storage structure 130 on a pallet (PAL) (FIG. 1E) for shipping. As used herein, lift module 150, storage structure 130, breakpack module 266, item bot 262, and container bot 110 are used to provide a three-dimensional multi-layer automated storage system (e.g., Multi-layer automation described above to define transport/throughput axes (in three dimensions) (e.g., relative to the container bot 110 reference frame (REF) - FIG. 6D - or any other suitable storage and retrieval system reference frame). may be collectively referred to as a storage system (e.g., storage and sorting sections), each throughput axis having an integrated “on-the-fly sorting” (e.g., sorting of case units during transport of the case units), and thus a case unit Sorting and throughput occur substantially simultaneously without a dedicated sorter, as previously disclosed in U.S. Pat. No. 9,856,083, incorporated herein by reference in its entirety.

As an example of case unit or breakpack item container throughput associated with sorting, referring to Figure 1E, storage and retrieval system 100 includes several areas of throughput or processing areas. For example, there is a multi-tiered case device storage throughput of 130 LTP that performs the placement of case devices into storage. The placement/configuration of case units in storage space 130S may be separate/independent (e.g., not pre-staged) from the classification of case units and/or breakpack articles (BPGs) in the various classification echelons disclosed herein. . Horizontal Case Unit Transport Throughput The 110TP performs the transport of case units from storage along the picking aisle, transfer deck, to and from the breakpack item interface. The horizontal case unit transport throughput 110TP at least partially performs one or more of the pallet output sort 185 echelon and the breakpack station input sorter 186 echelon. Pallet output sorting 185 sorts case units destined for mixed pallet loading, which case units are not provided to breakpack station 266. Breakpack station throughput 266TP (e.g., breakage of supply cases at the brakepack operator station) is determined by the brakepack station input sorter 186 echelon (e.g., via brakepack module lifts 310A, 310B) and ( Perform one or more of the brakepack station output sorting (187) echelons (via the brakepack operator station 140). Horizontal article transport throughput 262TP provides for the transfer of breakpack articles from the breakpack operator station 140 to the breakpack article interface and enforces breakpack order sorting 188 echelon. Case Buffering Throughput BTSTP provides buffering of case units to facilitate transfer of case units between storage/breakpacks and vertical transport, at least in part through one or more of pallet output sorting (185) and breakpack output sorting (189). can be carried out. Vertical transport throughput 150TP may facilitate transport of case units by vertical lift 150 and at least in part facilitate one or more of pallet output sorting 185 and breakpack output sorting 189. The throughput at the output station (160TP) is also provided and includes, for example, transport by conveyor 160CB and palletizing by palletizer 160PB. In one aspect, the classification of case units described herein includes the case unit's throughput along each throughput axis (e.g., the Performs substantially identically (i.e. "on the fly") to 130LTP, 110TP, 266TP, 262TP, BTSTP, and 150TP, and classification along each axis can be independently selected, allowing classification to be performed along one or more of the X, Y, and Z axes. .

Additionally, as shown in FIGS. 1A and 1B, the storage structure 130 includes container autonomous transport movement loop(s) 233, 233A (e.g., container formed on and along the transfer deck 130DC). The lift 150 is a transfer station (TS), herein referred to as a container infeed station if the lift 150 is an inbound lift 150A, and a container outfeed station if the lift 150 is an outbound lift 150B. ) to the container transfer deck 130DC, each lift having supply containers 265 (empty or filled) and breakpacks moved into and out of at least one elevated storage level 130L of the storage structure 130. Product container 264 (empty or filled, breakpack product container 264 is ready for shipping and filled so that the breakpack product (BPG) within the container comprises at least about 30% or at least about 50% of the total container volume. an array of storage shelves 130SA (e.g., forming at least a portion of the storage area of storage structure 130, also referred to herein as a multi-tiered container storage array) , consisting of container storage locations (or spaces) 130S disposed peripherally along a container transfer deck 130DC, wherein the transfer area of the storage structure 130 is substantially continuous, and the transfer area is connected to the storage shelf 130SA. At least a transfer deck 130DC and a picking aisle 130A to communicatively connect each storage shelf of the array to each other, for example, a plurality of storage rack modules (RM) configured as a high-density three-dimensional rack array (RMA). is accessible at storage or deck level 130L. As used herein, the term "dense three-dimensional rack array" refers to a three-dimensional rack array RMA with non-deterministic open shelves distributed along picking aisle 130A; In some embodiments, multiple stacking shelves are accessible from a common picking aisle travel surface or picking aisle level, as previously disclosed in U.S. Pat. No. 9,856,083, which is incorporated by reference in its entirety.

Each storage level 130L has a pick-up storage/handoff space 130S (referred to herein as storage space 130S or container storage location 130S) located peripherally along the container transfer deck 130DC. Includes. At least one of the storage locations 130S is a supply container storage location 130SS and another one of the container storage locations is a breakpack article (or order) container storage location 130SB. Storage space 130S is, in one aspect, formed by rack modules (RM), where the rack modules extend linearly, for example, through the rack modules and are connected to storage space 130S and transfer deck(s) 130B. Includes shelves disposed along the storage or picking aisle 130A (connected to the container transfer deck 130DC) providing access for the container bot 110 (e.g., the container bot 110 has a brake Each of the storage shelf(s) (as disclosed herein) on each level(s) of the storage structure 130 to the pack operator station is also accessed from a for container storage locations/spaces (as disclosed herein). (same) is configured to traverse the container transfer deck 130DC and the picking aisle 130A at each level(s) and transport container).

The container transfer decks 130DC are stacked or horizontally stacked over each other, such as having one container transfer deck 130DC at one end or side of the storage rack array RMA or at several ends or sides RMAE1, RMAE2 of the storage rack array RMA. placed at different levels that may be offset (corresponding to each level 130L of the storage and retrieval system), e.g., in the United States filed on December 15, 2011, the disclosure of which is incorporated herein by reference in its entirety. Disclosed in Patent Application No. 13/326,674. Container transfer deck 130DC is substantially open and traverses transfer deck 130B and along multiple travel lanes therewith (e.g., along the Configured for non-deterministic traversal of the container bot 110. As disclosed in U.S. Patent No. 10,556,743 (Application No. 15/671,591), issued February 11, 2020, the disclosure of which is incorporated herein by reference in its entirety, a plurality of travel lanes are located at each storage location 130S. Configured to provide multiple access passages or routes for (e.g., pick faces, case units, containers or other items stored on storage shelves of a rack module RM), container bot 110 can, for example, store If the primary path to a location is blocked, secondary paths can be used to reach each storage location. As may be realized, the transfer deck(s) 130B in each storage level 130L communicate with a respective picking aisle 130A in each storage level 130L.

Container bot 110 is configured to move along the picking aisle (e.g., to move along the Traverses in both directions between the picking aisles 130A of the level 130L and approaches the storage space 130S disposed on a rack shelf next to each picking aisle 130A (e.g., the container bot 110 , along the Y throughput axis, distributed storage space 130S can be accessed on each side of each aisle and thus the container bot 110 can have different directions when traversing each picking aisle 130A. For example, the drive wheel of the container bot 110 leads the direction of movement or the drive wheel follows the direction of movement). As may be realized, the outbound throughput from the storage array in the horizontal plane corresponding to the predetermined storage or deck level 130L is represented by or is represented by a combined or integrated throughput along both the X and Y throughput axes. . As described above, container transfer deck(s) 130DC also provides access for container bots 110 to each of the lifts 150 at each storage level 130L, wherein each lift 150 Supplying or removing case units to and/or from storage level 130L (e.g., along the Z throughput axis) and container bot 110 performs case unit movement between lift 150 and storage space 130S.

Container bot 110 may store case units and/or pickface and breakpack item containers 264 (which may be individually or collectively referred to as supply containers 265), e.g., storage and retrieval system 100. It may be any suitable independently capable autonomous transport vehicle that transports and transports/transports, respectively, along the X and Y throughput axes (see Figure 1B) throughout. In one aspect, container bot 110 is an automated, independent (e.g., free-riding) autonomous transport vehicle. Suitable examples of bots include, for illustrative purposes only, U.S. Patent Application Serial No. 13/326,674, filed December 15, 2011; U.S. Patent Application No. 12/757,312, filed April 9, 2010 (now U.S. Patent No. 8,425,173); U.S. Patent Application No. 13/326,423, filed December 15, 2011; U.S. Patent Application No. 13/326,447, filed December 15, 2011 (now U.S. Patent No. 8,965,619); U.S. Patent Application No. 13/326,505, dated December 15, 2011 (now U.S. Patent No. 8,696,010); U.S. Patent Application No. 13/327,040, filed December 15, 2011 (now U.S. Patent No. 9,187,244); U.S. Patent Application No. 13/326,952, filed December 15, 2011; U.S. Patent Application No. 13/326,993, filed December 15, 2011; U.S. Patent Application No. 14/486,008, filed September 15, 2014; and U.S. Provisional Patent Application No. 62/107,135, filed January 23, 2015, the disclosures of which are hereby incorporated by reference in their entirety. Container bots 110 (described in more detail below) place case units, such as retail items described above, into picking stock at one or more levels of storage structure 130 and then selectively retrieve ordered case units. It can be configured. As may be realized, in one aspect, the storage array's throughput axes The extendable end effector (as described herein) of container bot 110 (and in other aspects the extendable end effector of lift 150 also defines, at least in part, the Y throughput axis). The pickface (including supply container 265 in one aspect) is located between an inbound section of the storage and retrieval system 100 where the inbound pickface for the array is generated (e.g., input station 160IN) and (e.g., output station 160UT or output station 160UT). (such as a 160EC) is transported between load fill sections of a storage and retrieval system 100, with outbound pick faces from the array positioned to fill loads according to a predetermined load fill sequence or predetermined individual fulfillment order sequence(s). do. In another aspect, the pick face (e.g., of the supply container 265) is configured to connect the storage space 130S and the storage and retrieval system to fill the load according to a predetermined load filling sequence or predetermined individual fulfillment order sequence(s). The load is transported between filling sections of 100 (such as output station 160UT or output station 160EC). In another aspect, breakpack item container(s) 264 (in one aspect, multiple breakpack item containers may be placed and transported in a pick face) are configured to perform a predetermined load filling sequence or a predetermined individual fulfillment order. To fill the load in an orderly manner, between the storage space 130S and the load filling section and/or the breakpack article interface 263 of the breakpack module(s) 266 and the storage and retrieval system 100 (e.g. , is transported by the container bot 110 between the output station 160UT or the output station 160EC. The control server 120 is configured to control the pickface and breakpack article container 264 (e.g. of the supply container 265) according to one or more of the above aspects for the load filling section (e.g. of the supply container 265). The automated storage and retrieval system 100 can be operated in various modes of operation such that the pick faces (265) and the breakpack product containers 264 are transported to fill one or more of them.

As disclosed above, and with reference to FIG. 1B , in one aspect the storage structure 130 includes a plurality of storage rack modules (RM) comprised of a three-dimensional array RMAs (e.g., forming an array of storage shelves 130SA); , the racks are placed in the passageway 130A, and the passageway 130A is configured so that the container bot 110 moves within the passageway 130A. The container transfer deck 130DC has a non-deterministic transfer surface along which the container bot 110 moves, and the non-deterministic transfer surface (also referred to herein as deck surface) 130BS is a container formed by the container transfer deck 130DC. Multiple lanes of travel (e.g., more than one lane of travel in parallel (e.g., a high-speed bot travel path HSTP) for movement of the container bot 110 along the autonomous transport movement loop(s) 233 ), and the plurality of travel lanes connect the aisles 130A. The container autonomous transport movement loop(s) 233 are random for each picking aisle 130A for the container bot 110. Provides random access to any of the lifts 150A, 150B on each level 130L of access and storage structure 130. At least one of the plurality of travel lanes (container autonomous transport travel loop 233) to form). Among multiple movement lanes, other lanes have a movement sense that is opposite to the other movement lane senses.

In one aspect, the storage rack module (RM) and container bot 110 are a combination of the storage rack module RM and container bot 110,

arranged to perform on-the-fly sorting (e.g., pallet output sorting 185 echelon) of mixed case pickfaces consistent with transport for at least one of the throughput axes (or at least one of two or more axes in another aspect) so that two or more pickfaces are It is picked up from one or more storage spaces and placed in one or more pick face holding locations (such as buffer and transfer stations BS, TS) different from the storage space 130S according to a predetermined load filling order.

As may be realized, any suitable controller of storage and retrieval system 100, such as, for example, control server 120, may control their respective may be configured to create any number of alternative passageways or detours to retrieve one or more case units (and/or breakpack article containers) from storage location 130S, filed June 26, 2020; This may be performed in the manner disclosed in U.S. Provisional Patent Application No. 63/044,721, entitled “Warehousing System,” the entire contents of which are hereby incorporated by reference.

Note that the storage and retrieval system shown and disclosed herein has exemplary configurations only, and that in other aspects the storage and retrieval system may have any suitable configuration and component for storing and retrieving items as disclosed herein. do. For example, in another aspect, the storage and retrieval system may have any suitable number of storage sections, any suitable number of transfer decks, any suitable number of breakpack modules 266 and corresponding input/output stations. there is.

As may be realized, the juxtaposed travel lanes are juxtaposed along a common non-deterministic transport surface 130BS between opposing sides 130BD1, 130BD2 of the container transport deck 130DC. As shown in FIG. 1B, in one aspect, the passageway 130A is coupled to the container transfer deck 130DC at one side 130BD2 of the container transfer deck 130DC, but in another aspect, the passageway is coupled to the container transfer deck 130DC. ) to more than one side (130BD1, 130BD2), which may be performed in a manner substantially similar to that disclosed in U.S. Patent Application No. 13/326,674, filed December 15, 2011, the disclosure of which The content has previously been incorporated by reference herein in its entirety.

Disclosed in U.S. Provisional Patent Application No. 63/044,721, entitled “Warehouse System for Storing and Retrieving Items in Containers,” filed June 26, 2020, the disclosure of which is incorporated herein by reference in its entirety; , the other side (130BD1) of the container transfer deck (130DC) is a deck storage rack distributed along the other side (130BD1) of the container transfer deck (130DC) (e.g., an interface station (TS) and a buffer station, also referred to as a transfer station) (BS)), whereby the deck storage rack is in communication with the container bot 110 and the lift module 150 from the container transfer deck 130DC (e.g., the deck storage rack, Accessed by the container bot 110 from the container transfer deck 130DC, and by a lift 150 for picking and placing pick faces, the pick faces are moved between the container bot 110 and the deck storage rack, into the deck storage rack. It is transferred between the rack and the lift 150 and, accordingly, between the container bot 110 and the lift 150.

Referring back to FIG. 1A , each storage level 130L also has a charging station 130C (e.g., any suitable located at a container shipping location), which may include, for example, U.S. Patent Application Nos. 14/209,086, filed March 13, 2014, and 13/326,823, filed December 15, 2011 (now As disclosed in U.S. Pat. No. 9,082,112, the entire contents of which are incorporated herein by reference.

Referring to Figures 1A, 1B, 1C and 2. As described above, automated storage and retrieval system 100 includes one or more breakpack modules 266. Each breakpack module includes a breakpack station 140, one or more lift(s) (lift(s) 310A, 310B in one aspect and lift(s) 310A', 310B' in another aspect, (as disclosed herein) one or more container bot movement surface(s) 266RS (e.g., for inputting a supply container 265 into the breakpack module 266) communicatively coupled to the breakpack station 140 (as indicated); and a predetermined number of collective article deck levels 130DGL communicatively coupled to each of the breakpack stations 140 and storage levels 130L.

Although the breakpack module 266 is disclosed herein in connection with the automated storage and retrieval system 100, in other aspects the breakpack module 266 may be installed on any suitable deck or floor and/or other suitable via a single-level storage and retrieval system, a truck or trailer transporting goods (e.g., at a loading dock), the cargo compartment of a train (e.g., in a train depot), or a cargo aircraft (e.g., in an airport terminal). appropriate input of, or e.g., providing (manually or automatically) a supply container (as disclosed herein) to at least one guide conveyor(s) 500A, 500B, 500C of each breakpack module 266. It can be configured to couple to any other suitable input. Here, the breakpack module 266 may be connected to an automated order fulfillment system (or, if connected to an automated storage and retrieval system 100), given that the breakpack module may receive supply containers from any suitable input. It can be referred to as at least a part thereof, such as). Regardless of whether the breakpack module 266 is coupled to and forms part of the storage and retrieval system 100 or coupled to any of the other inputs as described above, the automated order fulfillment system may be equipped with a footwall or multi-level break. Pack article container filling array 263W, article transfer deck 130DG, and at least one article bot 262 described herein.

The footwall 263W has a plurality of levels (PWL), and each level (PWL) has a container charging station area (CFA), with the breakpack article interface location 263L disposed along the container filling station area (CFA) CFA), and also has corresponding breakpack article transfer decks 130DG1-130DG3 juxtaposed along the breakpack article interface location 263L of the container filling station area (CFA). As described in more detail herein, at least one article bot 262 may transport an array of multi-layer breakpack article containers along a corresponding breakpack article transfer deck 130DG (e.g., FIGS. 3A, 3B, 4). , 6a, 6b, 7a and 7b) between the corresponding breakpack article transfer decks 130DG-130DG3 at different levels, each breakpack article interface station/ at each level (PWL) of the footwall 263W. configured to transport breakpack articles (BPG) across (e.g., as disclosed herein) to container station 263L (see FIGS. 4 and 5C), where each breakpack article is transported to interface station 263L. is arranged to hold a breakpack article container 264 that is accessed by at least one article bot 262 and filled with a predetermined breakpack article fill payload BPGFP. As described in more detail herein, the corresponding transfer decks 130DG1-130DG3 at each level (PWL) are connected to the corresponding breakpack article transfer decks 130DG1-130DG3 at each level (PWL) and at each other level (PWL). of the footwall 263W by an autonomously guided brakepack article transfer vehicle path traversing between different brakepack article transfer decks 130DG1-130DG3 (e.g., lifts, ramps, etc. disclosed herein) that correspond to communicatively coupled to other transport decks 130DG1-130DG3 corresponding to each different level (PWL) (e.g., in some aspects, interlevel travel autonomously guided brakepack article transport vehicle paths may be connected to each other as described herein); Provides goods bot movement between decks (130DGL) of different deck gangs), whereby at least one goods bot (262) corresponds to each different level (PWL) from the corresponding breakpack transfer deck (130DG1-130DG3). Each of the different breakpack product transfer decks 130DG1-130DG3 moves between levels and moves through an autonomously guided breakpack product transfer path, and is also loaded into at least one product bot 262 of one level (PWL). A predetermined breakpack product (BPG) filling payload is transported and filled with breakpack product containers 264 at each breakpack product container station 263L at different levels (PWL).

Again, regardless of whether the breakpack module 266 is coupled to and forms part of the storage and retrieval system 100 or coupled to any of the other inputs as mentioned above, the The corresponding breakpack product transfer decks 130DG1-130DG3 and the interlevel movement autonomously guided breakpack product transfer path (e.g., ramp, lift, etc. disclosed herein) include at least one inter-level detour path (e.g., ramps 130DG1R, 130DG3R, 451, 452, 453, lifts 490, etc. described in ) and at least one interlevel bypass path (e.g., shunts 461-463 disclosed herein - see, e.g., Figure 7C). Forming at least a two-dimensional matrix of self-guided breakpack product transport vehicle detour routes (2DM) (see FIGS. 2, 3A, 3B, 4), whereby at least one product bot 262 is configured to: at least one of a common level (PWL) from station destination CSD1 (i.e. at the same level as the initial breakpack goods container station destination CSD1) and a level (PWL) different from (e.g. in relation to) the initial container station destination CSD1. Switching Breakpack Goods Container Station Allows for free switching (detour) on the fly via at least one of at least one inter-level detour route and at least one inter-level detour route to the destination CSD2. The corresponding breakpack article transfer decks 130DG1-130DG3 at each level (e.g., of each gang of deck level 130DGL where more than one gang is provided) are (e.g., substantially similar to the container deck 130DC disclosed herein). (in a similar manner) and the at least one inter-level detour path is non-deterministic (e.g., in a manner substantially similar to the container deck 130DC disclosed herein) such that at least one article bot 262 determines the corresponding breakpack article. Allows free movement between transfer decks (130DG1-130DG3) and at least one inter-level detour route (or vice versa). Item bot 262 performs attitude determination and localization along item decks 130DG1-130DG2, at least one inter-level detour path, and at least one inter-level detour path in the manner described herein (see FIG. 25). .

For the automated storage and retrieval system 100, each breakpack module 266 may be compared to the automated storage and retrieval system 100 in any suitable manner (e.g., to form a part thereof). The breakpack module 266 may be deterministically coupled (e.g., the breakpack module 266 may be configured such that the picking aisle 130A is positioned and one or more of the picking aisles 130A are configured to form the container bot mounting surface(s) 266RS). At any suitable location, for example one or more ends 130BE1, 130BE2, or Pick aisle 130A (and storage location) may instead be coupled to an automated storage and retrieval system 100 located centrally between the two ends 130BE1 and 130BE2). Although breakpack module 266 is non-deterministically coupled to the structure of automated storage and retrieval system 100, each component of breakpack module 166 is independent (e.g., self-contained as a unit). and/or the guidance and movement of the bot (e.g., item bot 262) is automated independently from components of the automated storage and retrieval system, such as components of the breakpack module 266 and the automated storage and retrieval system. Ensure that the interfaces between the components of (100) are non-deterministic.

Breakpack 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 mentioned above, breakpack module 266 may be used (e.g., in place of a storage rack module RM/picking aisle 130A or lift 150A, 150B, or in one or more picking aisles 130A) As an extension of - see FIG. 1B ), it may be located at one or more ends 130BE1, 130BE2 of the container transfer deck 130DC or on one or more sides 130BD1, 130BD2 of the container transfer deck 130DC. Each of the breakpack modules 266 is a plug and play module integrated with (or otherwise connected to) a container transfer deck 130DC such that the container transfer deck 130DC is communicatively coupled to the container bot mounting surface 266RS. In one aspect, the container transfer deck 130DC extends into a breakpack module to form a container bot mounting surface 266RS (e.g., the breakpack module forms a modular portion of the container transfer deck 130DC) ), causing the container bot 110 to traverse and move in and out of the breakpack module 266 along the non-deterministic container transfer deck 130DC, and at least one of the plurality of movement lanes of the container transfer deck 130DC is braked. The pack module 266 defines a queue for the container bot 110. In another aspect, container bot mounting surface 266RS includes rails 1200S extending from container transfer deck 130DC in a manner similar to picking aisle 130A, such that container bot 110 moves along rails 1200S. to traverse or move in and out of the breakpack module 266, and the rails 1200S define a queue for the container bot 110 in the breakpack module 266. If the container bot mounting surface 266RS is formed by rails 1200S, the mounting surface may include a non-deterministic rotational area 1200UTA (i.e., similar to an open non-deterministic container transfer deck 130DC), on which Container bot 110 rotates to transition between different moving portions of container bot mounting surface 266RS (e.g., inbound lane TL1 and outbound lane TL3 of movement loop 233BP disclosed herein). Movement loop 233BP provides container bot 110 with random access to any and each breakpack article interface location 263L of breakpack article interface 263 along bot movement surface 266RS, where: Breakpack product interface location 263L forms an asynchronous product distribution system.

As can be realized with reference to Figures 1C, 3A and 3B. Two or more brake pack modules 266 may be stacked on top of each other. Although three brake pack modules 266A, 266B, and 266C are shown here stacked on top of each other, in other embodiments any suitable number of brake pack modules 266 could be stacked on top of each other. Each breakpack module 266 (whether or not arranged in a stack) is moved to a stacked level (e.g., via container bot 110 and lift(s) 310A, 310B, 310A', 310B'). 130L) and receives an inbound supply container 265 from any one or more of the above. For example, each breakpack module 266 has a container bot mounting surface 266RS that forms a portion 130DCP of the container transfer deck 130DC of the storage level 130L of the automated storage and retrieval system 100. It has at least one container bot transfer deck 130EXT, each having. Referring also to Figure 2, the breakpack module 266 includes three container bot mounting surfaces 266RS1, 266RS2, 266RS3 (each corresponding to a container bot transport deck 130EXT), which are stacked on top of each other (for clarity Only a portion of the container bot mounting surfaces 266RS2 and 266RS3 are shown). Each container bot mounting surface 266RS1, 266RS2, 266RS3/container bot transfer deck 130EXT is positioned on a portion 130DCP of the container transfer deck 130DC at each level 130L of the automated storage and retrieval system 100. combined to form him. The loading surface 2666RS is substantially similar to that of the container transfer deck 130DC, although in other aspects the container bot loading surface 266RS may be substantially similar to that of the picking aisle 130A. For ease of explanation, aspects of the disclosed embodiment refer to container bot mounting surface 266RS within breakpack module 266 as part of container transfer deck 130DC. Note that in embodiments where the bot mounting surface 266RS is formed by (or is an extension of) a portion of the container transfer deck 130DC, the container transfer deck 130DC is shown in FIG. 2 as a single path transfer/movement loop. And, in another aspect, the transfer/movement loop of the break pack module 266 may be a multiple lane transfer/movement loop substantially similar to the container transfer deck shown in FIG. 1B. For example, referring to Figure 2, container bot movement surface 266RS is an open non-deterministic movement surface having at least one inbound travel lane TL1 and at least one outbound travel lane TL3, wherein a plurality of travel lanes TL1, TL3 functions as a bypass lane for each other, allowing container bot 110 to enter travel lane TL2 and move around obstacles in travel lane TL1 (or vice versa). Here, at least one mobile inbound lane TL1 and at least one mobile outbound TL3 are configured (at least in part) for the container bot 110 that interfaces with the breakpack module 266 (at least in part) with the breakpack station input sorter 186 and the breakpack station input sorter 186. Defines at least one queue capable of performing one or more of the pack output sorting (189). Movement lanes TL1, TL3 provide the container bot 110 with random access to any and each breakpack article interface location 263L of the breakpack article interface 263 along the bot movement surface 266RS. .

Continuing to refer to FIGS. 1A, 1C, 2, 3A, and 3B, as explained in more detail later, container bot 110 from any given level 130L (e.g., a given level 130L) ) each container bot moves along a movement surface 266RS1, 266RS2, 266RS3 and, in one aspect, delivers a supply container 265 to lift(s) 310A, 310B. Lifts 310A, 310B (and/or lifts 310A', 310B' disclosed herein) may be individually or collectively referred to as intervening classifiers that perform breakpack station input classifier 186. An intervening sorter is configured to communicatively connect the breakpack operator station 140 with a multi-tiered array transfer area (e.g., formed by picking aisle 130A and transfer deck 130DC of different storage levels 130L). It is placed. In some aspects, the guide conveyors 500A, 500B, 500C of the breakpack module 266 may be configured to divert or divert the guide conveyors 500A, 500B, 500C from the lifts 310A, 310B to the breakpack operator station 140. As provided for providing the transition, it may form part of an intervening sorter, which may at least partially implement the breakpack station input sorter 186. Each lift 310A, 310B is configured to sort supply containers 265 from container bot 110 and upstream of breakpack operator station 140. Sorting of the supply containers 265 by one or more of the lifts 310A, 310B upstream of the breakpack operator station 140 may be performed from a sub-optimized ordering of the items (e.g., transfer from storage in a non-staged manner). It is arranged to facilitate ordering of the supply containers 265 in a superior optimal order (e.g., ordered for optimized delivery from breakpack operator station 140 to other operator stations 801-804). Sorting by one or more lifts 310A, 310B involves predetermined ordering of supply containers 265 input to breakpack operator station 140 and the distribution of items (e.g., brakes) from supply containers 265 of operator station 801. At least one article bot 262 is sent from the breakpack operator station 140 to dispose of the pack article (BPG) and fill the footwall 263W. One or more lifts 310A, 310B (i.e., intervening sorters) upstream of the breakpack operator station 140 may have a plurality of orthogonal (e.g., separate and distinct/independent) one another (via other lifts 310A, 310B). It is configured to define sorting axes (each lift forming a respective sorting axis). At least one sorting axis in one direction may be configured such that, for example, lifts 310A, 310B are configured to feed containers ( 265) have parallel classification axes, such as to form parallel classification axes for classifying.

Referring also to FIG. 5A , each of the container bot travel surfaces 266RS1, 266RS2, and 266RS3 positions (e.g., transports) a supply container 265 from the container bot 110 to the respective guidance conveyors 500A, 500B, and 500C. ) is placed adjacent to each induction conveyor (500A, 500B, 500C). Here, each guidance conveyor (500A, 500B, 500C) is configured to transfer the supply container 265 to one of the lifts (310A, 310B). At least one of the guidance conveyors 500A, 500B, 500C includes a bypass conveyor portion 500AB, 500BB for diverting or diverting the supply container 265 from one or more lift(s) 310A, 310B ( Note that the bypass conveyor portion for guide conveyor 500C is obscured in the drawing (see FIGS. 3A, 6C, 6D). For example, at least in part, the supply container 265 may be delivered to a downstream lift (in the example shown, the upstream lift is lift 310A) to perform the breakpack station input sorter 186, such as an upstream lift (e.g. For example, upstream of the flow of supply containers 265 along the conveyor) may be diverted; In another aspect, one or more lifts 310A, 310B are configured, at least in part, to break from container bot 110 without transporting supply containers by lifts 310A, 310B to perform breakpack station input sorter 186. The pack operator station 140 may be bypassed for delivery of the feed container 265 substantially directly.

Guide conveyors 500A, 500B, 500C may be any suitable multi-directional drive/conveyor unit/section 370 configured to move supply containers 265 between conveyor sections or to/from lifts 310A, 310B. Includes. For example, multi-directional conveyor portion 370 may be configured to transfer supply containers 265 to lifts 310A, 310B (e.g., lifts 310A, 310B, best shown in Figure 6C). moving the supply container 265 along the longitudinal axis of each guide conveyor (500A, 500B, 500C) (interlocked between the lengths of at least one of the guide conveyors 500A, 500B, 500C) as described, and/ Alternatively, move the supply container 265 transversely to the longitudinal axis to move the supply container 265 to and from the respective bypass conveyor portions 500AB and 500BB.

The output of the bypass conveyors 500AB, 500BB (and the bypass conveyor for the induction conveyor 500C) and the output of the lifts 310A, 310B are the breakpack article container 264 of the footwall 263W as disclosed herein. A common output is to deliver the supply containers 265 to the breakpack operator stations 140 in a superior, optimized sequence of items carrying out a predetermined breakpack item filling sequence (e.g., the output is a single breakpack station input conveyor). merged into 510 - see Figures 6c, 8a and 8b). Also as disclosed herein, breakpack articles from the footwall to the breakpack article container 264

Each load filling of the BPG is independent/orthogonal to the load filling of another breakpack product container (BPG), so that filling two or more different breakpack product containers 264 can be performed in parallel. In the example shown, lifts 310A, 310B move supply containers from guide conveyors 500A, 500C to guide conveyor 500B, where bypass portion 500BB of guide conveyor 500B has a common output/brake. forming a pack station input conveyor 510 (i.e., the breakpack station input conveyor 510 is part of the guide conveyor 500B); In another aspect, guide conveyors 500A, 500C may be merged with guide conveyor 500B through any suitable combination of ramps and multi-directional conveyor portions 370.

The lift(s) 310A, 310B are configured to deliver the supply container 265 to a predetermined breakpack operator station 140 of the (stacked) breakpack module 266. For example, the lifts 310A, 310B are configured to transfer the supply container 265 between the guide conveyors 500A, 500B, and 500C to output the supply container 265 to the breakpack station input conveyor 510. do. In one or more aspects, the lifts 310A, 310B cause supply containers to be delivered to the breakpack operator station 140 in a predetermined order (e.g., wherein the predetermined order forms the best optimized order of items). ) configured to sort supply containers 265 for output from lift(s) 310A, 310B in a predetermined order/sequence, as described in U.S. Patent No. 10,442,622, issued October 15, 2019, entitled: , “Control System for Storage and Retrieval System”), the disclosure of which is incorporated herein by reference in its entirety. For example, if supply container(s) 265 are maintained (e.g., fully charged) on lift(s) 310A, 310B, supply container(s) 265 may The brake pack may remain on the lifts 310A, 310B (e.g., cushioned) until a predetermined time when it must be delivered to the operator station 140. In the illustrated example, lifts 310A and 310B are circular lifts; In another aspect, the lift is delivered in any suitable manner (e.g., under the control of any suitable controller, such as controller 120 and/or a dedicated lift controller) to the brakepack operator station 140 at a predetermined time. It may be any suitable lift configured to cushion any number of supply containers 265. The predetermined order may correspond to the packaging order of the breakpack articles (BPG) within the breakpack article container 264, e.g. It may also correspond to any other suitable sequence, for example corresponding to store planning rules. Store planning rules may include, for example, the customer store's aisle layout or family group or type of item that corresponds to the specific location in the store where the breakpack item container 264 (or the pallet (PAL) on which the breakpack item will be delivered) is unloaded. can be integrated. The predetermined order of supply containers 265 to breakpack operator station 140 (and ultimately breakpack article container 294) may also correspond to the durability of the breakpack article (BPG). For example, after the heavier, more durable brake pack items (BPG) are delivered to the brake pack operator station 140 (and ultimately to the brake pack item container 294), the more fragile brake pack items (BPG) are It may be delivered to the pack operator station 140 (and ultimately to the breakpack item container 294). Here, each lift 310A, 310B is common to each brakepack operator station 140 of the (stacked) brakepack modules 266A-266C (see Figure 3B).

In another aspect, as shown in FIGS. 20A-20C, the breakpack module 266 includes linear reciprocating through lifts 310A', 310B' instead of circular lifts 310A, 310B. In another aspect, the breakpack module 266 may include both linear reciprocating through lifts 310A', 310B' and circular lifts 310A, 310B. Each lift 310A', 310B' has at least three lift platforms 2011 that reciprocate along the mast 2010 upon stimulation of the mast 2010 and any suitable drive (e.g., chain drive, ball screw drive, etc.). , 2012, 2013). The lift platforms 2011, 2012, 2013 may be spaced apart from each other along the length of the mast 2010 by a fixed pitch P that is substantially equal to the pitch/spacing (PP) between the guide conveyors 500A, 500B, 500C ( That is, the pitch P does not change when the lift platform (2011, 2012, 2013) reciprocates along the mast (2010). As disclosed herein, at least three lift platforms (2011, 2012, 2013) "pass" lifts (310A', 310B') while moving along one or more of the guidance conveyors (500A, 500B, 500C). Provides passage of supply container 265. Each lift platform 2011, 2012, 2013 of lifts 310A', 310B' pulls supply containers 265 from upstream portions of guide conveyors 500A, 500B, 500C, at least in part, A conveyor 2021 (e.g., a belt conveyor, roller bed conveyor, etc.) as a seating surface for the supply container.

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). The lift 310A' is disposed between the upstream part (500AU, 500BU, 500CU) and the downstream part (500AD, 500BD, 500CD) to lift supply containers from the upstream part (500AU, 500BU, 500CU) to the downstream part (500AD, 500BD, 500CD). ) is transmitted. The lift 310B' is disposed between the downstream part (500AD, 500BD, 500CD) and the breakpack station input conveyor 510 to transport the supply container 265 from the downstream part (500AD, 500BD, 500CD) to the breakpack station input conveyor 510. It is delivered to the conveyor (510).

As can be seen in FIG. 20A, lifts 310A', 310B' are in line with guide conveyors 500A, 500B, 500C (one stacked on top of the other), so that supply containers 265 are guided Supply containers 265 moving along each one of the conveyors 500A, 500B, 500C (lift ( It can be transferred to a lift 310A' located upstream from 310B'). Placing the lifts 310A', 310B' in line with the guide conveyor provides a more compact breakpack module 266 compared to providing the lifts next to the guide conveyor. In this aspect, supply container 265 may “bypass” upstream lift 310A’ by “passing” lift 310A’. For example, as shown in FIGS. 20B and 20C, the supply container 265 moving along the guide conveyor 500B is connected to the lift platform 2012 of the lifts 310A' and 310B'. ) to the downstream portion 500BD (e.g., supply container 265 passes from upstream portion 500BU to lift platform 2012 of lift 310A' and then , (This is done with the lift platform remaining stationary, i.e. without vertical movement of the lift platform.) A similar transit transfer of the supply container 265 from the downstream portion 500BD to the breakpack station input conveyor 510 is as follows: It occurs at the lift platform 2012 of the lift 310B'. Here, as described above, the output of the guide conveyors 500A, 500B, 500C and the output of the lifts 310A', 310B' are, as described below. A common output conveys the supply container 265 to the breakpack operator station 140 (e.g., the outputs are merged into a single breakpack station input conveyor 510 - see FIGS. 20A, 20B, 20C). In an example, one or more lifts 310A', 310B' guide supply container 265 (in the case of lift 310A') from an upstream portion (500AU, 500BU, 500CU) of guidance conveyor 500A, 500B, 500C. to the downstream portion 500BD of conveyor 500B or (in the case of lift 510B') to breakpack station input conveyor 510; In another aspect, guide conveyors 500A, 500C may be merged with guide conveyor 500B through any suitable combination of ramps and multi-directional conveyor portions 370.

For example, referring to FIG. 20C, supply container 265B is placed on input conveyor 500A by container bot 110. For illustrative purposes only (e.g., for ordering containers in the breakpack station input sorter 186 or for any other suitable purpose), supply container 265A is transferred from the upstream portion 500AU of input conveyor 500A to the input conveyor ( It is desirable to deliver it to the downstream part (500CD) of 500C). Here, lift 310A' transfers supply container 265A (e.g., using platform 2011) from upstream portion 500AU to downstream portion 500CD. From downstream portion 500CD, lift 310B' transfers supply container 265A (via lift platform 2013) to breakpack station input conveyor 510. When the lift 310A' includes three lift platforms, the input conveyors 500A, 500B are located at the downstream portion of the input conveyor 500C ( 500CD) may be stopped during delivery of the supply container 265A. Accordingly, in some aspects, lift 310A' is configured to lift a supply container, such as supply container 265B, when at least one other supply container (e.g., supply container 265B) is transferred between conveyors 500A, 500B, and 500C. Includes an additional transit lift platform or transition section (2014, 2015, 2016, 2017) that functions as a transit platform. The transit lift platforms 2014, 2015, 2016, 2017 are moving between conveyor levels. Note that transit lift platforms (2014, 2015, 2016, 2017) may not normally be used to transfer supply containers between conveyor levels, and such transfers between conveyor levels may occur in an opportunistic manner. . For example, if the supply container 265B (shown in FIG. 20C) is to be transferred from the upstream portion 500BU to the downstream portion 500AD, after transferring the supply container 265A to the downstream portion 500CD, the lift platform Rather than waiting for (2011) to align with input conveyor 500B, transit platform 2015 may be employed for such transfer. In some aspects, the additional transit lift platform 2014, 2015, 2016, 2017 may be configured to stack stacked breakpack modules (e.g., stacked breakpack module 266A in a manner substantially similar to that disclosed with respect to lifts 310A, 310B). , 266B, 266C) can be used to transfer the supply container 265 between them.

In a similar manner as disclosed above, the lift(s) 310A', 310B' are configured to deliver the supply container 265 to a predetermined breakpack operator station 140 of the (stacked) breakpack module 266. . For example, lifts 310A', 310B' are configured to transfer supply containers 265 between guide conveyors 500A, 500B, and 500C to output supply containers 265 to breakpack station input conveyor 510. . In one or more aspects, at least a portion of the lifts 310A', 310B' and input conveyors 500A, 500B, 500C are configured to store the supply containers in a predetermined order, such as the superior optimized item order disclosed herein. Supply containers 265 (e.g., breakpack station input sorter 186) for output to breakpack station input conveyor 510 in a predetermined order/sequence (e.g., to breakpack operator station 140). For example, the downstream portions (500AD, 500BD, 500CD) of the guide conveyors (500A, 500B, 500C) are separated from the brake pack by the lift (310B') from the downstream portions (500AD, 500BD, 500CD). Up to the station input conveyor 510, forming a buffer where supply containers are staged (or otherwise maintained) for sequential delivery (e.g., according to any suitable sequence, such as filling an order-out load at an operator station 140, etc.). In another aspect, a single lift 310B' is configured to allow guide conveyors 500A, 500B, 500C (or at least a portion thereof) to pass to lift 310B' and then brake from lift 310B'. It may be provided to operate (e.g., intermittently) to buffer the supply cases 265 for delivery to the pack station input conveyor 510. The predetermined sequence forms a good optimized sequence of articles; It may correspond to a packaging order of breakpack articles (BPG) in the breakpack article container 264, or may correspond to any other suitable sequence, for example, corresponding to a store plan rule. The store plan rule may correspond, for example, to a store plan rule. For example, an aisle layout of a customer store that corresponds to a particular location in the store on which the breakpack product container 264 (or the pallet (PAL) on which the breakpack product container 294 will be delivered) is unloaded, or a series group of items or other types of items. The predetermined order of supply containers 265 to breakpack operator station 140 (and ultimately breakpack article container 294) may also correspond to the durability of the breakpack article (BPG). . For example, after the heavier, more durable brake pack items (BPG) are delivered to the brake pack operator station 140 (and ultimately to the brake pack item container 294), the break pack items (BPG) may break. It may be delivered to the pack operator station 140 (and ultimately to the breakpack item container 294). Here, each lift 310A, 310B is common to and acts on each brakepack operator station 140 of the (stacked) brakepack modules 266A-266C (see Figure 3B).

3A, 6C, 7D, 8A and 8D, from lifts 310A, 310B (or substantially directly from container bot 110), supply container 265 is transferred to breakpack station input conveyor 510. It moves to the brake pack operator station 140. The breakpack operator station 140 is configured to disassemble one or more breakpack articles (BPG) from supply container(s) 265 at the breakpack operator station 140, and at least one article bot 262 One or more breakpack articles (BPG) are configured to be loaded into a breakpack operator station 140 that performs breakpack station output sorting 187. Each brakepack operator station 140 can be either a manual station (see FIGS. 8A and 8B - where the brakepack items (BPG) are picked up and placed by the operator HUM) or an automatic station (see FIG. 7D - where the brakepack items are picked up and placed by the operator HUM). It has at least one worker station 801, 802, 803, 804, which may be deployed by a bot worker ROB. In the example shown there are four operator stations 801, 802, 803, 804; In other embodiments there may be more or less than four operator stations. The picking and transfer of breakpack items (BPG) at one operator station (801, 802, 803, 804) are orthogonal to the picking and transfer of breakpack items (BPG) at other operator stations (801, 802, 803). (e.g., separate and distinct/independent). For example, a breakpack article (BPG) picked at one operator station (801, 802, 803, 804) may be picked at another operator station (801, 802, 803, etc.) (e.g., in article type, order, picking sequence, etc.). , may be unrelated/independent of the brake pack article (BPG) picked at 804).

Supply container 265 moves along breakpack station input conveyor 510 to predetermined operator stations 801, 802, 803, 804, where multi-directional conveyor portion 370 transports supply container 265 to operator stations. It is transmitted to the lift (811) of (801, 802). Input conveyor 510 is any suitable type of conveyor, such as a roller conveyor, continuous belt conveyor, etc. This conveyor is configured in a position to pick up breakpack articles (BPG) from the supply container 265, either humanly or robotically. Lift 811 may be any suitable lift configured to transfer supply container 265 and/or breakpack article container 264 between conveyors (e.g., between conveyors arranged at different heights or at the same height). am. The supply container 265 is pulled from the lift 811 by an operator (human or robot) who opens the supply container and uses the item bot 262 and/or the breakpack (e.g., performing breakpack station output sorting 187). The break pack product (BPG) is transferred to the pick conveyor 818, which picks it up for positioning in the product container 264. Item bots 262 are positioned in queue 844 placed on commodity deck 130DG adjacent operator stations 801, 802, 803, 804, and breakpack commodity containers 264 are placed in queue 844 adjacent to operator stations 801, 802, 803, 804. 803) is located on the batch conveyor 817 (the batch conveyor consists of a container queue 817Q and a lift 817L so that breakpack article containers 264 are filled and transported at operator stations 801, 802, 803, 804). When removed, another breakpack article container 264 is positioned for placing breakpack articles into this other breakpack article container 264 .

Operator stations 801, 802, 803, 804 are positioned at the operator stations to pick up product(s) placed in the item bot 262, product(s) placed in the breakpack item container 264, etc. and any suitable sensor/tracking device and/or indicator displays for indicating and identifying one or more predetermined products. The sensors/tracking devices and/or indicator displays may be substantially similar to those disclosed in U.S. Patent No. 9,037,286, entitled “Each Pick,” issued May 19, 2015, the disclosure of which is incorporated by reference in its entirety. It is integrated into the main hospital. For example, any suitable display 899D may be provided at an operator station 801, 802, 803, 804 to indicate to a (human) operator which product to place (e.g., into the article bot 262 or the breakpack article container 264). Let them know what to pick up, how many of those products to pick up, and where to place the products. Operator stations 801, 802, 803, and 804 may also track the breakpack item container within the automated storage and retrieval system 100, including the SKU of the supply container, the batch of product, the quantity of product placed, and the item. It may include a sensor suite 899 configured to verify the identification of the bot 262 and a record of the breakpack item container.

Operator stations 801, 802, 803, 804 include a waste conveyor 870 where empty (to be discarded) supply containers 265 and other waste are positioned to be removed from the operator stations.

3A, 5A, 5B, 6D, 8A and 8B, supply container 265 and/or partially filled breakpack item container 264 (placed back in storage or supply container 265, and/or where breakpack article containers 264 are filled (e.g., as disclosed) to be transferred to a transfer station (TS) or buffer station (BS) for output from storage and retrieval system 100 (see FIG. 1A). Product (including product, as filled to at least about 30% or at least about 50% capacity) is removed from operator stations 801, 802, 803, 804, at least in part, by pick conveyor 818. For example, For example, pick conveyor 818 transfers supply container 265 and/or breakpack article container 264 to lift 811, which lifts supply container 265 and/or breakpack article container 264. Container output conveyor 820. Container output conveyor 820 is adjacent to or disposed at operator stations 801, 802, 803, 804, operator station conveyor portion 820A, lift 667, and containers. Includes stacked bot transfer conveyor portions 820B, 820C, 820D corresponding to bot travel surfaces 266RS1, 266RS2, 266RS3 Operator station conveyor portion 820A extends to lift 667 and supplies container 265 ) and/or is configured to transfer the breakpack product container 264 to the lift 667. The lift 667 transports the supply container 265 and/or the breakpack product container 264 to the stacked bot transfer conveyor portion. (820B, 820C, 820D), wherein the container bot 110 disposed on each of the moving surfaces 266RS1, 266RS2, 266RS3 is configured to transport a supply container 265 and/or a heat-resistant article container ( 264 ) for storage or for output from the automated storage and retrieval system 100 (carrying at least in part breakpack output sorting 189 ), predetermined stack conveyor portions 820B, 820C. , 820D).

As can be seen in FIGS. 2, 3A, 4 and 7B, breakpack article interface 263 is configured to form footwall 263W (e.g., of article deck 130DG).

having more than one breakpack article interface location or breakpack article container station 263L disposed along at least the entire edge of at least each of the article deck levels 130DG1, 130DG2, 130DG3, each breakpack article interface location ( 263L) is configured to hold each breakpack article container 264. As disclosed, the footwall or multi-layer breakpack article container filling array 263W has a number of levels (PWL), each level (PWL) having a breakpack article interface location 263L at a container filling station area (CFA). When disposed along, it has a container filling station area (CFA), and corresponding breakpack article transfer decks 130DG1-130DG3 juxtaposed along a breakpack article interface location 263L of the container filling station area (CFA). . Here, the footwall 263W is different from and is distinct from the array of storage shelves 130SA of the storage structure 130. Footwall 263W provides at least two degrees of freedom (e.g., multi-axis transition) for article transfer to and from breakpack article interface location 263L, e.g., two degrees of freedom for article transfer deck (263L). 130DG) and across/between levels 130DG1-130DG3 and one or more lengths across/between the gang of levels 130DGL of the footwall 236W. Here, the footwall 263W is at each level of the footwall 263W (e.g., each level of the footwall 263W corresponds to respective levels 130DG1-130DG3 of the gang of levels 130DL). It includes more than one level of breakpack product interface locations 263L distributed along each storage structure level 130L with a corresponding product transfer deck 130DG. The transfer of goods between gangs of different levels 130DG1 - 130DG3 and/or levels 130DGL is carried out by goods bots 262 traversing the ramp of goods deck 130DG, at different levels 130DG1 - 130DG3 and/or gangs of levels 130DGL. 130DG3) and/or a bot lift 490 that transports the article bot 262 between gangs of levels 130DGL, allowing the article bot 262 to exchange breakpack articles (BPG) with the breakpack article lift. This may be accomplished by a breakpack article (BPG) lift transporting the breakpack article (PBG) between different levels, and/or in any other suitable manner.

As container bot 110 transfers one or more (supply) containers to breakpack operator station 140, container bot 110 opportunistically (i.e., container bot 110 264) was not planned to be recovered, but accidentally moved by the break pack product container 264, and for efficiency, the control server 120 sends a command to the container bot 110 to retrieve the break pack product container 264. (in the sense of opportunistic retrieval)), breakpack article containers 264 (designed for storage or transfer to outbound lift 150B) can be picked up from each breakpack article interface location 263L. In another aspect, the breakpack article container 264 in storage may be located in the same picking aisle 130A as the supply container 265, where both the breakpack article container 264 and the supply container 265 are located in the same pick aisle 130A. Designated (e.g., by control server 120) for transfer to pack module 266. Container bot 110, which has previously been commanded to pick up supply container 265, may pick the same pick (e.g., breakpack item container 264 designated for transfer after the initial command is issued to container bot 110). may be commanded by the control server 120 to opportunistically pick up the breakpack item container 264 while moving along the aisle. Here, the container bot 110 can move to the breakpack operator station 140 of the breakpack module 266 by both the breakpack article container 264 and the supply container 265, and then breakpack article container ( 264) can be transferred to a predetermined brake pack product interface location 263L of the same brake pack module 266.

Referring now to FIGS. 1A, 1C, 2, 3A, 3B, 4, 6A, 6B, 7A, 7B, 7C, 7D, 8A and 8B, each breakpack operator station 140 has a respective article deck 130DG. connected to The breakpack article transfer deck 130DG is separate and distinct from the movement loop 233BP formed by the container bot movement surface 266RS, and each edge of the container autonomous transport movement loop 233BP of the container bot movement surface 266RS. Has a breakpack product interface 263 that connects to the moving loop(s) DG1L, DG2L, DG3L (see FIG. 4) of the product transfer deck 130DG disclosed herein. Each item deck level 130DG1, 130DG2, 130DG3 on each level of footwall 263W is separate and distinct from each container bot transfer deck 130EXT connected to each breakpack operator station 140. Here, the breakpack product transfer deck 130DG is configured to allow at least one product bot 262 to traverse the breakpack product transfer deck 130DG and to be transported by at least one container bot 110 on the container transfer deck 130DC. It is configured to transfer the breakpack article (BPG) from the brakepack operator station 140 to the corresponding brakepack article container 264. The article bot(s) 262 are positioned between the breakpack operator station 140 and the breakpack article interface 263 along the breakpack article autonomous transport movement loops DG1L, DG2L, and DG3L formed by the article transfer deck 130DG. is shipped or otherwise configured to transport one or more breakpack articles (BPG) (unpacked from the supply container). Container bot(s) 110 may also interact with breakpack article interface 263 at breakpack article interface 263 as described herein (e.g., operator stations 801, 802, as described herein). 803, 804) and is configured to autonomously pick up and place.

For example, as can be seen in FIG. 1B, one or more breakpack modules 266 may be provided in automated storage and retrieval system 100, where each breakpack module is associated with a respective footwall 263W. Includes. Here, a common portion of the multi-level container storage array (e.g., storage structure 130) and the transfer area (e.g., at least the picking aisle 130A and the container transfer deck 130DC) include one or more of the breakpack operator stations 140. It is communicatively connected to one or more of the footwalls (263W). Each footwall 263W is independent of each other footwall 263W. Each footwall 263W is filled (e.g., with containers and/or breakpack items) independently of each other footwall 263W. As a further example, each footwall 263W performs an independent breakpack goods container 264 output, where each footwall 263W is accessed by container bot(s) 110 and each other footwall ( The independent breakpack article container 264 output of each other footwall 263W is independent of the breakpack article container 264 output of each other footwall 263W, so that they are filled perpendicularly to each other (e.g., separate and distinct/independently). is to provide a breakpack article container 264 output. As an example, orthogonal filling of breakpack container 264 includes filling breakpack container 264 with breakpack articles (BPG) in the order defined by breakpack article container 264, thereby Charging of 264 is allowed to be completed without interfacing with the outputs from footwall 263W or with any other input (e.g., to another breakpack container 264). Here, the breakpack items (BPG) for any given order are grouped together and arranged so that the grouped breakpack items for a given order are shipped directly to a customer (e.g., a commercial customer or an e-commerce customer) or to a distribution center. To form an independent batch of breakpack items defined by the breakpack container 263.

Each independent footwall 263W has a different breakpack article container station or interface location 263L, each of which is connected to a respective other breakpack article container 264 of the independent breakpack article containers 263W. arranged to hold different breakpack article containers (264) that are independently filled with respect to each other, such that each different filled breakpack article container(s) (264) is positioned to hold an independent brake of an independent footwall (263W). Specify pack item container output.

In one aspect, article transfer deck 130DG allows articles to be picked up from one container (such as supply container 265 or any other suitable standardized container) of breakpack operator station 140 and placed at breakpack article interface 263. Facilitates a decanting process that is integrated with articles (generally of the same type) in other (e.g., outbound) supply containers 265 or standardized containers, wherein the other supply containers 265 or Standardized containers are returned to storage. Typically, supply containers 265 inbound to breakpack module 266 are picked up until empty, but only some (but not all) of the items from the inbound supply container may be transferred. Herein, what may be referred to as an outbound (i.e., outbound from the breakpack module 266) supply container 265 or a standardized container (e.g., tote, tray, etc.) may contain breakpack items to facilitate the decanting process. Container 264 may be positioned at breakpack article interface 263 by container bot 110 in a manner similar to that disclosed herein. In the decanting process, the article is removed from the supply container 265 (which may be the original product/item(s) case packaging) at the breakpack operator station 140 and placed at the breakpack article interface 263 (e.g. , are consolidated into outbound supply container(s) 265 or standardized containers (with items of the same type as those being removed from the breakpack operator station 140). Consolidation (and storage by the return container bot 110) of items of the same type from multiple supply containers 265 into fewer supply containers 265 ensures that the supply containers 265 stored in the storage rack are (of the same type therein) of items can be maintained substantially “full” (rather than having multiple containers that are not full), thereby increasing the storage density of the automated storage and retrieval system 100. In some embodiments, the decant articles (in standardized containers or outbound supply containers) may be palletized as part of a pallet load (e.g., at output station 160UT) or shipped individually (e.g., at output station 160EC). It is withdrawn from the storage and retrieval system 100 via lift 150.

Item bot 262 may be any suitable type of autonomous guidance bot with a payload configured to contain breakpack items, rather than an item container (e.g., case unit, pick face, etc.). The article bot 262 traverses the article deck 130DG and along the corresponding/each article deck 130DG and the article decks at different levels (e.g., collective level 130DGL) of the footwall 263W. 130DG), and is configured to transport a breakpack article (BPG) to each breakpack article interface location 263L at each level of the footwall 263W. Also, referring to Figure 25, the product bot 262,

Z using a two-dimensional or three-dimensional camera 2593 to raise or lower at least one autonomously guided breakpack goods transport vehicle longitudinally and between levels along a path (e.g., along goods deck 130DG). One or more of wheel odometer measurement (2590), dead reckoning (2591), range measurement and origin detection, alone or in combination, with an electromagnetic distance sensor or vision device (2592) that informs vehicle attitude and position in the direction of the vehicle, brakes, etc. Perform attitude determination and positioning of the article bot 262 within the pack module 266 and also detour between the breakpack article transfer decks 130DG1-130DG3 and at least one level at a substantially constant movement speed during transitions. It is configured to perform free transition of vehicle movement between routes (e.g., ramps and lifts of the brakepack module 266 disclosed herein) and vice versa. Each of the article bots 262 has a payload holding/support portion 262PS configured differently from the payload support portion of the container bot 110. As disclosed herein, article bots 262 are configured to generate, from each payload support 262PS, a breakpack article unit (comprising at least one breakpack article BPG - see FIGS. 7A and 7B) transported thereto. It is configured to output the payload (BPGPL) to the breakpack article container 264 at each breakpack article interface location 263L at each level of the footwall 263W. The article bot 262 is configured to autonomously move along and across the breakpack article autonomous transport movement loop(s) DG1L, DG2L, DG3L formed by the article deck 130DG. The article bot 262 autonomously transports one or more breakpack articles (BPG) (retrieved from the breakpack operator station 140) from the article bot 262 to the breakpack article container 264 at the breakpack article interface 263. It is configured to unload.

In one or more aspects, with reference to FIGS. 21 and 22 , article bots 262 are substantially similar to container bot 110, but have a payload configured differently from the payload support of container bot 110, as previously mentioned. It may be a non-holonomic autonomous vehicle with a support or a non-holonomic article bot (262NH). For example, item bot 262 may each include a frame or chassis 262F1, a drive system 2100, a controller 262C, and one or more sensors 2110. The drive system 2100 includes any suitable number of motor(s) configured to drive a pair of drive wheels 262DW disposed at or adjacent to one end of chassis 262F1. The drive wheels 262DW are configured to rotate at the same rotational speed (e.g., for substantially straight-line movement of the article bot 262) or at different speeds (e.g., for rotating the article bot 262 along an arcuate path of movement). It may also be driven differentially in opposite directions (e.g., to pivot article bot 262 about a pivot axis located substantially midway between drive wheels 262DW). 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 retainers 2120A, 2120S (integrated or coupled to chassis 262F1 in any suitable manner) configured to retain one or more breakpack articles (BPG). Payload holding portion 2120A, 2021S is an open container, box, tray or other suitable structure configured to receive/hold breakpack article (BPG) for transportation by article bot 262, wherein payload holding portion ( 2120A, 2120S) lack grippers, alignment, etc. that can grip and prevent the breakpack article (BPG) from moving within the payload holding portion 2120A, 2120S. As an example (see FIG. 21), payload holder 2120A is an asymmetric payload holder extending longitudinally along the longitudinal axis LAX of chassis 262F (e.g., payload holder 2120A). The longitudinally extending sides LS1 and LS2 of the 2120A are longer than the laterally extending sides LS3 and LS4 of the payload holding unit 2120A). In this example, the breakpack article (BPG) is moved along the longitudinal/axis LAX of article bot 262 (e.g., into a container positioned at breakpack article interface location 263L) from payload holder 2120A. may be released accordingly (see also Figure 25). In another aspect, the breakpack article (BPG) is transferred from the payload holder 2120A (e.g., to a container disposed at the breakpack article interface location 263L) in the lateral direction/axis (LAT) of the article bot 262. (see also Figure 25). As another example (see FIG. 22), the payload holding portion 2120S has longitudinally extending sides LS1 and LS2 of the payload holding portion 2120A, and lateral extending sides LS3 of the payload holding portion 2120A. , LS4) and is a symmetrical payload holding portion of substantially the same length. In this example, the breakpack article (BPG) is transferred from payload holder 2120S (e.g., to a container positioned at breakpack article interface location 263L) along the lateral orientation/axis (LAT) of article bot 262. may be released accordingly (see also Figure 25). In another aspect, the breakpack article (BPG) is transferred from the payload holder 2120S (e.g., to a container disposed at the breakpack article interface location 263L) along the longitudinal/axial LAX of the article bot 262. (see also Figure 25).

Sensors 2110, under the control of controller 262C, facilitate traversal of article bot 262 along article deck 130DG and release of breakpack article (BPG) at breakpack article interface location 263L. and any suitable navigation and/or object detection sensors. Sensors 2110 may include, by way of example, one or more reference points located in the storage and retrieval system 100 structure, a guide tape disposed on item deck 130DG, an indoor GPS, a navigation beacon, and/or any other suitable Any suitable navigation aid 2510 (see FIG. 25), including a navigation aid, may be employed/configured to detect navigation of each item bot 262 along item deck 130DG.

In one or more aspects, as shown in FIGS. 23 and 24 , article bot 262 is a holonomic autonomous device with payload retention configured not similarly to the payload retention of container bot 110 as noted above. It may be a vehicle or a holonomic item bot (262H). For example, item 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 longitudinal ends of frame or chassis 262F2. The drive wheels 262DW rotate at the same rotational speed (e.g., for substantially straight movement of the article bot 262) or at different speeds (e.g., to rotate the article bot 262 along an arcuate path of movement). , and differentially in opposite directions (e.g., to pivot article bot 262 about a pivot axis located substantially in the middle of chassis 262F2 between drive wheels 262DW). One or more caster wheels 262CW are located at each longitudinal end of chassis 262F2.

Chassis 262F2 includes any suitable payload retainers 2120A, 2120S (integral to or coupled to chassis 262F1 in any suitable manner) configured to retain one or more breakpack articles (BPG). Payload holding portion 2120A, 2021S is an open container, box, tray or other suitable structure configured to receive/hold breakpack article (BPG) for transportation by article bot 262, wherein payload holding portion ( 2120A, 2120S) lack grippers, alignment, etc. that could otherwise grab the breakpack article (BPG) and prevent its movement within the payload holding portions 2120A, 2120S.

As an example (see FIG. 23), payload holder 2120A is an asymmetric payload holder extending longitudinally along the longitudinal axis LAX of chassis 262F (e.g., payload holder 2120A). The longitudinally extending sides LS1 and LS2 of 2120A are longer than the lateral extending sides LS3 and LS4 of the payload holding portion 2120A). In this example, the breakpack article (BPG) is transferred from payload holder 2120A (e.g., to a container positioned at breakpack article interface location 263L) along the longitudinal/axial (LAX) of article bot 262. (see also Figure 25). In another aspect, the breakpack article (BPG) is transferred from the payload holder 2120A (e.g., to a container positioned at the breakpack article interface location 263L) in the lateral/axial (LAT) direction of the article bot 262. (see also Figure 25). As another example (see FIG. 24), the payload holding portion 2120S is configured such that the longitudinally extending sides LS1 and LS2 of the payload holding portion 2120A are lateral extending sides of the payload holding portion 2120A. It is a symmetrical payload holding portion that is substantially the same length as (LS3, LS4). In this example, the breakpack article (BPG) is transferred from the payload holder 2120S (e.g., to a container positioned at the breakpack article interface location 263L) in the lateral direction/axis (LAT) of the article bot 262. (see also Figure 25). In another aspect, a breakpack article (BPG) is transferred from payload holder 2120S in the longitudinal/axial direction (LAX) of article bot 262 (e.g., to a container positioned at breakpack article interface location 263L). ) can be released (see also Figure 25).

Sensors 2110, under the control of controller 262C, facilitate traversal of article bot 262 along article deck 130DG and release of breakpack article (BPG) at breakpack article interface location 263L. and any suitable navigation and/or object detection sensors. Sensors 2110 may include, by way of example, one or more reference points located in the storage and retrieval system 100 structure, a guide tape disposed on item deck 130DG, an indoor GPS, a navigation beacon, and/or any other suitable Any suitable navigation aid 2510 (see FIG. 25), including a navigation aid, may be employed/configured to detect navigation of each item bot 262 along item deck 130DG.

The article bot 262 (as either a non-holomic article bot 262NH or a holonomic article bot 262H) may include an asymmetric payload retainer depending on the configuration of the breakpack article container 264 that interfaces with the article bots 262. (2120A) or a symmetrical payload holding portion (2120A). For example, the orientation and/or (symmetrical or asymmetrical) shape of the payload retainers 2120A, 2120S (e.g., longitudinal release of the breakpack article BPG or lateral release of the breakpack article BPG) , matches the orientation/shape of the breakpack product container 264 to maximize loading of the breakpack product container 264. As disclosed herein, the fill of the breakpack article container 264 is considered maximized when the breakpack article (BPG) therein occupies at least about 30% of the container volume or at least about 50% of the container volume. It can be. For example, as can be seen in FIG. 25 , when filling the breakpack article container 264, the article bot 262 orients the payload retainer, particularly the asymmetric payload retainer 2120A, to: The orientation of the payload holding portion 2120A is ensured to match the orientation of the breakpack article container 264 to be filled. As can be seen in FIG. 25, when the longitudinally extending sides 264S1 and 264S2 of the longitudinally extending breakpack article container 264 extend away from the side of the article deck 130DG, the article bot 262 extends the longitudinally extending sides LS1 and LS2 of the payload holding portion 2120A to the movement lane 2120A, and extends the longitudinally extending sides LS1 and LS2 of the payload holding portion 2120A to the breakpack product container 264. An article deck moving substantially into the travel lanes L1, L2, L3 to align with the longitudinally extending sides 264S1, 264S2 of the breakpack article container 264 for longitudinal discharge of breakpack article PBG. It can be self-oriented with respect to (130DG). Also, as can be seen in FIG. 25, when the longitudinally extending sides 264S1 and 264S2 of the longitudinally extending breakpack product container 264 extend along the side of the product deck 130DG, the product bot (262) is that the longitudinally extending side (L side (264S1, 264S2)) of the payload holding portion (2120A) is for lateral discharge of the breakpack article (PBG) into the breakpack article container (264). It may orient itself relative to the article deck 130DG substantially along one of the travel lanes L1, L2, L3 to align with the longitudinally extending sides 264S1, 264S2 of the breakpack article container 264. .

Automated storage and retrieval system 100 may include non-holonomic item bots, holonomic item bots, or both non-holonomic item bots and holonomic item bots traversing item deck 130DG. Suitable examples of article bots 262 include those manufactured by Tompkins International of Raleigh, North Carolina (USA - see e.g. US Patent No. 10,248,112, issued April 2, 2019), Seattle Washington (USA). These include the Pegasus drive bot, available from Amazon.com Inc., and mobile bots (e.g., Latent Mobile Robot) available from Hikrobot Technology Co., Ltd., Hangzhou, China. Other suitable examples of item bots 262 and container bots 110 are disclosed in U.S. Patent Application No. 17/358,383, filed June 25, 2021, which is a U.S. patent application filed on June 26, 2020. General Application No. 63/044,721, both entitled “Warehouse System for Storing and Retrieving Items in Containers,” the disclosure of which is incorporated herein by reference in its entirety.

As described herein, the breakpack article autonomous transport movement loop(s) (DG1L, DG2L, DG3L) formed by article deck 130DG are configured to, relative to article bot 262, the article bot 262 operates. Provides random and respective random access of the breakpack article interface 263 on each article deck level (130DG1, 130DG2, 130DG3) and random of the gang on each article deck level (130DGL).

Each article deck 130DG includes gangs at the article deck level 130DGL. For example, each article deck 130DG (which may be one or more article decks stacked on top of each other - see FIG. 3B) may have deck levels 130DG1, 130DG2 (in the example shown, substantially one stacked on top of the other). , including gangs at operator station deck level (130DG0) and goods deck level (130DGL), including 130DG3. Here, operator station deck level 130DG0 is an article deck level 130DGL at which article bot 262 navigates and/or moves articles on multiple article deck levels 130DG0, 130DG1, 130DG2, 130DG3 as part of a transport operation. Common to each commodity deck level (130DG1, 130DG2, 130DG3) of the gang (e.g., the above task routes commodity bots 262 in real time between multiple commodity deck levels 130DG0, 130DG1, 130DG2, 130DG3 to breakpack selecting the article BPG, placing the breakpack article BPG, and returning it to an operator station 801, 802, 803, 804 or another suitable location such as an article bot introduction/removal station disclosed herein).

In aspects of the disclosed embodiments, each gang of article deck levels 130DGL comprises three article deck levels 130DG1, 130DG2, 13DG3 substantially stacked one above the other, although in other embodiments each gang of article deck levels 130DGL ) can contain any suitable number of item deck levels in a gang. Breakpack goods (BPG) (FIG. 7B) are transported by a breakpack operator to breakpack goods container 264 in one of the goods deck levels 130DG1, 130DG2, 130DG3 of the gang at goods deck level 130DGL. It is delivered from the station 140 to the product bot 262 of the breakpack module 266.

As can be seen in Figure 4, each of the article deck levels 130DG1, 130DG2, and 130DG3 combines with the operator station deck level 130DG0 to form breakpack article autonomous movement loops DG1L, DG2L, and DG3L (e.g. For example, operator station deck level 130DG0 forms a common/shared loop portion for each of the breakpack article autonomous movement loops DG1L, DG2L, and DG3L). Item bot 262 stores breakpack items between breakpack item interface 263 and operator stations 801, 802, 803, 804 (e.g., at different item deck levels 130DG1, 130DG2, 130DG3). Circulate along autonomous movement loops (DG1L, DG2L, DG3L).

In the illustrated example, operator station deck level 130DG0 is at the same height (i.e., substantially in the same plane) as article deck level 130DG2, where deck transition 130DG2R is between article deck level 130DG2 and operator station deck. Available between levels 130DG0); However, in another aspect, operator station deck level 130DG0 may be the same level as any of the article deck levels 130DG1, 130DG2, and 130DG3. In another aspect, ramps may be provided between each of the operator station deck level 130DG0 and the article deck levels 130DG1, 130DG2, and 130DG3 (e.g., the operator station deck level is one of the article deck levels). may not be coplanar with anything). In the example shown, ramps 130DG1R, 130DG3R are provided between operator station deck level 130DG0 and article deck level 130DG1, 130DG3. Although ramps 130DG1R, 130DG3R are shown, any suitable lift, escalator, elevator, ladder, etc. may be provided, and item bot 262 operates at operator station deck level 130DG0 and item deck levels 130DG1, 130DG2. , 130DG3)) is configured to traverse/climb to transition between them. .

Ramps 130DG1R, 130DG3R and deck transition 130DG2R extend from the output end 130DG0E1 of the operator station deck level 130DG0. One or more of the article deck levels 130DG1, 130DG2, 130DG3 extend to return to the input end 130G0E2 of the operator station deck level 130DG0. In the shown, article deck level 130DG1 includes a return ramp 455 in communication with an input end 130DG0E2 of operator station deck level 130DG0. Return ramp 455 is common to each of the article deck levels 130DG1, 130DG2, 130DG3, where ramps (described below) are provided from article deck levels 130DG2, 130DG3 to article deck level 130DG1, Item deck levels 130DG2, 130DG2, 130DG3 provide access to return ramp 455.

According to the disclosed embodiment, item bot 262 does not need to travel to operator station deck level 130DG0 to transition between item deck levels 130DG1, 130DG2, and 130DG3. For example, one or more ramps 451, 452, 453, 454 may be provided between article deck levels 130DG1, 130DG2, 130DG3 so that article bot 262 can access articles without crossing operator station deck level 130DG0. This allows virtually direct switching between deck levels (130DG1, 130DG2, 130DG3). In some aspects, item bot 262 moves bidirectionally on one or more ramps 451, 452, 453, 454 to transition between different item deck levels 130DG1, 130DG2, 130DG3; In another aspect, by moving along one or more ramps 451, 452, 453, 454, the article bot 262 reaches the article deck level 130DG2, 130DG3 for return to operator stations 801, 802, 803, 804. It may be unidirectional to transition from one or more of the goods deck levels 130DG1.

One or more shunts 461, 462, 463 are provided at one or more (or each) of the article deck levels 130DG1, 130DG2, 130DG3. The shunts 461, 462, and 463 are designed to effectively reduce the size of the breakpack article autonomous movement loop moved by the article bot 262 to substantially reduce the size of each breakpack article autonomous movement loop (DG1L, DG2L, DG3L). provides a transition between opposing sides. The shunt 461 at article deck level 130DG1 is a shunted breakpack article autonomous movement loop that effectuates circulation of article bots 262 on article deck level 130DG1 without traversing article bots at operator station deck level 130DG0. (DG1LS) is formed. The shunt 462 at article deck level 130DG2 is a shunted breakpack article autonomous movement loop that effectuates circulation of article bots 262 at article deck level 130DG2 without traversing article bots at operator station deck level 130DG0. (DG2LS) is formed. The shunt 463 at article deck level 130DG3 is a shunt breakpack article autonomous movement loop DG3LS that performs circulation of article bots 262 at article deck level 130DG3 without traversing article bots at operator station deck level 130DG0. forms. Although one shunt is shown for each of the article deck levels 130DG1, 130DG2, 130DG3 for illustrative purposes only, any suitable number of shunted breakpacks in each article deck level 130DG1, 130DG2, 130DG3 may be used. There may be one or more shunts for each of the article deck levels 130DG1, 130DG2, 130DG3 to form article autonomous movement loops.

Note that at least some of the lanes of the travel loop (DG1L, DG2L, DG3L, DG1LS, DG2LS, DG3LS) are separated from each other by a physical barrier. In the example shown, operator station deck level 130DG0 may have multiple travel lanes similar to container deck 130D, ramps 130DG1R, 130DG3R, 451, 452, 453, deck transition 130DG2R, and Deck levels 130DG1, 130DG2, and 130DG3 are configured to allow item bots 262 to move from one lane to another (with shunts each providing a single bot movement lane, except for predetermined locations such as the shunts described herein). have single lane movement surfaces (e.g., forming at least part of a movement loop) that are physically separated to prevent Here the physical separation is provided by an "air gap" in the center of the moving loop, but in other embodiments the physical separation may be provided by a wall or other suitable structural barrier.

In another aspect, the movement surfaces of the ramps 130DG1R, 130DG3R, 451, 452, 453, deck transition 130DG2R, article deck level 130DG1, 130DG2, 130DG3, and operator station deck level 130DG0 are configured to each move: There may be multiple lanes providing unidirectional and/or bidirectional movement of the item bot around the loop. For example, referring to Figure 25, one or more of the above-mentioned portions of article deck 130DG (Figure 25 shows the moving surfaces of ramps 130DG1R, 130DG3R, 451, 452, 453, deck transition 130DG2R, article deck Note that it represents one or more of levels 130DG1, 130DG2, 130DG3, and operator station deck level 130DG0) includes a number of travel lanes (L2, L2, L3). Although three lanes of movement L1, L2, L3 are shown in Figure 25, it should be understood that there may be more or less than three lanes of movement. For example, as shown in FIGS. 3A, 4, 7A and 7C, at least a portion of the item deck levels 130DG1, 130DG2, and 130DG3 include multiple lanes L1 and L2. Multiple lanes (L1, L2, L3) allow one article bot 262 to pass another article bot 262 or otherwise move in any suitable manner (e.g., obstacle avoidance navigation).

As an example of item bot obstacle avoidance navigation, item bot 262 is configured to execute item bot actions by actuation system 2100, such as via controller 262C and sensor 2110. may be, whereby the article bot 262 travels in lanes L1, L2, L3 along a substantially smooth curved bot traverse path 2550 (see FIG. 25) on the article deck 130DG transport surface. Allows switching between The substantially smooth curved bot crossing path 2550 includes a stopover point (LW1) in one of the travel lanes (L1, L2, L3) along the substantially smooth curved bot crossing path 2550, where the product Connects the different stopping point LW2 to another of the travel lanes L1, L2, L3 with a predetermined optimal trajectory of the article bot 262, determined based on the bot dynamic model. A suitable example of obstacle avoidance navigation is described, for example, in U.S. Patent No. 11,117,743, entitled “Storage and Retrieval System,” issued September 14, 2021, the disclosure of which is incorporated herein by reference in its entirety. do.

Continuing to refer to FIGS. 3A, 4, 7A, 7C, and 25, one of a plurality of lanes (e.g., lane L2 in FIGS. 3A, 4, 7A, and 7C or any of lanes L1, L2, L3 in FIG. 25) One) may be an article bot lane (e.g., a broken lane) that is, at least partially, unusable and an article bot in need of repair (e.g., by the disclosed article bot lift module 490 or by a human operator) is located in the breakpack module. It is stored in a dynamically variable portion of lane L2 for removal from 266. For example, an unusable (or in-service) item bot 262D (see FIG. 7A) located in lane L2 (or in other embodiments lanes L1 or L3) may indicate that item bot 262D is unusable. A signal indicating the signal is sent to the controller 120 and its position within the brake pack module 266 is notified to the controller 120. The controller 120 determines the location of the dead article bot 262 as a damage zone 777 (which may be located anywhere along lane L2, or in other embodiments, such as L1 where the dead article bot 262D is located). Designates and operationally routes article bots 262 around dynamically designated damage zones 777 (where rerouting is performed by redirection through one or more bypass lanes or shunts/ramps). When there are two or more movement lanes (L1, L2, L3), designating at least a portion of one of the movement lanes (L1, L2, L3) by the controller 120 as the damage zone 777 (or bypass lane). This may be dynamic, such that the controller 120 may use one or more of the travel lanes (L1, L2, L3) as a breakdown zone (or bypass lane) for a period of time corresponding to the presence of a disabled bot. Based on a signal transmitted to the controller 120 by the failure bot 262, a portion of any one or more movement lanes L1, L2, and L3 can be temporarily designated as the failure zone 777. Suitable examples of bypass lanes include, for example, U.S. Patent No. 9082112, entitled “Autonomous Transport Vehicle Charging System,” issued July 14, 2015, and US Patent No. 9082112, issued February 7, 2017, entitled “Autonomous Transport Vehicle.” It can be found in U.S. Patent No. 9561905, the disclosure of which is hereby incorporated by reference in its entirety.

As disclosed herein, one or more barriers 766A, 766B (FIG. 7C shows a dynamically designated breakage zone ( 777) can be deployed to close access to

One of the plurality of lanes (e.g., lane L2 in FIG. 7A or e.g., any one or more of lanes L1, L2, L3 in FIG. 25) is, at least in part, a breakpack article of footwall 263W. Can be a buffer 778 for the product bot 262 that executes sequential delivery of breakpack articles (BPG) (e.g., breakpack order sorting 188) by the article bot 262 at the interface 263. (Therefore, the ordering of any given one or more breakpack article containers 264 placed at the breakpack article interface 263 of the footwall 263W - the ordering also allows the article bot 262 to move around the loop. can be provided by circulating )). Here, the controller 120 allows the product bot 262 to traverse a movement loop or to select different breakpack products (BPG) from the same (i.e., common) breakpack in a predetermined order of mixed breakpack products (BPG). Until the predetermined time is reached for delivery of the breakpack goods (BPG) carried by the goods bot 262 to be placed in the goods container 264, lane L2 (or if there are two lanes L1, L2) can be instructed to buffer itself in L1, or in any of the lanes L1, L2, L3, ...Ln, where n is an integer representing the maximum number of lanes (e.g., a predetermined order is: The more durable/larger breakpack products or any other suitable sequence such as disclosed herein is followed by the more fragile/smaller breakpack items in any suitable order such as being placed in the breakpack item container BPG).

As mentioned herein, sequencing may be performed at a single article deck level (130DG1, 130DG2, 130DG3) or across/between multiple article deck levels (130DG1, 130DG2, 130DG3) and may be performed on a breakpack article (BPG). ) switches between item deck levels 130DG1, 130DG2, 130DG3 to pick up and place and return to the breakpack operator station 140.

Also referring to FIG. 7B , note that one or more breakpack article containers 264 on footwall 263W may be partitioned breakpack article containers 264PP. Here, the partitioned breakpack article container 264PP is shown as having two partitions P1 and P2; In other aspects, two or more partitions may be provided. Typically, each breakpack item container 264 corresponds to an order for any particular (e.g., one) customer (i.e., store, e-commerce customer, distribution center, etc.). Compartmented breakpack product container 264PP provides for, or otherwise performs, batch processing of breakpack product orders from two or more customers. For example, a distribution center customer (e.g., referred to as a regular customer) who holds inventory and ships corresponding items to his or her own customers (herein referred to as downstream customers) may place two separate Breakpack product orders, each Orders correspond to sub-customers. The storage and retrieval system 100 can batch process two separate breakpack product orders (corresponding to two sub-customers) into a single compartmentalized breakpack product container 264PP for delivery to a general customer.

3A, 4, 7A, 7C, and 25, as noted above, one of the multiple lanes (e.g., lane L2) is, at least partially, an unusable bot lane (e.g., a broken lane). ), wherein items requiring maintenance (or otherwise unusable) may be stored for removal from the breakpack module 266 (e.g., by the item bot lift module 490 disclosed herein or by a human operator). do. Here, item deck levels 130DG1, 130DG2, 130DG3 (and/or item deck level 130DG0) close (or restrict) access to the portion of the deck level where unusable item bots are located and/or item Bots 262 are configured to instruct bots 262 to leave the affected area (if they are able to leave or otherwise block any item bots remaining in the affected area). For example, the commodity deck levels (130DG0, 130DG1, 130DG2, 130DG3) are described in detail in the U.S. patent issued August 11, 2020 and entitled “Automated Storage and Retrieval System with Integral Secured Personnel Acess Zones and Remote Rover Shutdown.” No. 10,739,766, and U.S. Patent No. 10,507,988, entitled “Maintenance Access Zones for Storage and Retrieval Systems,” issued December 17, 2019, the disclosures of which are incorporated herein by reference in their entirety.

For example, referring to Figure 7C, one or more portions of article deck 130DG are positioned to close (or block) access to each portion of article deck 130DG. Includes collapsible barriers (e.g., gates, nets, fences, etc.) that retract to provide access to each portion of the goods deck 130DG. As can be seen in Figure 7C, at least one barrier 766A, 766B is provided, for example, at article deck level 130DG1 (similar barriers may also be provided at other article deck levels). Barriers 766A, 766B are positioned adjacent shunt 461 along respective portions L1A, L1B of lane L2 (e.g., to block or close). The barriers 766A, 766B may be configured to allow item bot 262 to continue operating within open (e.g., unblocked) portions of breakpack module 266. These are locations at article deck level 130DG1 to allow access to shunt 761 when deployed. In one or more aspects, the breakpack article autonomous movement loops DG1L, DG2L, DG3L are disclosed as generally having a common direction of movement (i.e., the article bot moves in a single loop direction), but the barriers 766A, 766B When deployed, one or more portions of the breakpack article autonomous movement loops DG1L, DG2L, DG3L may allow movement of the interactive article bot 262 (e.g., under traffic management control of controller 120).

When a portion of article deck levels 130DG1, 130DG2, 130DG3 (and/or article deck level 130DG0) is closed, operation of breakpack module 266 places breakpack article (BPG) in breakpack article container 264. By directing/redirecting (redirecting) the commodity bot to different commodity deck levels (130DG1, 130DG2, 130DG3) (and/or commodity deck level 130DG0), or ramps (451-453, 130DG1R-130DG3R) and using shunts 461 (see FIGS. 2 and 4 ) to direct/redirect article bots around closed portion(s) of article deck levels 130DG1, 130DG2, 130DG3 (and/or article deck level 130DG0). This allows it to continue without interruption. The controller 120 can redirect item bot 262 on the fly (e.g., while performing an item bot task), or on the fly (e.g., while performing an item bot task), along a different travel route (other than a previously planned route). For example, while performing a commodity bot task, it may be configured to redirect to a different breakpack commodity container 264 (other than the previously determined breakpack commodity container), thereby causing the commodity deck level 130DG1, 130DG2 , 130DG3) (and/or goods deck level 130DG0) to avoid closed areas and maintain uninterrupted operation of the breakpack module 266.

4 and 10, article deck 130DG includes at least one article bot lift module 490 for inputting and/or removing article bots 262 into or from breakpack module 266. Includes. In one or more aspects, at least one article bot lift module 490 facilitates removal of an unusable article bot 262D and/or lifts article bot 262 to/from breakpack module 266 for any suitable reason. ) and at least one item bot lift module 490 for performing placement and removal of the product. For example, product bots 262 may be entered or removed based on load balancing (e.g., predetermined throughput), product bot congestion/traffic, product bot maintenance, and/or any other suitable criteria. Item bot lift module 490 may be substantially similar to that disclosed in U.S. Patent No. 10,221,013, entitled “Storage and Retrieval System Rover Interface,” issued March 5, 2019, the disclosure of which is incorporated herein in its entirety. Incorporated by reference. As an example, at least one item bot lift module 490 may be interfaced with item deck(s) 130DG. 4 and 10, at least one article bot lift module 490 interfaces with article deck levels 130DG1, 130DG2, 130DG3 of a stack of gangs of article deck level 130DGL; In another aspect, at least one item bot lift module 490 is interfaced with one or more (stacked) operator station deck levels 130DG0 (see Figure 4) in a manner substantially similar to that shown in Figure 10. The interface between at least one article bot lift module 490 and an article deck 130DG may be positioned at a predetermined location on the article deck 130DG, thereby providing an article bot 262 for each article deck 130DG. The input and output of the breakpack module 266 becomes substantially separate from the throughput of the breakpack module 266 (e.g., the input and output of the article bot 262 at each article deck level does not affect the throughput). In one aspect, at least one item bot lift module 490 is configured to include a spur or staging area 491 connected to or forming part of item deck 130DG for each item deck level 130DG1, 130DG2, 130DG3. (e.g., a loading platform of an item bot - see FIG. 4) and/or an operator station deck level 130DG0. In another aspect, at least one article bot lift module 490 may interface substantially directly with one or more of the operator station deck level 130DG0 and/or the article deck levels 130DG1, 130DG2, 130DG3.

Item deck 130DG and/or staging area 491 may include any suitable barrier that substantially prevents item bot 262 from moving out of item deck 130DG and/or staging area 491 at the lift module interface. Please note that it may include 1032). In one aspect, the barrier 1032 has a placement location to substantially prevent the article bot 262 from moving out of the article deck 130DG and/or the staging area 491 and the article bot 262 lifts the article bot. It may be a movable barrier that can move between a retracted position to transition between lift platform 1031 of module 490 and item deck 130DG and/or staging area 491.

In addition to inputting or removing an article bot 262 from the breakpack module 266, in one aspect, each article bot lift module 490 may lift an article bot 262 from the breakpack module 266. , between article deck levels 130GD0, 130DG1, 130DG2, 130DG3 of a gang of article deck levels 130DGL and/or article deck levels 130GD0 of other (e.g. stacked) gangs of article deck levels 130DGL. , 130DG1, 130DG2, and 130DG3). The controller 120 may utilize the article bot lift module 490 to perform article bot balancing wherein the article bot lifts between article deck levels 130DG1, 130DG2, 130DG3 and/or between different gangs of article deck levels 130DGL. Workloads can be introduced from outside the rakepack module 266 into predetermined gangs of commodity deck levels 130DG0, 130DG1, 130DG2, 130DG3 and/or commodity deck levels 130DGL through the introduction of commodity bots 262, Removal of article bot ret module 490 from breakpack module 266, and/or article bot 262 and/or breakpack module 266 between article deck levels 130DG0, 130DG1, 130DG2, 130DG3. Balances the transfer of gangs at the commodity deck level (130DGL) without removing the commodity bots 262 from them. In one aspect, the transfer of gangs of article bots and/or article bot lift modules 490 between different article deck levels 130DG0, 130DG1, 130DG2, 130DG3 includes article bot payloads Performed independently of transport (e.g., breakpack items (BPG) are not placed in the item bot 262 when transported between storage deck levels or gangs of deck levels using the item bot lift module 490 )). In another aspect, article bot 262 may use article bot lift module 490 to transport a payload (e.g., breakpack article BPG) while being transferred between storage deck levels or gangs of deck levels. .

For illustrative purposes only, each item 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 that allows the lift platform 1031 to move between deck levels 130DG1, 130DG2, 130DG3 and/or deck level 130DG0. The rover lift module 190 controls the lift platform 1031 to cause movement of the lift platform 1031 in the direction of arrow Z between deck levels 30DG1, 130DG2, 130DG3) and/or deck level 130DG0. It may include any suitable drive system 1019M coupled to.

The lift platform 1031 has a frame 1031F that forms the article bot support 1051 having at least one opening 1052 to allow the article bot 262 to move to and from the article bot support 1051 ) includes. Frame 1031F may have any suitable configuration and may be moveably coupled to frame 1030 and drive system 1019M in any suitable manner. The movable coupling between frame 1031F and frame 1030 may also include any suitable guidance elements to substantially prevent movement of lift platform 1031 in the X-Y plane. For illustrative purposes, frame 1031F may support article bot support 1051, for example, to substantially prevent article bot 262 from driving or otherwise moving on lift platform 1031 during transportation of article bot 262. ) may further include one or more fences (1050A-1050C) to substantially surround the. At least one of the fences 1050A-1050C is moved to frame 1031F so that item bot 262 can move between rover support 1051 and, for example, item deck 130DG (and/or staging area 491). Possibly installed. In one aspect, frame 1031F includes a first end 1031E1 and a second end 1031E2 longitudinally separated from first end 1031E1. The item bot 262 is positioned between a first position for allowing the item bot 262 to enter or exit the lift platform 1031 and a second position for supporting the item bot 262 to the lift platform 1031. One or more of the fences 1050B and 1050C located at the first and second ends 1031E1 and 1031E2 may be moved up and down the lift platform 1031 along the longitudinal axis LA. Fence 1050A loads article bots 262 onto/from lift platform 1031, for example, from the floor (or other “ground” level) of a warehouse where automated storage and retrieval system 100 is located. It may be similarly pivotable so that it can be moved or removed. In other aspects, item bot 262 may be loaded onto lift platform 1031 in any suitable manner.

It may be desirable for any item bot 262 to have the ability to initiate operation substantially anywhere within the breakpack module 266. To do so, it is desirable for the item bot starting location to be determined in a substantially autonomous manner. In one aspect, registration station(s) 1013R may be distributed throughout the breakpack module 266 to provide sufficient location data for article bots 262 that lack article bot pre-positioning data, thereby Controller 262C of 262 (FIG. 1A) allows item bot 262 to determine where within automated storage and retrieval system 100 (FIG. 11, block 1100). Registration station 1013R may be configured, for example, for item bot cold start (if item bot lacks pre-positioning data) and item bot derivation/extraction update at any desired location throughout automated storage and retrieval system 100; For example, an item bot 262 location and/or automatic registration system may be provided to allow for the item bot's onset, offset, and updated registration. The location of each registration station 1013R is within a frame of reference (e.g., a global three-dimensional reference space, in other aspects the global reference space may have any suitable number of dimensions) of the automated storage and retrieval system 100 structure. can be mapped. When the item bot 262 and the registration station interface, the position in the three-dimensional reference space with which the item bot 262 is interfacing is transmitted to both the item bot 262 and the controller 120 to control one or more autonomous item bots. And the product bot 262 can be controlled by the controller 120.

The product transfer deck(s) 130DG of the breakpack module 266 facilitate physical guidance and extraction of the product bot 262 at each deck level (130DG0, 130DG1m, 130DG2, 130DG3) of the breakpack module 266. To do so, the item bot 262 may be positioned with any suitable rover entry/exit feature, such as the lift module 490 or any other structural features (e.g., ports, openings, platforms). In one aspect, in a manner substantially similar to that described above with respect to item bot 262 lift module 490, registration station 1013R may be located and associated with a particular entry/exit station. Registration station 1013R may be initialized and mapped to a stored three-dimensional reference space using any suitable controller, such as control server 120 (Figure 11, block 1110). Each registration station 1013R has item bot(s) 262 (which may lack bot pre-positioning data) within a predetermined proximity and/or orientation to the registration station 1013R. ) (Figure 11, block 1120). In one aspect, item bot 262 provides location data when item bot 262 lacks pre-placement data (FIG. 11, block 1131) to enable item bot 262 to perform pickup, location, and return operations. may communicate with registration station 1013R to provide product bot 262 (FIG. 11, block 1132). As previously discussed, registration station 1013R may also be configured to load an item bot 262, such as an item bot 262 lift module 490, to inform item bot 262 at which position the item bot 262 is being inserted or removed. Bots 262 may be used at induction and extraction points. In another aspect, registration station 1013R may collect data from item bot 262 (Figure 11, block 1130) and transmit that data to controller 120 (Figure 11, block 1140), where the data is This may be sufficient for autonomous article bot registration by the controller 120 (FIG. 11, block 1150) (i.e., the data may be used to identify a unique article bot in the global three-dimensional reference space of the automated storage and retrieval system 100 and to register the article bot. location can be provided). This allows the controller 120 to perform product bot 262 guidance to the breakpack module 266, which may be associated, for example, with a global three-dimensional reference space. Conversely, item bot 262 extraction may be performed such that the item bot 262 deregisters from the automated storage and retrieval system 100 in a manner substantially similar to that disclosed above when the item bot 262 exits the breakpack module. (Figure 11, block 1151). Item bot registration and deregistration requires derivation or extraction of information (e.g., which item bot 262 is being inserted or removed, which breakpack module 266 it is in, which deck level (130DG0, 130DG1, 130DG2, 130DG3) ), etc.) to automatically update the system software as well as automatically check other configuration settings of the automated storage and retrieval system 100.

In one aspect, registration station 1013R may also function as a location update function (e.g., item bot 262 has transposition data), where registration station 1013R may perform a location update function within breakpack module 266. Provides positioning data to article bot 262 to update or otherwise modify the location of article bot 262 (Figure 11, block 1133). In one or more aspects, registration stations 1013R may be located throughout breakpack module 266 to provide continuous updates of good bot locations. Communicator 262T of item bot 262 may also be configured to obtain data from registration station 1013R in any suitable manner. Registration station 1013R may be used by article bot 262 to determine whether article bot 262 is in normal operation in case article bot 262 needs to reset itself.

3A, 4, 6A, 6B, 7A-7D, 8A and 8B, as disclosed herein, item bot 262 operates at operator stations 801, 802, 803 of breakpack operator station 140. 804 and a breakpack product container 264 located at the breakpack product interface 263. For example, the controller 120 may pick up a breakpack article (BPG) from one of the operator stations, such as operator station 802 (shown in Figure 8B) and place the breakpack article (BPG) in (Figure 8B). Item bot 262 may be instructed to deliver to a predetermined breakpack item container 264 at a predetermined breakpack item interface location 263LP located along item deck level 130DG1 (shown in 7b). Here, an operator, such as a human operator (HUM) (or a robotic operator ROB), places breakpack items (BPG) into item bots 262 located in queue 844 of item deck 130DG. From operator station 802, article bot 262 traverses operator station deck level 130DG0 and moves to ramp 130DG1R where article bot 262 enters article deck level 130DG1. As disclosed herein, if there is an obstruction, such as a closed portion of article deck level 130DG1, controller 120 may, for example, block another article deck level 130DG2, 130DG3, shunt 461 and/or ramp. The path of the item bot 262 can be instantly changed around the obstacle by redirecting the item bot along a movement path that includes crossing one or more of 451-454.

In one or more aspects, item bot 262 may use any suitable sensor(s) 733 configured to verify the identity of a breakpack item container 264 located at a predetermined breakpack item interface location 263LP. ) is composed of. Sensor(s) 733 may be an optical sensor (e.g., a barcode reader), a radio frequency identification (RFID) tag reader, or any suitable identification indicia/tag on the breakpack item container 264. Include one or more of the other suitable sensors. By locating the product bot 262 at the predetermined breakpack product interface location 263LP, the product bot 262 confirms the identity of the breakpack product container 264 located at the predetermined breakpack product interface location 263LP. do. If the correct breakpack product container 264 is located at the predetermined breakpack product interface location 263LP, the product bot 262 is configured to deliver the breakpack product (BPG) to the breakpack product container 264. The article bot 262 is configured to position the incorrect breakpack article container 264 at a predetermined breakpack article interface location 263LP, and the article bot 262 communicates this with the controller 120, and the controller 120 ), on the fly, reassigns the work of the article bot 262 and directs the article bot 262 to another breakpack article container in the breakpack article interface 264 (e.g., at the same or a different level) and redirect article bot 262 to the buffer area of article deck 130DG to retrieve the correct breakpack article container (or a supply container from which a breakpack article is removed but containing the same SKU as the breakpack article BPG). ) to wait for delivery, and/or redirect the product bot 262 back to the brake pack operating station 140.

Once breakpack article (BPG) is delivered to breakpack article container 264 for transport to storage or out of automated storage and retrieval system 100 by container bot 110, article bot 262 It is possible to return to the breakpack operator station 140 for delivery of pack goods (BPG). In another aspect, the item bot 262 may be removed by traversing the breakpack module 266 or transported by the item bot lift module 490 to another breakpack module.

As noted above, a delivered (one or more) breakpack article (BPG) is placed therein (e.g., from one article bot 262 or multiple breakpack articles from any number of article bots 262). ) is placed therein, the breakpack article container 264 is moved to the article deck level ( 130DG) to perform transfer of the breakpack item container 264 to storage or out of the automated storage and retrieval system 100 (see, e.g., FIG. 3A , where the container bot moving surface (266RS1) acts corresponding to article deck level 130DG1, container bot movement surface 266RS2 acts corresponding to article deck level 130DG2, and container bot movement surface 266RS3 acts corresponding to article deck level 130DG3. In one aspect, the container bot(s) 110 transfer the breakpack article container 264 from the breakpack article interface 263 to a container release station (TS) for release of the breakpack article container 264. ) and transporting another breakpack article container 264 from the breakpack article interface 263 to the container storage location 130S, which is the breakpack article container storage location 130SB for storage, which is configured in 2020 No. 63/044,721, entitled “Warehousing System for Storing and Retrieving Goods in Containers,” filed June 26, 2013, the disclosure of which is hereby incorporated by reference herein in its entirety. It is incorporated by reference.

2, 3A, 4, 7B, 8B, and 27, exemplary operation of the breakpack module or automated order fulfillment system 266 is described. A multi-layer breakpack article container filling array or footwall 263W is provided (FIG. 27, block 2700). Each level (PWL) of the footwall 263W is configured to fill containers, with breakpack article container stations 263L positioned along the container filling station area (CFA) (e.g., along article deck 130DG). It has a station area CFA, and also has corresponding breakpack article transfer decks 130DG1-130DG3 juxtaposed along the breakpack container station 263L in the container filling station area (see Figure 4). This method involves, by means of at least one article bot 262, corresponding breakpack article transfer decks 130DG1-130DG3 and at different levels (PWL) of the multi-tiered breakpack article container filling array 263W. Traversing and transporting breakpack articles (FIG. 27, block 2710) between breakpack article transfer decks 130DG1-130DG3 to each breakpack article container station 263L at each level (PWL). Each breakpack article container station (263L) is arranged to hold a breakpack article container (264) accessed by at least one article bot (262) and filled with a predetermined breakpack article fill payload (BPGFP), At least one article bot 262 has a payload support 262PS for supporting at least one breakpack article (BPG) unit for transport by the at least one article bot 262 (e.g. see Figure 7b).

The corresponding transfer decks (130DG1-130DG3) of each level (PWL) are the corresponding breakpack product transfer decks (130DG1-130DG3) of each level (PWL) and other breakpack product transfer decks ( Autonomous guidance of inter-level movements traversing between 130DG1-130DG3) and communication with other transport decks 130DG1-130DG3 corresponding to each different level (PWL) of the footwall 263 by way of the breakpack goods transport vehicle path (ITPS). connected to each other, whereby at least one article bot 262 moves between levels, through an autonomously guided breakpack article transfer path (ITPS), to the corresponding breakpack article transfer decks 130DG1-130DG3 rotors at each different level ( A predetermined breakpack product (BPG) charging page is moved to each of the different breakpack product transfer decks (130DG1-130DG3) corresponding to the PWL and loaded into at least one product bot 262 on one level (PWL). Transfer loads and fill breakpack article containers 264 at each breakpack article container station 263L at different levels (PWL). Here, the corresponding breakpack product transfer decks 130DG1-130DG3 of each level (PWL) and the interlevel movement autonomous guide brakepack product transfer path (ITPS) are at least (e.g., ramps, lifts, etc. disclosed herein). forming at least a two-dimensional matrix of autonomously guided breakpack article transport vehicle bypass routes, including one inter-level bypass route and at least one inter-level bypass route (e.g., a bypass or shunt as disclosed herein); , whereby at least one article bot 292 is transferred from the initial breakpack article container station destination (CSD1) to the common level (PWL) and the At least one transition of a different level (PWL) from the initial breakpack product container station destination CSD1 allows for immediate and free direction change to the breakpack product container station destination CSD2 (see Figure 4). Here, the corresponding breakpack product transfer decks 130DG1-130DG3 at each level (PWL) are non-deterministic and at least one inter-level detour path is non-deterministic, so that at least one product bot 262 moves to the corresponding breakpack product transfer deck. (130DG1-130DG3) and at least one inter-level detour route, and vice versa.

2, 3A, 4, 7B, 8B, and 26, exemplary operation of automated storage and retrieval system 100 for storing and retrieving items is described. Storage structure 130 is provided as disclosed herein (Figure 26, block 2600). Containers (e.g., breakpack item containers and/or supply containers) are stored at each container storage location/space 130S of the storage shelves of the array of storage shelves 130SA at each level of the storage structure 130. and transported by at least container bots 110 (FIG. 26, block 2610), accessed therefrom or accessed from the breakpack operator station 140, where at least one container bot 110 is positioned on the container transfer deck at each level. 130DC and picking passage 130A, and is distinct from the container transfer deck, at least one of the container bots 110 is located at each level of the storage structure 130. A footwall 263W is provided (FIG. 26, block 2620) with more than one of the breakpack article interface locations 263L distributed along each level of the corresponding breakpack article transfer deck 130DG at each level of the footwall 263W. Contains many levels. Breakpack product (BPG) is transported by at least one product bot 262 along the corresponding breakpack product transfer deck 1230DG and at different levels of the footwall 263W to the corresponding breakpack product transfer decks. Between 130DG (e.g., 130DG1-130DG3), each level of the footwall 263W is delivered to each breakpack article interface location 263L. Operation of the container bot 110 causes the controller 120 to operate the breakpack items located at the container storage location 130S, the breakpack operator station 140, and the breakpack item interface location 263L of the footwall 263W. This is performed between containers 264 (Figure 26, block 2640).

Exemplary operation of the breakpack module 266 is described with reference to FIGS. 2, 3a, 4, 7b, 8b, 9, 9a, and 9b. As described above, container bot 110 may be configured to store containers (e.g., supply container 265, empty breakpack article container 264E, partially filled breakpack article container 264PF, and/or having any suitable status/fill level). It is configured to deliver (any suitable container) to the breakpack module 266. These supply containers 265 and breakpack product containers 264 are delivered to one or more of the operator station 140 and the breakpack product interface 263. For example, container bot 110 is configured to deliver supply container 265 (or breakpack container 264) to operator stations 801-804 of breakpack operator station 140 in the manner described above ( (For example, the container bot 110 may deliver supply containers substantially directly to the breakpack operator station 140 or sort/order supply containers 265 for delivery to the breakpack operator station 140. to lifts 310A and 310B) (FIG. 9B, block 19150). In one aspect, after placing supply container 265, e.g., on conveyor 500A, container bot 110 moves conveyor 500A. ) (FIG. 9B, block) from the empty breakpack container lift 222 disposed adjacent to and/or in communication with the container output conveyor 820. 19100), where the container bot picks up an empty breakpack container 264E substantially directly from the empty breakpack container lift 222 or the container output conveyor 820 (where the empty breakpack container is , is transferred from the lift 222 to the conveyor 820 in any suitable manner, such as by the multi-directional drive/conveyor unit/section 370. Next, the empty breakpack container 264E is placed at the breakpack article interface. It may be located at a predetermined empty breakpack article interface location 263L at 263 (FIG. 9B, block 19110).

After delivering/positioning the empty breakpack container 264E to the predetermined empty breakpack article interface location(s) 263L, the container bot 110 (e.g., in the breakpack output sort 189 (e.g., as part of a pallet load or other outbound container as disclosed herein), for transport to a breakpack article container storage location 19000 or out of the storage and retrieval system 100 according to a corresponding predetermined order output sequence. 9B, block 19120) from one or more other breakpack item interface location(s) 263L (e.g., filled, partially filled, or empty) of footwall 263W for transfer of one or more Pick up another breakpack container(s) (264). Here, the container bot 110 positions one or more other breakpack container(s) 264 at a storage location (130S), a transfer station (TS), a buffer station (BS), or substantially lifts ( 150) (FIG. 9B, block 19130). (e.g., as in Figure 9B, returning to block 19150). Container bot 110 may select another supply container for placement in breakpack article module 266 in the manner described above (Figure 9B, block 19150). Here, the container bot 110 replaces the supply container 265 with an empty breakpack article container 264E at a location between the operator station 140 and the breakpack article interface 263 and then ), replace the empty breakpack product container 264E with a filled or partially filled breakpack product container.

In another aspect, as disclosed herein, container bot 110 may facilitate decanting of breakpack items or supply containers. For example, a partially filled supply container 265 or a partially filled breakpack article container 264 may be transferred from operator station 140 to container output conveyor 820. Container bot 110 may pick up a partially filled supply container 265 or a partially filled breakpack item container 264 (FIG. 9B, block 19100) after placing the supply container at operator station 140 (FIG. 9b, block 19150). Container bot 110 positions partially filled supply container 265 or partially filled breakpack article container 264 at predetermined breakpack article interface location 263L (FIG. 9B, block 19110) to partially Filled supply containers 265 or partially filled breakpack item containers 264 are filled with SKU items similar to those disclosed herein.

After delivering/placing the partially filled supply container 265 or partially filled breakpack article container 264 to the predetermined empty breakpack article interface location(s) 263L, the container bot 110 may: one or more other breakpacks for transfer to the breakpack article container storage location 19000 or for transfer out of the storage and retrieval system 100 (e.g., as part of a palletized or outbound container, according to a predetermined release sequence). Pick up one or more different breakpack container(s) 264 (filled, partially filled, or empty) from the item interface location(s) (FIG. 9B, block 19120). Here, the container bot 110 positions one or more different breakpack containers at a storage location 130S, a transfer station TS, a buffer station BS, or substantially directly on the lift 150. (Figure 9b, block 19130). Container robot 110 may select another supply container (Figure 9B, block 19140) for placement in breakpack article module 266 (e.g., returning to Figure 9B, block 19150) in the manner described above. Here, the container bot 110 places the supply container 265 at a location between the work station 140 and the breakpack article interface 263, either a partially filled supply container 265 or a partially filled breakpack article container 264. and then replace the partially filled supply container 265 or the partially filled breakpack product container 264 with another filled or partially filled breakpack product container at the breakpack product interface 263.

In another aspect, the container bot 110 is configured to substantially directly transfer an empty breakpack article container 264 from any suitable empty breakpack article container lift 222 to the breakpack article interface 263 . Empty breakpack container lift 222 may be located adjacent to conveyor 500A and/or adjacent to container deck 130DC at the entrance to breakpack article module 266 as described above. Container bot 110 may be configured to operate a controller 120 (or other suitable controller) to pick up a breakpack article container 264 from an empty breakpack article container lift 222 or any suitable breakpack article container storage location 19000. The command can be received by (FIG. 9B, block 19100). Breakpack article container storage location 19000 is located on one or more storage deck levels 130L and is accessible by container bot 110 from one or more container decks 130DC and picking aisle 130A. For example, the breakpack article container storage location 19000 is a dedicated location for storage (storage) of the breakpack article container 264; a storage space (130S) located next to (or along) the picking aisle (130A); and container holding locations at transfer stations (TS) or buffer stations (BS); It may be one or more of: In another aspect, the container bot 110 may pick up an empty breakpack container 264 from the lift 150 without the breakpack container 264 entering storage.

Container bot 110 may transport one or more empty breakpack article containers 264 from breakpack article container lift 222 and/or breakpack article container storage location 19000 to breakpack article interface 263 (FIG. 9A, Block 19110), e.g., transporting empty breakpack items to interface location 263L (see FIG. 9A), or in another aspect, transporting to breakpack operator station 140 in the manner described above for supply container 265. do. In one aspect, container bot 110 delivers empty breakpack container(s) 264E to predetermined empty breakpack item interface location(s) 263L as shown in Figure 9A; In another aspect, a partially filled breakpack article container 264PF is delivered by container bot(s) 110 to an empty breakpack article interface location(s) 263L. As may be realized, the container bot 110 has the feature of classifying containers mounted on the container bot 110 as described herein, wherein the container bot 110 first selects a predetermined breakpack article interface location. Create an empty breakpack by picking up a filled or partially filled breakpack container 264 from 263L and then placing the empty breakpack article container (carried by the container bot) at the just created breakpack article interface location 263L. Pack article interface locations 263L may be created (filled breakpack containers are exchanged for empty breakpack containers at predetermined breakpack article interface locations 263L).

After delivering the empty brakepack container 264E and/or the partially filled brakepack container 264PF to the predetermined empty brakepack item interface location(s) 263L, the container bot 110 (filled or partially filled brakepack container (with or without breakpack containers) transported from replacement of pack containers,

(e.g., as part of a palletized or outbound container according to a predetermined release sequence), one or more other breakpack article containers for transfer to or out of the storage and retrieval system 100 to the storage location 19000. Pick up one or more other different breakpack container(s) 264 (full, partially filled, or empty) from different breakpack item interface location(s) (FIG. 9B, block 19120). In another aspect, after delivering the empty breakpack container 264E and/or the partially filled breakpack container 264PF to the predetermined empty breakpack item interface location(s) 263L, the container bot 110 may It is possible to leave breakpack station 266 without picking up breakpack station 266 from item interface 263. In another aspect, after delivering the empty breakpack container 264E and/or the partially filled breakpack container 264PF to the predetermined empty breakpack article interface location(s) 263L, the container bot 110 Empty or partially filled supply containers 265 can be picked up from the container output conveyor 820 for transfer to storage or out of the storage and retrieval system in the manner mentioned. Next, container bot 110 may select another empty breakpack product container or supply container for delivery to breakpack product module 266.

Referring back to supply container 265, at operator stations 801-804, supply container(s) 265 are scanned by sensor suite 899 (FIG. 9, block 9000) to identify the supply container(s) 265 as expected. Check whether it is a supply container. The operator (human operator HUM or bot operator ROB) opens supply container 265 (Figure 9, block 9010) and verifies that the stock storage unit (SKU) of the breakpack article (BPG) in supply container 265 is correct (Figure 9). 9, block 9020), where any suitable sensor or indication information from sensor suite 899 is provided to displays 899D of operator stations 801-804. The operator selects the desired number of breakpack articles (BPG) from supply container 265 (Figure 9, block 9030) and deposits the breakpack articles (BPG) into breakpack article container 264 or article bot 262. Place (Figure 9, block 9031). Sensor suite 899 may be configured to track breakpack product and/or operator hand movements in any suitable manner (e.g., by determining echelon weight changes of container 264/item bot 262, etc.). configured to confirm (via an appropriate vision system) the pickup amount of brake pack items placed by the operator (FIG. 9, block 9040).

When breakpack product(s) (BPG) are placed in the breakpack product container 264, the breakpack product container 264 is transported from the operator station to the container output conveyor 820 as described above. Container bot 110 picks up breakpack product container 264 from container output conveyor 820 and outputs breakpack product container 264 from automated storage and retrieval system 100. is transported to storage or transfer station (TS) or buffer station (BS). When breakpack article(s) (BPG) are placed in article bot 262 (e.g., waiting in queue 844 at operator station deck level 130DG0 adjacent operator stations 801-804), The item bot 262 is configured to move an item deck (e.g., in the manner disclosed above) to a predetermined parcel item container 264 at the breakpack item interface 263 at a predetermined item deck level 130DG1, 130DG2, 130DG3. 130DG) (Figure 9, block 9050). In one or more aspects, item bot 262 may be configured to wait in any suitable manner (e.g., buffer 778 (see FIG. 7C) or to complete one or more travel loops (DG1L, DG2L, DG3L, DG1LS, DG2LS, DG3LS). 4) by cycling around)) may be ordered (Figure 9, block 9055). In one or more aspects, breakpack articles (e.g., corresponding to a predetermined (destination) breakpack article container 264). By the article bot 262 at the interface location 263L, the article bot 262 determines the predetermined breakpack article container 264 where the breakpack article container 264 at the predetermined breakpack article interface location 263L is expected. 9, block 9060, scans the breakpack item container 264 to determine if the predetermined breakpack item container 264 is identified, then the item bot 262 determines whether the predetermined breakpack item container 264 is Positioning the breakpack article(s) BPG at 264 (FIG. 9, block 9070) and determining the location of the breakpack article by sensor 733 of article bot 262 (or at breakpack article interface location 263L). Verify (FIG. 9, block 9080) the location of the breakpack article (BPG) within the predetermined breakpack article container 264 (by any other suitable sensor in the breakpack article module 266 configured to identify the In the disclosed manner, container bot 110 selects a predetermined breakpack article container 264 from a predetermined breakpack article interface location 263L and directs the breakpack article container 264 to any suitable destination (e.g. 9, block 9090) transfers the breakpack article container 264 from the automated storage and retrieval system 100 to a storage or transfer station (TS) or buffer station (BS) for output.

12A and 12B, the rack module array (RMA) of storage structure 130 includes vertical support members (also referred to herein as rails) that define a high-density automated storage array, as described in detail below. 1212) and a horizontal support member 1200. Rails 1200S (also referred to as an aisle deck or deck) may be mounted, for example, on one or more of the vertical and horizontal support members 1212, 1200 of picking aisle 130A and allow container bot 110 to support the picking aisle ( 130A) may be configured to travel along the rail 1200S. At least one side of at least one picking aisle 130A of at least one storage level 130L may have one or more storage shelves (e.g., formed by rails 1210, 1200 and slats 1210S). In one aspect, one or more shelves form a plurality of shelf levels 130LS1-130LS3 between storage or deck levels 130L defined by (rails 1200S forming the aisle deck) and transfer deck 130B. Can be provided at different heights to form Accordingly, a plurality of rack shelf levels 130LS1-130LS3 corresponding to each storage level 130L, extending along one or more picking aisles 130A in communication with the container transfer deck 130DC of each storage level 130L. ). As may be realized, multiple rack shelf levels 130LS1-130LS3 may be configured to store stacks of stored case units/supply containers 265 (or case tiers) and/or stored breakpack item containers 264 (or breakpacks). each storage level 130L accessible from the common deck 1200S of each storage level 130L having a stack of layers (e.g. stacks of storage cases are located between storage levels). .

As may be realized, at the corresponding storage level 130L, the container bot 110 traversing the picking aisle 130A (e.g., to pick and place case units and/or breakpack article containers) Each available storage space 130S is accessible at each shelf level 130LS1-130LS3, wherein each shelf level 130LS1-130LS3 is connected to one or more side(s) of picking aisle 130A (PAS1, PAS2). It is located between adjacent vertically stacked storage levels 130L (see for example Figure 1B). As mentioned above, each storage shelf level 130LS1-130LS3 is connected from a rail 1200 (e.g., a common picking aisle deck 1200S corresponding to the container transfer deck 130DC of each storage level 130L). ) is accessible by the container bot 110. As shown in FIGS. 12A and 12B , one or more intermediate shelf rails 1210B, 1210C are vertically spaced (e.g., in the Z direction) from each other (and from rail 1200) in a plurality of stacked storage spaces 130S. ), thereby forming a plurality of stacked storage spaces each accessible by the container bot 110 from the common rail 1200S. As may be realized, the horizontal support member 1200 also forms shelf rails (in addition to the shelf rail 1210) on which the case unit is positioned.

Each stacked shelf level 130LS1-130LS3 (and/or each single shelf level described below) of a corresponding storage level 130L (e.g., as shown in FIG. defines an open, non-deterministic two-dimensional storage surface (with a pack article container support plane (CUSP)) longitudinally (e.g. along the length of an aisle or coincident with a bot movement path defined by picking) and laterally. Facilitates dynamic allocation of pickfaces (e.g. supply containers) and/or breakpack item containers (e.g. across aisles or bot travel paths in relation to rack depth). Dynamic allocation of pickfaces and case units comprising the pickfaces is provided, for example, in the manner disclosed in U.S. Patent No. 8,594,835, issued November 26, 2013, the disclosure of which is incorporated herein by reference in its entirety. The supply container 265 is shown in FIG. 12A as being stored on the side (PAS2) of the picking passage (130A) and the breakpack article container 264 is stored on the side (PAS1) of the picking passage (130A), but in other In an aspect, a mix and/or common of breakpack item containers 264 and supply containers 265 stored on common sides PAS1, PAS2 (e.g., one or both sides PAS1, PAS2) of picking aisle 130A. It may be a mix of supply containers 265 and breakpack article containers 264 stored on the shelf surface.

In one aspect, as shown in FIGS. 12C and 13B, each storage level 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 storage shelves 130L) and Container bot 110, including case unit support plane (CUSP), is configured to transfer case units to and from storage shelves of each storage level 130L. For example, the container bot 110' shown in FIG. 13B is substantially similar to the container bot 110 disclosed herein, but as described above, the container bot 110' includes case units placed on multiple storage shelf levels ( 130LS1-130LS3) (e.g. accessible from common rail 1200S), sufficient Z-travel of the transfer arm 110PA is not provided. wherein a transfer arm drive 250 (which may be substantially similar to one or more of drives 250A, 250B) lifts the case unit from the case unit support plane (CUSP) of the single level storage shelf, and lifts the case unit from the payload area 110PL. Transferring the case unit to and from the case unit and includes only sufficient Z-movement to transfer the case unit between the fingers 273 of the transfer arm 110PA and the payload bed 110PB. A suitable example of a container bot 110' can be found, for example, in U.S. patent application Ser. No. 13/326,993, filed December 15, 2011, the disclosure of which is incorporated herein by reference in its entirety.

Referring back to FIG. 1B , each container transfer deck 130DC or storage level 130L includes one or more lift pick face interface/handover stations (TS), herein referred to as interface stations (TS), where: Case units (e.g., individual case units, pick faces, supply containers, etc.), totes and/or breakpack item containers 264 are transported to and from a lift load handling device (LHD) and container bot 110 on the container transfer deck 130DC. ) is transferred between. The interface station (TS) is located on the container transfer deck (130DC) opposite the picking aisle (130A) and the rack module (RM), so that the container transfer deck (130DC) is interposed between the picking aisle and each interface station (TS). do. As mentioned above, each container bot 110 at each picking level 130L (via the corresponding container transfer deck 130DC) operates at each storage location 130S, each picking aisle 130A, and each storage level ( Each lift 150 in 130L is accessible where each container bot 110 is also accessed for each interface station TS in each level 130L. In one aspect, the interface station is offset from the high-speed bot travel path (HSTP) along the container transfer deck 130DC such that the approach of the container bot 110 to the interface station (TS) corresponds to the bot speed on the high-speed travel path (HSTP). Be inconclusive about it. Accordingly, each container bot 110 transfers case units (e.g., individual case units, picks) from all interface stations TS to all storage spaces 130S corresponding to deck level 130L (and vice versa). Faces (embedded by bots), supply containers, etc.), totes and/or breakpack item containers 264 can be moved.

In one aspect, the interface station (TS) includes case units (e.g., individual case units, pick faces, supply containers, etc.), tote and/or container bots 110 and lifts 150, as disclosed in more detail below. ) of the load handling device (LHD) (e.g., the interface station (TS) has no moving parts for transporting the case units). For example, referring to FIG. 14, an interface station (TS) and/or buffer station (BS) may be configured to take advantage of the lifting capabilities of container bot 110 (e.g., in conjunction with a stackable rack shelf (RTS)). (to take) one or more stacking levels (TL1, TL2) of transfer rack shelving (RTS), which in one aspect allows container bot 110 handoff (e.g., pick and place) between container bot 110 and cases. Substantially similar to the storage shelves described above such that units or totes are transferred to and from the shelf in a passive manner substantially similar to the passive manner between container bot 110 (as disclosed herein) and storage space 130S. (e.g. each of these is formed by rails 1210, 1200 and slats 1210S),

In one aspect, the buffer station (BS) of the stacking levels (TL1, TL2) also functions as a handoff/interface station to the load handling device (LHD) of lift 150. In one aspect, a single rail breakpack item container for bots case units (e.g., individual case units, pick faces, supply containers, etc.), totes and/or storage shelves 130L, such as container bot 110'. 264), the interface station (TS) and/or buffer station (BS) may also have a single level storage rack shelf (e.g., substantially similar to the storage rack shelf at storage level 130L described above with respect to FIG. 12B). Includes transfer rack shelves. As may be realized, the operation of a storage and retrieval system with container bots 110' serving as single level storage and transfer shelves is substantially similar to that disclosed herein. As may also be realized, a load handling device (LHD) (or lift) may support case units (e.g., individual case units, pick faces, supply containers, etc.), totes and/or stacked rack shelves (RTS) (and/ or a single level rack shelf) may be configured to include a container bot 110 (as described above) through which case units, totes and/or breakpack item containers 264 are transferred to or from the shelf. This occurs in a passive manner substantially similar to that between storage spaces 130S. In another aspect, the shelves may include a transfer arm where the transfer arm transfers case units, totes, and/or from one or more of the load handling devices (LHDs) of the container bot 110 and lift 150. The container bot 110 transfer arm 110PA shown in FIG. 13A and substantially similar). A suitable example of an interface station with an active transfer arm is disclosed, for example, in U.S. Patent Application Serial No. 12/757,354, filed April 9, 2010, the disclosure of which is incorporated herein by reference in its entirety.

In one aspect, the positioning of the container bot 110 relative to the interface station TS occurs in a substantially similar manner as the bot's positioning 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 as set forth in current U.S. patent application Ser. No. 13/327,035, filed December 15, 2011. 9,008,884) and 13/608,877, filed September 10, 2012 (now U.S. Patent No. 8,954,188), the disclosures of which are incorporated herein in their entirety). For example, as shown in FIGS. 1A and 12B , container bot 110 may have slats 1210S or positioning features 130F (e.g., apertures, reflective surfaces) disposed on/on rails 1200. , RFID tags, etc.) and one or more sensors 110S. The slats 1210S and/or positioning functions 130F are arranged to identify the location of the container bot 110 within a storage and retrieval system, for example, in relation to a storage space and/or an interface station (TS). do. In one aspect, container bot 110 includes a controller 110C that counts slats 1210S, for example, to determine at least in part the location of container bot 110 within storage and retrieval system 100. In another aspect, location function 130F is arranged to form an absolute or incremental encoder that provides location determination of container bot 110 within storage and retrieval system 100 when detected by container bot 110. .

As may be realized, with reference to FIG. 14 , a transport rack shelf (RTS) at each interface/handoff station (TS) may be located on a common transport rack shelf (RS) (e.g., a corresponding number of A plurality of load stations are defined) having one or more storage case unit holding positions for holding case units or totes. As mentioned above, each load at multiple load stations is picked up and placed by a container bot 110 or load handling device (LHD) (e.g., multiple case units/totes/breakpacks moved as a single unit). single case unit/tote/breakpack item container (with item container) or multi-case pick face. Additionally, as may be realized, the above-described bot location allows the container bot 110 to be positioned at the multi-load station to pick up and place case units/totes and pick faces from predetermined positions among the holding positions of the multi-load station. Let them decide their own position. The interface/handoff station (TS) may have multiple place buffers (e.g., one or more buffers (e.g., positioned along the A buffer having a case holding position - see FIG. 13b)) is defined, where the inbound and/or outbound case unit/tote/breakpack article container and pick face are load handling devices of the container bot 110 and the lift 150. It is stored temporarily when moved between (LHD).

In one aspect, one or more peripheral buffer/handoff stations (BS) (substantially similar to an interface station (TS) and herein referred to as buffer stations (BS)) are also located opposite the picking aisle 130A and the rack module (RM). It is located on the side of the container transfer deck (130DC), so that the container transfer deck (130DC) is interposed between the picking passage and each buffer station (BS). A peripheral buffer station (BS) is interposed in one aspect as shown in FIGS. 1B and 14 and is otherwise coincident with the interface station (TS). 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 thereof) of the interface station (TS) (e.g., the interface station and peripheral The buffer station is formed by common rails 1210, 1200)). As such, the peripheral buffer station (BS) also, in one aspect, comprises one or more stacked levels (TL1, TL2) of transfer rack shelves (RTS) as described above for the interface station (TS), while the other In an aspect the buffer station includes a single level of transfer rack shelves. The peripheral buffer station (BS) allows case units/totes/breakpack article containers and/or pickfaces to be transferred from one container bot 110 to another container bot 110 of the same storage level 130L as described in detail later. Defines buffers that are temporarily stored when transferred to . As may be realized, in one aspect, peripheral buffer stations are located at any suitable location in the storage and retrieval system, including any location within picking aisle 130A and along container transfer deck 130DC.

With continued reference to FIGS. 1B and 14 , in one aspect at least the interface station TS is located at a pier 130BD or an extension extending from the container transfer deck 130DC, while in another aspect the interface station ( TS) can be positioned and extended along the container transport. In one aspect, pier 130BD resembles a picking aisle along which container bot 110 moves along rail 1200S attached to horizontal support member 1200 (in a manner substantially similar to that described above). In another aspect, the moving surface of pier 130BD may be substantially similar to the moving surface of container transfer deck 130DC. Each pier 130BD is located on the side of the container transfer deck 130DC, for example, located on the opposite side of the picking aisle 130A and the rack module RM, so that the container transfer deck 130DC is connected to the picking aisle 130DC and each pier ( 130BD). Peer(s) 130BD extend from the transport deck at a non-zero angle with respect to at least a portion of the high-speed bot transport path (HSTP). In another aspect, the pier(s) 130BD extend from any suitable portion of the container transfer deck 130DC, including the ends 130BE1 and 130BE2 of the container transfer deck 130DCD. As may be realized, a peripheral buffer station (BSD) (substantially similar to the peripheral buffer station BS described above) may be located along at least a portion of peer 130BD.

Now referring to Figures 15a, 15b, 13b and 16. As described above, in one aspect, the interface station (TS) is a passive station such that the load transfer device (LHD) of the lifts (150A, 150B) has an active transfer arm or pick head (4000A). In one aspect, inbound lift module 150A and outbound lift module 150B have different types of pick heads (as previously disclosed in U.S. Pat. No. 9,856,083, the entire contents of which are incorporated by reference), while in another embodiment, The inbound lift module 150A and the outbound lift module 150B have pick heads of the same shape similar to the pick head 4000A. The pick heads of lifts 150A, 150B may define, at least in part, a Y throughput axis as disclosed herein. In one aspect, both the inbound and outbound lift modules 150A, 150B have a vertical mast 4002 along which a slide 4001 is connected (e.g., to a control server 120 and configured to accommodate a slide (and a The mounted pick head (4000A) is configured to raise and lower) and is moved by motive power from any suitable lift drive device. The inbound lift module(s) 150A includes a pick head 4000A mounted on the slide 4001 such that the pick head 4000A moves vertically with the slide 4001 when the slide moves vertically. In this aspect, pick head 4000A includes one or more tines or fingers. The base member 4272 is movably mounted on one or more rails 4360S of the frame 4200 mounted on the slide 4001. ((Drive 4005 may be smaller than Drive 4002D, so the form may be substantially similar but the capacity may not be similar to Drive 4002D)) Any suitable drive, such as a belt drive, chain drive, screw drive, gear drive, etc. A drive device 4005 is mounted on the frame 4200 and moves the base member 4272 to drive the base member 4272 in the direction of arrow 4050 (e.g., extension direction 4050A and retraction direction 4050B). The outbound lift module(s) 150B may be substantially similar to the inbound lift module(s) 150A.

As may be realized, the lift modules 150A, 150B are under the control of any suitable controller, such as control server 120, so that when picking up and placing case unit(s) and/or breakpack item containers: Causes the pick head 4000A to rise and/or lower from the predetermined storage level 130L to a predetermined height corresponding to the interface station TS. As may be realized, the lift modules 150A, 150B may be configured to operate in a storage and retrieval system (of reference REF) where the output lift module 150B sorts case units on the fly to the output station 160US, as described below. Z throughput axis (for both the bot frame and the rack frame of the reference REF2). At the interface station TS, a pick head 4000A or an individual part thereof (e.g. an effector) corresponding to one or more case unit holding position(s) of the interface station TS from which one or more case unit(s) are picked up or load handling device (LHD)) is extended to interlock between slats 1210S (shown in FIG. 15B) underneath the case unit (and/or breakpack item container) being picked up. Lifts 150A, 150B raise pick head 4000A to lift case unit(s) from slats 1210S and transport case unit(s) and/or breakpack item containers to different levels of the storage and retrieval system. To do this, the pick head 4000A is retracted, for example, to transport the case unit(s) to one or more of the output stations 160UT and 160EC. Similarly, to position one or more case unit(s), a pick head 4000A or an individual portion thereof corresponding to one or more case unit holding position(s) of the interface station TS where the one or more case units are located ( For example, an effector or load handling device (LHD)) extends such that the fingers 4273 are above the slats. Lifts 150A, 150B lower the pick head 4000A and position the case unit(s) on the slats 1210S so that the fingers 4273 are positioned between the slats 1210S below the case unit(s) being picked up. Make sure they fit together.

Referring now to FIG. 13A , as noted above, container bot 110 has an interface, a stacked storage space 130S defined at least in part in the Z direction by one or more rails 1210A-1210C, 1200. a transfer arm 110PA that performs pickup and placement of case units from station TS and peripheral buffer stations BS, BSD (e.g., storage space, interface station and/or peripheral buffer station, As described, it can be further specified in the As may be realized, the bot defines an As described above, container bot 110 transports case units between each storage space 130S and each lift module 150 on each storage level 130L. The containerbot 110 includes a frame 110F having a driving unit 110DR and a payload unit 110PL. The drive unit 110DR includes one or more drives each connected to a respective drive wheel(s) 202 to propel the container bot 110 along the X direction (relative to the bot frame of the reference REF to define the X throughput axis). Includes wheel motor.

As may be realized, as container bot 110 moves through picking aisle 130A, the X-axis of the bot's movement coincides with the storage location. In this aspect, the container bot 110 has a protrusion 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. Although it includes two oppositely positioned drive wheels 202, in other embodiments the container bot 110 is provided with any suitable number of drive wheels. In one aspect, each drive wheel 202 is independently controlled such that the container bot 110 can be steered through differential rotation of the drive wheels 202, while in another aspect, the rotation of the drive wheels 202 These can be coupled to rotate at substantially the same speed. Any suitable wheel 201 is mounted on the frame on the opposite side of the container bot 110 at end 110E2 (e.g., the second longitudinal end) to support the container bot 110 on the drive surface. . In one aspect, wheel 201 is a freely rotating caster wheel that allows container bot 110 to pivot through differential rotation of drive wheel 202 to change the direction of movement of container bot 110. In another aspect, the wheel 201 may be configured to control the bot controller 110C (configured to exercise control of the container bot 110 as disclosed herein), for example, to change the direction of movement of the container bot 110. It is a steerable wheel that rotates under control. In one aspect, container bot 110 includes one or more guide wheels 110GW positioned, for example, at one or more corners of frame 110F. The guide wheel 110GW guides the container bot 110 on the container transfer deck 130DC and/or a predetermined distance to/from a location where one or more case units are positioned and/or picked up. At an interface or transfer station for interfacing with a lift module 150 for positioning 110 , it may interface with a storage structure 130 such as a guide rail (not shown) in picking aisle 130A, which may, for example, As disclosed in U.S. Patent Application Serial No. 13/326,423, filed December 15, 2011, the disclosure of which is hereby incorporated by reference in its entirety. As described above, the container bot 110 may enter the picking passage 130A having different opposing directions in order to access the storage space 130S located on both sides of the picking passage 130A. For example, the container bot 110 may enter the picking aisle 130A with the end 110E2 guiding the direction of movement, or the bot may enter the picking aisle 130A with the end 110E1 guiding the direction of movement. You can enter.

The payload section 110PL of the containerbot 110 includes a payload bed 110PB, a fence or reference member 110PF, a transfer arm 110PA, and a pusher bar or member 110PR. In one aspect, payload bed 110PB is positioned at and/or at a predetermined location within payload section 110PL (e.g., for longitudinal front/back alignment of the case unit). One or more case units and/or breakpack article containers carried within payload section 110PL may be configured to position the case unit and/or breakpack article container in relation to other case units and/or breakpack article containers therein. It may be moved longitudinally along the longitudinal axis LX of 110 (e.g., aligned to a predetermined position of the frame/payload section and/or to a datum reference of one or more case units).

In another aspect, container bot 110 moves a case unit and/or breakpack article container over rollers 110RL to move the case unit and/or breakpack article container to a predetermined location within payload section 110PL. It includes one or more longitudinally movable pusher bars (not shown) for pushing. The longitudinally movable pusher bar may be substantially similar to, for example, that disclosed in U.S. Patent Application No. 13/326,952, filed December 15, 2011, the disclosure of which is hereby incorporated by reference in its entirety. was integrated into. The pusher bar 110PR is movable in the Y direction with respect to the reference frame REF of the container bot 110, and together with the pick head 270 of the fence 110PF and/or the transfer arm 110PA, the case unit ( s) and/or lateral alignment of the item container(s) within the payload area 110PL, in the manner disclosed in U.S. Provisional Patent Application No. 62/107,135 filed on January 23, 2015. It can be done.

With continued reference to FIG. 13A , case units and/or breakpack article containers are placed in and removed from payload bed 110PB with transfer arms 110PA along the Y throughput axis. Transfer arm 110PA includes a lift mechanism or unit 200 substantially located within payload section 110PL, as disclosed, for example, in U.S. Provisional Patent Application No. 62/107,135, filed January 23, 2015. which is hereby incorporated by reference in its entirety. Lift mechanism 200 includes a storage structure 130 for picking up and placing pickfaces and/or individual case units in storage spaces 130S (e.g., in each storage space 130S in which container bot 110 is located). ) Gross and fine positioning of the pick face (which may include a case unit or a breakpack article container, or both a case unit and a breakpack article container) carried by the container bot 110 to be lifted vertically into a position of provides. For example, the lift mechanism 200 may be configured to move multiple elevated storage shelf levels 130LS1-130LS3, TL1, TL2 or container bot movement surface(s) 266RS accessible from a common picking aisle (e.g., FIG. 2, Provided for picking up and placing a case unit at a breakpack article interface location 263L accessible from (see 12a and 14).

Lift mechanism 200 is configured to perform combined bot axis movement (e.g., pusher bar 110PR, such as the longitudinally movable pusher bar described above, lift mechanism 200, pick head extension combined substantially simultaneous movement of the secondary and forward/backward alignment mechanism(s), thereby allowing different/multiple SKUs or multi-pick payloads to be processed by the container bot 110. In one aspect, the lifting mechanism 200 ) is independent of the operation of the pusher bar 110PR, as will be explained below. The separation of the lift mechanism 200 and the pusher bar 110PR axis results in reduced pick/place cycle time, increased storage, as described above. and providing a combined pick/place sequence that performs retrieval system throughput and/or increased storage and retrieval system storage density. For example, lift mechanism 200 may be configured to provide a common picking aisle and/or a retrieval system, as described above. Provides for picking and placing case units at multiple elevated storage shelf levels accessible from the interface station deck 1200S.

The lifting mechanism may be configured in any suitable way 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 lifting mechanism includes a mast 200M, and the pick head 270 is moveably mounted on the mast 200M in any suitable manner. The mast is movably mounted on the frame in any suitable manner such that it can move along the lateral axis (LT) of the container bot 110 (e.g., in the Y direction to define the Y throughput axis). In one aspect, the frame includes guide rails 210A and 210B on which the mast 200 is slidably mounted. Transfer arm drives 250A, 250B may be mounted on the frame to effect movement of at least transfer arm 110PA along lateral axes LT (eg, Y axis) and Z axes. In one aspect, transfer arm drives 250A, 250B include an extension motor 301 and a lift motor 302. The extension motor 301 can be mounted on the frame 110F and can be mounted on the mast 200M in any suitable manner, such as a belt and pulley transmission 260A, a screw driven transmission (not shown), and/or a gear driven transmission (not shown). ) can be combined. Lift motor 302 may be mounted on mast 200M and picked up by any suitable transmission, such as belt and pulley transmission 271, screw driven transmission (not shown), and/or gear driven transmission (not shown). It may be coupled to the head 270. As an example, the mast 200M includes guides such as guide rails 280A and 280B, along which the pick head 270 is mounted for guided movement in the Z direction. In another aspect, the pick head is mounted on the mast in any suitable way for guided movement in the Z direction. For the transmission 271, the belt 271B of the belt and pulley transmission 271 is fixedly coupled to the pick head 270, so that when the belt 271 moves (e.g., driven by the motor 302) When) the pick head 270 moves with the belt 271 and is driven in both directions in the Z direction along the guide rails 280A and 280B. As may be realized, if a screw drive is employed to drive the pick head 270 in the Z direction, engagement between the nut and the screw causes movement of the pick head when the screw is turned by the motor 302. A nut may be mounted on the pick head 270 to do so. Similarly, if a gear driven transmission is employed, a rack and pinion or any other suitable gear drive may drive the pick head 270 in the Z direction. In another aspect, a suitable linear actuator is used to move the pick head in the Z direction. Transmission 260A for extension motor 301 is substantially similar to that disclosed herein with respect to transmission 271.

Continuing to refer to FIG. 13A, the pick head 270 of the container bot 110 is connected to case units between the container bot 110 and the case unit and/or, for example, a storage space 130S, a peripheral buffer station (BS). , BSD), breakpack item container pickup/placement locations, such as interface stations (TS) (see FIGS. 1B and 14 ), and guide conveyors 500A, 500B for delivering supply containers 265 to breakpack operator stations 140. , 500C) (see FIGS. 5A and 5C), and/or breakpack article interface 263 (see FIG. 6D), and, in other embodiments, substantially interconnected between the container bot 110 and the lift module(s) 150. conveyed directly to 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. As described above, the base member 272 is mounted on the mast 200M and travels along the guide rails 280A and 280B. One or more tines 273A-273E are mounted to the base member 272 at the proximal ends of the tines 273A-273E such that the distal ends (e.g., free ends) of the tines 273A-273E are positioned at the base member 272. It is formed in a cantilever manner from member 272. Referring back to FIG. 12B , tines 273A-273E are storage shelves (and case units on container support surfaces of peripheral buffer stations (BS, BSD), interface stations (TS), and/or breakpack modules 266. It is configured for insertion between slats forming a support plane (CUSP) (and similar slats of guide conveyors 500A-500C, container output conveyor 820 and breakpack article interface location 263L). .

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

In this aspect, the pick head 270 has three tines 273B- for transferring smaller sized case units (and/or groups of case units/breakpack article containers) to and from the container bot 110. Use as few as 273D) and as many as five tines (273B-273D) to transport larger size case units (and/or groups of case units/breakpack item containers) to and from the container bot 110. do. In other embodiments, less than three tines are used to carry the smaller size case unit (e.g., more than two tines are movably mounted on the base member 272). For example, in one aspect, the smallest case unit transferred to and from the container bot 110 without disturbing other case units, e.g., on storage shelves, has a distance of about X1 between the slats 1210S. Only one tine 273A-273E is movably mounted on the base member to have a width (see Figure 12B).

The immovable tines 373B-373D define the picking plane (SP) of the pick head 270 and define the picking plane (SP) of the pick head 270 and of all sizes of case units, breakpack article containers (and/or case units and/or breakpack article containers). When transporting a pick face, the movable tines 373A, 373E move the actuator 274A relative to the immovable tines 373B-373D (e.g., for transporting a larger case unit and/or pick faces). 274B) in the Z direction) and is used during selective raising and lowering. Continuing to refer to FIG. 13A , all tines 273A-273E are positioned such that the case unit support surface (SF) of each tine (273A-273E) is aligned with the picking plane (SP) of pick head 270. As may be realized, the two end tines 273A, 273E are positioned so that the case unit support surface SF of the tines 273A, 273E is, for example below) the tines 273A, 273E are aligned with the picking plane SP. ) one or more case units movable (e.g. in the Z direction) relative to the other tines 273B-273D so as to be offset from (e.g. downward) so that tines 273A, 273E are carried by the pick head 270 or an unselected case unit or breakpack article container that is not in contact with the breakpack article container (and/or the pick faces of the case unit and/or the breakpack article container) and is located in the storage space 130S of the storage shelf. or other appropriate case unit/breakpack item container holding positions.

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

As may be realized, movably mounting one or more tines 273A-273E to the base member 272 of the pick head 270 may result in a large case unit, a breakpack article container, and/or a pick head 270. ), while full support of the pick face (e.g. of the case unit) is provided, while also providing, for example, a storage space (as disclosed herein), an interface station, a peripheral buffer station, and/or a breakpack module 266 It also provides the ability to pick up and place small case units or breakpack article containers on/there container storage areas without disturbing other case units or breakpack article containers that are placed there.

The ability to select and place case units of various sizes without interfering with other case units on/on the storage space, interface station, peripheral buffer station, breakpack operator station and/or breakpack item interface, its storage shelves. Reduce the size of the gap (GP) between the upper case units (see Figure 12a). As may be realized, the tines 273B-273D are secured to the base member 272 so that when picking up/placing the case unit, the case unit and/or pick face is lifted to or from the case unit holding position. Since raising and lowering is performed only by the lift motors 301 and 301A, there is no redundant operation.

Referring again to FIG. 13A, note again that the pusher bar 110PR is movable independently of the transfer arm 110PA. The pusher bar 110PR is movably mounted on the frame in any suitable manner, such as, for example, a guide rod and a slide device, and is moved along the Y direction (e.g., substantially in the extension/retraction direction of the transfer arm 110PA). operates in a parallel direction). In one aspect, at least one guide rod 360 is mounted within payload section 110PL to extend transversely to the longitudinal axis LX of frame 110F. The pusher bar 110PR may include at least one slide member 360S configured to engage and slide along each guide rod 360. In one aspect, at least a guide rod/slide device keeps pusher bar 110PR confined within payload section 110PL. The 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 another aspect, pusher bar 110PR may be actuated by a linear actuator substantially free of rotational components.

The pusher bar 110PR is disposed within the payload section 110PL such that it is substantially perpendicular to the roller 110RL and does not interfere with the pick head 270 . As shown in FIG. 17C, container bot 110 is configured in a transport configuration where at least one case unit/damaged goods container is supported on rollers 110RL (e.g., the rollers collectively support the payload bed). form). In the transport configuration, the tines 273A-273E of the pick head 270 are engaged with the roller 110RL and are (along the Z direction) below the case unit support plane (RSP) of the roller 110RL (see FIG. 17A). is located. The pusher bar 110PR is comprised of slots 351 (FIG. 17D) through which tines 273A-273E pass, allowing the tines to move below the case unit support plane (RSP) and also pusher bar. Sufficient clearance is provided within the slot 351 so that 110PR can move freely without interference from others 273A-273E. Pusher bar 110PR also includes one or more openings through which roller 110RL passes, the openings being sized to allow free rotation of the roller about its respective axes. As may be realized, the independently actuable pusher bar 110PR is configured to drive the roller 110RL, extend the transport arm 110PA in the transverse direction (e.g., Y direction), and raise/lower the pick head 270. do not disturb

As described above, because the pusher bar 110PR is a separate, independent axis of the container bot 110 that operates without interference from the pick head 270 extension and lift axis, the pusher bar 110PR is attached to the transfer arm 110PA. It may be operated substantially simultaneously with lifting and/or extending. Combined axis movement (e.g., transfer arm 110PA extension and/or simultaneous movement of pusher bar 110PR with the lift axis) provides increased payload handling throughput within and along the Y throughput axis; Multiple pick operations (picking) of two or more case units and/or breakpack item containers from a common picking aisle in one common pass of the picking aisle for transfer to the breakpack work station 140 (e.g., predetermined (according to the breakpack sequence, which may be based at least in part on the factory order). For example, as shown in FIGS. 17A-17B, during a multi-pick/place sequence of transfer arm 110PA, pusher bar 110PR has a contact depth (case unit(s), breakpack article container () to a position spaced a predetermined distance s) and/or as the pick face is selected and transferred to the payload section 110PL) is pre-positioned. The distance

As case unit(s) (CU) and/or breakpack article container(s) 264 are lowered onto rollers 110RL (FIG. 18, block 1110), case unit(s) (CU) and/or The distance moved by the pusher bar 110PR to contact the breakpack article container(s) 264 is the rear (or rear) 402 of the payload section 110PLa ( It is a shorter distance When the case unit (CU) and/or the brake pack article container 264 is lowered by the transfer arm 110PA and transferred to the roller 110RL to be supported only by the roller 110RL, the pusher bar 110PR (Pay (relative to the lateral and approach side 401 of the load section 110PL) to align the case unit(s) (CU) and/or breakpack article container(s) 264 (FIG. 18, block 1120). For example, the pusher bar 110PR may laterally push the case unit(s) (CU) and/or breakpack article container(s) 264 in the Y direction, such that the case unit(s) may be positioned in the payload section ( 110PL) is brought into contact with the fence 110PF located on the access side 401, thereby establishing contact between the case unit(s) (CU)/breakpack article container(s) 264 and the fence 110PF. This allows a case unit reference datum to be formed. In one aspect, pusher bar 110PR supports case unit(s) (CU) and/or breakpack article container(s) 264 with each other and the frame of reference (REF) of container bot 110 (FIG. 13A). (FIG. 18, block 1130), (e.g., to support the case unit(s) and/or breakpack article container(s) 264 relative to the fence 110PF. ) The case unit(s) (CU) and/or the breakpack article container(s) 264 may be engaged or otherwise held during transport of the case unit/breakpack article container(s). When placing case unit(s) and/or breakpack article container(s) 264, case unit(s) (CU) and/or breakpack article container(s) 264 relative to fence 110PF. After aligning, the pusher bar 110PR is withdrawn (e.g. in the Y direction) from contact with the case unit(s) CU and/or the breakpack article container(s) 264 (Figure 18, block 1140). Almost immediately after the pusher bar 110PR is separated from the case unit(s) CU and/or the breakpack article container(s) 264, (e.g. in the Z direction) the lift axis and transfer arm 110PA One or more of the extension axes (e.g. in the Y direction) are actuated substantially simultaneously with the retracted movement of the pusher bar 110PR (FIG. 18, block 1150). In one aspect, both the lift and extension axes are actuated when the pusher bar is withdrawn from contact with the case unit(s) (CU) and/or the breakpack article container(s) 264, while in another aspect the lift and extension axes are actuated. One of them works. As may be realized, simultaneous movement of the lift axis and/or extension axis of the transfer arm 110PA with retraction of the pusher bar 110PR, as well as for aligning the case unit(s) CU and/or the brake pack. The reduced distance that the pusher travels reduces the time required to transfer case unit(s) (CU) and/or breakpack article container(s) 264 to and from the container bot 110 and the storage and retrieval system. Increases throughput by (100).

As an example of case handling by the container bot 110, referring to FIGS. 17C-17F, it may be a supply container 265 (e.g., pick face, case unit(s), etc.) or a breakpack item container 264. )) Container(s) (CUA) ((s) ((storage space 130S in a common picking aisle for performing ordered multi-picks), and, in another aspect, from a lift interface station (TS), a breakpack article interface ( Containers ( As the container(s) (CUA) are transferred into the payload section 110PL, the pusher bar 110PR can be pre-positioned adjacent the fence 110PF so that the container(s) are moved to the CUA for transfer to the rollers 110RL. When lowered, the pusher bar 110PR is positioned between the container(s) (CUA) and the fence 110PF. The pusher bar 110PR is positioned between the container(s) (CUA) (placed on the roller 110RL). is pushed in the Y direction toward the rear (e.g. rear) 402 of the payload section 110PL such that the container(s) (CUA) contact the alignment surfaces 273JS (FIG. 17A) of the others 273A-273E. so that it is aligned with the rear surface 402 of the payload section 110PL.

In one aspect, the container bot 110 continues to traverse a common picking aisle in the same direction (XC) (e.g., all case units in an ordered multi-pick are picked up on a common pass of the picking aisle) and stopping at another predetermined storage space 130S according to a predetermined breakpack sequence (this breakpack sequence is determined, at least in part, by an automated storage and retrieval system 100 for order fulfillment). ) can be determined by the shipping sequence of ). As described above, the pusher bar 110PR maintains contact (e.g., grips) with the container(s) (CUA) while the case unit(s) (CUA) are transported between case unit holding positions. (s) (CUA) is maintained at a predetermined position (and/or a longitudinal predetermined position) on the backside 402 of the payload section 110PL relative to the frame of reference (REF) of the container bot 110. . For example, other storage spaces in a common picking aisle (or in other aspects, e.g., from lift/handoff interface station TS, breakpack mule interface locations 263L, and/or buffer/handoff station BS) To pick up the subsequent container, the pusher bar 110PR is moved in the Y direction to separate the container(s) CUA and the lift and extension axes of the transfer arm 110PA are moved to separate the container(s) CUA from the other storage space 130S2. Operated to retrieve (s) (CUB). While the container(s) (CUB) is being picked up, the pusher bar (110PR) is positioned in the Y direction adjacent to the backside (402) of the payload section (110PL) to hold the container(s) (CUA) and others (273A- 273E). The container(s) (CUB) are transferred to the payload section (110PL) and lowered/placed on rollers (110RL) such that the containers (CUA, CUB) are positioned relative to each other along the Y axis. The pusher bar (110PR) pushes the containers (CUA, CUB) toward the fence (110PF) to align the containers (CUA, CUB) forward and holds the containers (CUA, CUB) for transportation to the break pack module 266. /It operates in the Y direction to support. As may be realized, in one aspect the containers (CUA, CUB) are placed together as a unit in a storage location, whereas in another aspect the containers (CUA, CUB) are sorted and stored, e.g., by a brakepack operator. Placement of the container (CUB) at station 140 and the container (CUA) on lift 150B or at another holding location (e.g., at another breakpack operator station 140 in another breakpack module 266). , are transported and placed into separate locations at a common holding location, either on the common support surface 140S of the brake pack operator station 140 or at another case unit holding location. Referring to Figures 1B and 16, for example, the multi-pick The container bot 110 carrying the payload transfers containers CUA and CUB of the multi-pick payload to one or more interface stations (TS) (including a buffer shelf) corresponding to the output lift 150B.

As may be realized, in one aspect where container bot 110 turns into peer 130BD (FIG. 16), bots moving on a high-speed bot travel path (HSTP) of container transfer deck 130DC (FIG. 1B) The spacing is such that a bot interfacing with an interface station (TS) can be substantially moved to the interface station (TS) without interference from and/or with other container bots 110 moving along the container transfer deck 130DC. It allows you to slow down and switch speeds. In another aspect, the container bot 110 moving on the container transfer deck 130DC is configured to move across and along the container transfer deck 130DC when the container transfer deck 130DC is substantially open, as described above. Configured for non-deterministic crossing of 110), it can travel around the container transfer deck 130DC, which is converted into an interface station (TS).

When multi-pick containers (CUA, CUB) are placed at different positions, for example, on the common buffer shelf (BS) of the interface/handover stations (7000A, 7000B) of the lifts (150B1, 150B2), the container bot ( 110) places the first container among the containers CUA at the first position of the buffer shelf 7000A and places the second container among the containers CUA at the second position on the buffer shelf 7000A. When multiple picks of containers are placed at a common container holding location, the container bot 110 holds two containers (CUA) as one unit (e.g., a pick face) at a common location on the buffer shelf 7000A, for example. , CUB) is placed.

When containers (CUA, CUB) are grouped for placement in separate or different storage locations of a common storage location (e.g., as previously disclosed in U.S. Patent No. 9,856,083, the contents of which are hereby incorporated by reference), the containers (CUA) , CUB) are separated from each other in the payload section 110PL. For example, as shown in FIGS. 13A, 13B, and 17A-17F, the pick head 270 of the transfer arm 110PA allows the pusher bar 110PR to pass under the containers CUA and CUB. The containers (CUA, CUB) can be moved in the Z direction to lift them off the rollers 110RL by a sufficient amount (FIG. 19, block 1250A). As the containers CUA and CUB are lifted, the pusher bar 110PR is positioned along the Y direction (FIG. 19, block 1250B) to be positioned between the containers CUA and CUB (see FIG. 17F). The pick head 270 may be lowered so that the containers CUA and CUB are transferred to the rollers 110RL and a pusher bar is inserted between the containers CUA and CUB (FIG. 19, block 1250C). Pusher bar 110PR maintains (FIG. 19, block 1250D) while container CUB remains in front of payload section 110PL adjacent to fence 110PF (e.g., as shown in FIG. 17D). , (e.g., relative to alignment surface 273JS of others 273A-273E or any other suitable location) to move container CUA toward rear surface 402 of payload section 110PL ( (e.g., to separate the container) in the Y direction. As may be realized, if the container is held against others' alignment surfaces 273JS during transport, the container CUA is aligned with the alignment surfaces 273JS. While remaining at the rear of the payload section 110PL adjacent to the container (e.g., against the fence 110PF or any other suitable location) toward the front 401 of the payload section 110PL, the pusher bar CUB) is moved in the Y direction (e.g., to separate the container). As may be realized, the container CUA is connected to one of the others 273A-273E (e.g., pick head 270). With substantially positioned relative to alignment surface 273JS, the container CUA can be positioned in a container holding position (FIG. 19, block 1250F) without substantial interference from the container CUA, e.g. (CUA) is not in contact with other containers placed in the container holding position.The container (CUA) is lowered/transferred back to the payload section 110PL (e.g. by retracting and lowering the transfer arm 110PA) (Figure 19, block 1250G).Pusher bar 110PR, pre-positioned between alignment surface 273JS and container CUA, pushes container CUA disposed on roller 110RL against fence 110PF (e.g., The container (CUA) is front aligned for placement in another container holding location (different from the storage location where the container (CUB) is placed) (FIG. 19, block 1250H). The pusher bar 110PR remains relative to the container CUA to grip the container (e.g. to a fence) while being transported to another container holding location (Figure 19, block 1250I). The pusher bar 110PR moves away from the container CUA and the transfer arm is actuated to lift and extend the pick head 270 to place the container CUA in another container holding position (FIG. 19, block 1250J).

Similarly, with reference to FIGS. 1A, 1B and 2, in one embodiment the container bot 110 transitions from the transfer deck (see FIG. 1B) to the breakpack module 266, the high-speed bot movement path on the container transfer deck 130DC. Spacing between bots moving on (HSTP) (FIG. 1B) allows bots interfacing with interface station TS to interfere with and/or interfere with other container bots 110 moving along container transfer deck 130DC. It is designed to be able to substantially slow down and transition to an interface station (TS) without interference. In another aspect, a container bot 110 moving on a container transfer deck 130DC may move the container bot 110 across and along the container transfer deck 130DC when the container transfer deck 130DC is substantially open, as described above. Configured for non-deterministic traversal of 110 , the container bot 110 may then be converted to a breakpack module 266 . When multiple picks of containers (CUA, CUB) are placed at different positions on a common support surface of, for example, guide conveyors 500A, 500B, 500C (FIG. 3A), container bot 110 supports the support surface. Place a first of the containers (CUB) at a first position and place a second of the containers (CUA) at a second position of the support surface of the guidance conveyor (500A, 500B, 500C). When multiple picks of containers are placed at a common container holding location, container bot 110 may, for example, hold one unit (e.g., pick face) at a common location on the support surfaces of the guide conveyors 500A, 500B, 500C. ) to deploy two containers (CUA, CUB).

When containers (CUA, CUB) are sorted for placement in a separate location of a common storage location or in a different storage location (e.g., previously disclosed in U.S. Pat. No. 9,856,083, the entire contents of which are incorporated by reference), the containers (CUA, CUB) , CUB) are separated from each other in the payload section 110PL. For example, as shown in FIGS. 13A, 13B, and 17A-17F, the pick head 270 of the transfer arm 110PA moves in the Z direction so that the pusher bar 110PR moves under the containers CUA and CUB. Lift the container (FIG. 19, block 1250A) from the roller 110RL by a sufficient amount to pass through (FIG. 19, block 1250A). As the containers CUA and CUB rise, the pusher bar 110PR is positioned along the Y direction (see FIG. 17F) to be positioned between the containers CUA and CUB (FIG. 19, block 1250B). The pick head 270 is lowered so that the containers CUA and CUB are transferred to the rollers 110RL and the pusher bar is inserted between the containers CUA and CUB (FIG. 19, block 1250C). The pusher bar 110PR pushes the container CUA toward the backside 402 of the payload section 110PL (e.g., relative to the alignment surface 273JS of the tines 273A-273E or any other suitable location). While being moved in the Y direction to move (e.g., to separate the container), the container (CUB) is moved to the payload section (110PL) adjacent to the fence (110PF) (e.g., as shown in FIG. 17D). ) (FIG. 19, block 1250D). As may be realized, if the containers are supported against the alignment surfaces 273JS of others during transport, a pusher bar (e.g. to separate the containers) Movement in the Y direction moves the container (CUB) toward the front 401 of the payload section 110PL (e.g. relative to the fence 110PF or any other suitable location), while the container (CUA) It remains behind payload section 110PL adjacent to alignment surface 273JS.Pusher bar 110PR also moves in the Y direction to realign container CUB with respect to fence 110PF into the container holding position. Place containers on tines 273A-273E for placement (FIG. 19, block 1250E). As may be realized, containers CUA may be placed on tines 273A (e.g. of pick head 270). -273E), the container CUB is disposed in a container holding position on the support surfaces of the guide conveyors 500A, 500B, 500C without interference from the container CUA. may be, for example, the container (CUA) is not in contact with other containers placed on the support surface of the guidance conveyor (500A, 500B, 500C). The container (CUA) (e.g., retracts the transfer arm (110PA) and lowers (FIG. 19, block 1250G). Pusher bar 110PR, pre-positioned between alignment surface 273JS and container CUA, is lowered/transferred back to payload section 110PL (Figure 19, block 1250G). , 500C) or another support surface of another guide conveyor (500A, 500B, 500C) for front alignment for positioning in another container holding position (e.g., different from the holding position in which the container CUB is located). For pushes the container CUA positioned on the rollers 110RL (Figure 19, block 1250G). The pusher bar 110PR remains on the container CUA to grip the container (e.g., with a fence) during transfer to another container holding location (Figure 19, block 1250I). The pusher bar 110PR holds the container moves away from (CUA) and the transfer arm is operated to lift and extend the pick head 270 (FIG. 19, block 1250J) to place the container (CUA) in another container holding position. FIGS. 1A-1C, 1E, 28 and 30A, the automated storage and retrieval system 100 may be configured to store items (e.g., pallets, cases, containers, packages of items, individual (unwrapped) items (herein referred to as units or individual It includes orthogonal classification transfer echelons (15000, 15100, 15200) (also referred to herein as classification echelons) that identify the classification of the article), etc. The identification of the article is carried out through the automated storage and retrieval system 100. Performs separation and differentiation of goods from the transport of goods, or alternatively performs classification of goods separation and differentiation (e.g., performs further identification of the goods classification). The orthogonal classification echelon is an orthogonal classification echelon that separates and distinguishes goods from the carriage of goods (e.g., pallets, cases, packs, units) into their smallest commodity components, sorting the smallest commodity components individually, and then reassembling the smallest commodity components into larger groups (e.g., one or more pallets, (reassembled into cases, packs), thereby providing a recursive sorting of the items so that sorting can be performed. Each of these reassembled larger groups is sorted each time the reassembly is repeated. As an example, see Figure 30A. In this case, if the smallest essential item component is a unit (also referred to herein as an individual item), the incoming pallet is disassembled into a case, the case containing the unit is disassembled into packs, and the pack is disassembled into units. A number of unit(s) are sorted at the unit level and reassembled into sorted packs.The 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 sorted in a recursive manner to build a pallet load (PAL).

Orders for filled items (e.g., pallets, cases, containers, packages of goods, individual (unpackaged) items, etc.) may be stochastic (e.g., the items ordered and the time the order is received may vary substantially). may be random), or may be performed by the automated storage and retrieval system 100 as a function of time (e.g., sorting ordered items at a predetermined scheduled time in advance of the time the order is to be shipped/fulfilled). Classification of goods in a timely manner). This probabilistic ordering determines the pickup sequence of assorted items, such as for building a pallet load or pallet (PAL), as disclosed herein with respect to Figure 1D (e.g., on February 24, 2015 See issued U.S. Patent No. 8965559, entitled “Pallet Building System,” the disclosure of which is incorporated herein by reference in its entirety. Although the pallet in FIG. 1D is shown and described as a mixed case pallet, this example also represents a mixed case, mixed tote, mixed pack, pallet load with mixed units (or individual items) per tote, etc. Here, sorted items are selected from a common storage array (e.g., a storage array formed by storage space 130S of storage structure 130). The automated storage and retrieval system 100 executes given orders (e.g., pallet orders, case orders, pack orders, mixed orders, etc.) from a common storage array independent of the order sequence and independent of the order type. each order (e.g., received for processing by automated storage and retrieval system 100) by using or processing an order through one or more of the orthogonal sorting echelons 15000, 15100, 15200 to the required sorting level in order to Perform maximum throughput of goods for an order.

The orthogonal classification echelons (15000, 15100, 15200) are controlled by the controller 120 to classify articles at various classification levels of the articles in order to provide maximum throughput of articles through the automated storage and retrieval system 100. Distinguished from transportation, it allows for maximum flexibility in order fulfillment. Correspondingly, orthogonal sorting echelons 15000, 15100, 15200 realize minimized filling costs for each order processed through automated storage and retrieval system 100.

The various sorting echelons described herein may be performed by the storage and retrieval system 100 and/or the asynchronous transport system of the breakpack module 266. As disclosed herein, automated storage and retrieval system 100 includes an automated transport system (e.g., at least one for transporting cases/products at a given storage structure level 130L (e.g., level transport)). an automated transport system (bots, breakpack modules, and other appropriate level transport units, as disclosed herein) with an asynchronous transport system, wherein a storage and retrieval system 100, as disclosed herein, includes a non-deterministic container bot 110 that moves along one or more physical paths of the storage and retrieval system to provide at least one level of asynchrony, e.g. At least another level of asynchrony is provided (as disclosed herein) to be greater than the number of bots carrying. As may be implemented, the controller 120 can transfer the breakpack item container 264 from the supply container 265 a container bot 110 and an article bot 262 (both at least part of an asynchronous transport system) for assembling orders to and infeed of breakpack article containers 264 through a container outfeed station (TS) For example, the controller 120 may operate a container storage location 130S, a breakpack operator station 140, and a breakpack article transfer deck 130DG, as disclosed herein. is configured to execute the operations of container bot(s) 110 between breakpack article containers 264 positioned along. As another example, controller 120 may be configured to execute operation of article bot(s) 110, as described herein. Configured to perform the operations of 262, transportation of breakpack articles (BPG) by article bot 262, e.g., at unit/individual article level sorting (e.g., breakpack order sorting 188). and is configured to sort breakpack articles (BPG), traverse article transfer deck 130DG, into corresponding breakpack article containers 264. As a further example, controller 120 may operate container bot(s) 110. ), as described herein, where the container bot(s) 110 access the corresponding breakpack article container 264 on the article transfer deck 130DG and the container output/transport station. A breakpack article container via a traverse along the container transfer deck 130DC to at least one of the corresponding container storage locations 130SB of a storage shelf of a corresponding level 130L of a multi-tiered storage array (such as (TS) and breakpack output classification 189). (264) should be transferred.

30A, with respect to recursive classification of articles through orthogonal classification echelons 15000, 15100, 15200, the configuration of controller 120 (e.g., internal non-transitory computer program code) may be configured to perform orthogonal classification echelons 15000, 15100, 15200. By mimicking the physical structure of the echelon 15000, 15100, 15200, the controller 120 performs the recursive classification in the same way that the solution is performed by the physical components of the orthogonal classification echelon 15000, 15100, 15200. Let's approach the solution. For example, the controller 120 may, alone or in combination (e.g., depending on the sort level required to fulfill an order), separate larger item unit(s) from smaller item units as described herein. a case level sorting echelon control module (120M1), a pack level sorting echelon control module (120M2) and units that disassemble and perform subsequent recursive sorted assembly of smaller sorted item units into sorted larger item units. /Includes individual article level sorting echelon control module (120M3).

As disclosed herein, and with reference to FIGS. 28 and 30A, an automated storage and retrieval system 100 includes a plurality of sorting (or transport) echelons 15000, 15100 formed by an asynchronous transport system and at least one lift 150B. , 15200). Each classification echelon 15000, 15100, 15200 has a common portion of the storage array (e.g., storage space 130S of each storage level 130L) and an output (e.g., output station 160UT). As disclosed herein, each classification echelon (15000, 15100, 15200) performs orthogonal classification corresponding to the classification echelon (15000, 15100, 15200) of the article units distributed in the common portion, Ensures that mixed output article units of corresponding class echelons (15000, 15100, 15200) are classified in a predetermined order.Orthogonal classification of article units by each class echelon (15000, 15100, 15200) is performed in more than one class echelon (15000). , 15100, 15200), such that each classification echelon (15000, 15100, 15200) is a mixed single article unit (e.g., a unified pack (PCK) - see FIGS. 29C-29E), a mixed More than one sort, each associated with the output of one or more output article units of a packaging group (e.g., PCK and/or UNT unit pack, see FIGS. 29D and 29E located in a common container) and mixed cases, each sorted in a predetermined order. Each of the echelons (1500, 15100, and 15200) becomes an orthogonal class echelon to each of the other class echelons (15000, 15100, and 15200).

As disclosed herein, the orthogonal classification of each classification echelon 15000, 15100, 15200 that performs output of units of goods in a predetermined sequence is independent of one or more order orders and order times.

Referring to Figures 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 output lift 150B. In some aspects, case level classification echelon 15000 also includes input lift 150A. At least a portion 15010 of the case level classification echelon 15000 is configured to perform construction of a classified pallet (PAL) in a manner substantially similar to that disclosed in U.S. Patent No. 10,947,060 (previously incorporated by reference in its entirety). Forms a vertical sequencer that places sorted cases/containers (SCUs) in a predetermined order. As shown in FIG. 29B, case level classification echelon 15000 receives cases CU from a storage array formed at least in part by storage space 130S of each storage structure level 130L and places cases CU in predetermined categories. Classified as pallet (PAL).

The pack level sorting echelon 15100 includes at least a container bot 110, a portion of the container transfer deck 130DC 130DCP, and a breakpack operator station 140. 29C and 29E, cases (CU) are transferred from the storage space 130S to the pick level classification echelon 15100, divided into pack levels, and classified at the pack level. Sorted packs (SPCK) are passed by container bot 110 to portion 15010 of case level sorting echelon 15000 for recursive sorting into pallets (PAL) and breakpack article container 264 (sorting Breakpack article containers (represented generally as “cases” in FIGS. 29C and 29E) form a group of classified mixed packs with other classified packs (SPCKs) or classified units (SUNTs). The breakpack item container 264 is transported by the container bot 110 to portion 15010 of the case level sorting echelon 15000 for iterative sorting on pallets (PALs). Place the pack (PCK) in the breakpack item container 264 or, for example, on a support surface in the staging area of the breakpack operator station 140 (e.g., for pickup by container bot 110). Positioning is carried out in any suitable way, for example by an operator at a brakepack operator station. Placing a pack (PCK) into a breakpack article container 264 (such as interface location 263L for grouping with another pack PCK or unit UNT) may also form part of the pack level sorting echelon 15100. 262). .

The unit/individual article level classification echelon 15200 includes at least an article deck 130DG, an article bot 262, and an interface location 263L. Here, as shown in FIGS. 29D and 29E, the case (CU) is transferred from the storage space 130S to the unit/individual product level classification echelon 15200, and is divided into unit levels to be divided into unit level product bots 262. ) is classified by. The item bot 262 places the sorted unit (SUNT) with other sorted units (SUNTs) in the breakpack item container 264 (again generally indicated as a “case” in FIGS. 29E and 29E), Transported by container bot 110 to portion 15010 of case level sort echelon 15000 for recursive sorting (see FIG. 30A) from breakpack item container 264 to pallet (PAL) (as disclosed herein) method) to form a unified product unit.

Referring to Figure 28, multiple classification echelons (15000, 15100, 15200) are dynamic such that transient assets of one classification echelon can be switched to form transient assets of another classification echelon. For example, the container bot 110, which carries/transports cases/containers between echelons, can be converted from an asset in the case level classification echelon 15000 to an asset in the pack level classification echelon, and vice versa. The item bot 262 can move any given item bot 262 from an asset in the pack level sorting echelon 15100 to an asset in the unit level sorting echelon 15200, depending on the transport task assigned to that particular item bot 262. It is configured to carry/transport both packs and units, or vice versa. .

Still referring to FIGS. 28 and 30A and 29A-29E, the automated storage and retrieval system 100 includes pallet (PAL) sorting (e.g., for placement in a transport vehicle) (FIG. 29A), sorting Sorting of cases (CU) for placement in sorted pallets (PAL) (FIG. 29B), sorting of packs (PCK) (e.g., removed from case CU) for placement in sorted containers (SCU) (FIGS. 29C and 29E) ), providing sorted units/individual articles (UNTs) (e.g., removed from packs) for placement in sorted containers (SCUs). Here, each of the classification echelons 15000, 15100, and 15200 provides an orthogonal classification informed by a recursive classification decision. For example, as shown in Figures 29B-29E, product classification by the case level classification echelon may be dependent on the classification performed by one or more of the pack level classification echelon 15100 and the unit/individual item level classification echelon 15200. Notified by, classification involves breaking down commodity components (e.g., pallets, cases, packs, units) into their smallest essential commodity components, classifying the smallest essential commodity components individually, and then classifying the smallest essential commodity component. This is accomplished by reassembling into larger groups (e.g., one or more pallets, cases, packs). Each of these larger reassembled groups is sorted each time the reassembly is repeated.

Controller 120 is configured (e.g., 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 sorting echelon control module 120M1, a pack level sorting echelon control module 120M2, and a unit/individual item level sorting echelon control module 120M3, alone or in combination ( Perform decomposition of larger product unit(s) into smaller product units (e.g., depending on the level of sorting required to perform order fulfillment) and then sort the smaller product units as described herein. Performs recursive sorting and assembly into sorted larger item units. For example, each sort echelon 15000, 15100, 15200 is configured to sort ordered items at each sort level (e.g., case level, pack level, unit/individual item level) necessary to perform order fulfillment. A plurality of sorting echelons 15000, 15100, 15200 are configured to store at least one of each sorted item unit/individual item, one or more sorted item packs, one or more sorted cases, and one or more sorted pallets from an automated storage and retrieval system. It is configured to output one. Each classification echelon (15000, 15100, 15200) operates under the control of a controller 120 that is independent (i.e., separate) from each other. Here, the controller 120 is configured to separate the throughput of cases CU from the classification of items (eg, pallets, cases, packs, units/individuals) through the automated storage and retrieval system 100. Controller 120 is configured to receive one or more product fulfillment orders and determine demand for instances dictated by the product fulfillment order(s). The controller 120 processes product orders by employing one or more of a case level classification echelon control module (120M1), a pack level classification echelon control module (120M2), and a unit/individual article level classification echelon control module (120M3). Determine/resolve the classification and level of supplies needed for fulfillment. Resolving the classification and level of items for one or more fulfillment orders provides batch efficiency and batching/grouping the transfer of items that are common to more than one fulfillment order provides an automated storage and retrieval system (100). Minimizes the work done by (additional movements are virtually eliminated).

As disclosed herein, controller 120 is communicatively coupled to an asynchronous transport system and configured to use classification echelons 15000, 15100, 15200 to generate orthogonal classifications of each classification echelon 15000, 15100, 15200. do. Here, the controller 120 is configured to: It is configured to solve the movement of items (collectively referred to as objects), bots, lifts, etc. Resolution of the object's motion is performed by the controller 120 as a function of time relative to a predetermined time at which the order must be fulfilled. Here, the controller 120 (e.g., given the physical path, required article classification level, and classified articles to be combined from previous classifications) may control (e.g., between and within classification echelons 15000, 15100, and 15200). ) is configured to optimize the release of articles (e.g., from the storage array formed by the storage space 130) through the storage and retrieval system 100, thereby allowing articles to be sorted through the sorting echelons 15000, 15100, and 15200 ( For example, pallets, cases, packs, units/individual items) are transported through the storage and retrieval system 100 close to each other in time and space.

The controller 120 is also configured to manage (e.g., balance) the transportation of items along the physical path to ensure that no single node (e.g., lift, breakpack station, bot, etc.) of the automated storage and retrieval system transportation is overloaded. . Here, the passage of goods through automated storage and retrieval system 100 controls over- and under-production (e.g., transfer of goods through storage and retrieval system 100) and moves goods through lower cost routes. is balanced along the available physical paths to minimize cost.

The sorting echelons 15000, 15100, 15200 disclosed herein are modular, wherein the modularity of the sorting echelons 15000, 15100, 15200 allows storage and retrieval system assets, such as transfer decks, bots, and bot interface stations. Perform the addition of a breakpack module (266) or other appropriate location (such as a deck) of a given storage level (130L). As an example, referring to FIGS. 1B, 2-4, and 31, the breakpack module 266 is configured to stack on the transfer deck 130B so that additional product transfer decks 130DGE1-130DGE3 can be stacked on top of the product transfer decks 130DG1-130DG3. or configured in and communicatively coupled to the picking aisle 130A, each of the article transfer decks 130DG1-130DG3, 130DGE1-130DGE3 being accessible by the breakpack operator station 140. The addition of article transfer decks 130DGE1-130DGE3 (e.g., at each higher level (130DGL1-130DGL3, 130DGLE1-130DGLE3)) provides an increased number of breakpack article interface locations 263L and article bots 262. By doing so, the capacity of the goods transfer deck 130DG is expanded. In a similar manner, an additional container transfer deck 130DCE is stacked on (or below) the container transfer deck 130DC so that the container bot 110 can use the additional goods transfer deck ( 130DGE1-130DGE3) while ramps similar to ramps 222, 222C, 222R are provided to perform movement of container bot 110 between stacked goods transfer decks 130DG, 130DGE. In another aspect, the additional article transfer deck 130DGE may be communicatively coupled to each of the different (stacked) storage levels 130L, such that the additional article transfer deck 130DGE may be communicatively coupled to each of the other (stacked) storage levels 130L. ) of the container bot 110. The additional assets provided by the modularity of the sorting echelon are designed to minimize the cost of moving product through the storage and retrieval system 100 for any given fulfillment order. Affects a scalable increase in throughput by providing an increased number of physical paths through the storage and retrieval system 100.

With reference to Figures 1a, 1b, 2-4, 28, 29a-29e, 30a, 30b and 31. Example operations of orthogonal classification echelons (15000, 15100, 15200) are described. In operation, pallets are received from input station 160IN into automated storage and retrieval system 100 (FIG. 30B, block 17000). Cases (CU) of pallets are depalletized by depalletizer 160PA (FIG. 30B, block 17005) and delivered to the common storage array by input lift module 150A and container bot 110. Controller 120 may provide automation to fulfill orders, for example, where orders may include one or more of cases (CUs), packs (PCKs), and units/individual items (UNTs) (collectively referred to as products). This is a storage and retrieval system 100. Product is released from a common storage array by controllers 120 that are close together in time and space to travel along one or more physical paths through the automated storage and retrieval system 100 storage structures 130 . Here, orthogonal sorting echelons 15000, 15100, 15200 are employed in parallel to sort ordered products where sorting is distinct from transportation of the products through storage and retrieval system 100. As disclosed herein, controller 120 batches product releases from a common repository and resolves classification of ordered products to perform batch classification through orthogonal classification echelons 15000, 15100, 15200. Once product sorting is resolved, the controller addresses the movement of the product along various physical paths in an automated storage and retrieval system. Here, cases, packs and units ordered for any particular order are released in time and space close to each other.

Ordered cases are transported by container bot 110 to case level sorting echelon 15000 and ordered vertically by buffer station (BS) or transfer station (TS) and/or lift 150B in any suitable manner. Sorted into a predetermined sequence (Figure 30B, block 17030). Classified cases (SCUs) are retrieved by the case level classification echelon 15000 (Figure 3B, block 17035) and transported (as disclosed herein) for placement on pallets 17050 (Figure 30B, block 17050). .

When packs (PCKs) are interrogated, the case (CU) containing the pack (PCK) is removed by the container bot 110, for example, the pack (PCK) is removed from the case (CU) in the manner disclosed herein ( e.g., case removal) (FIG. 30B, block 17010) and sorted (FIG. 30B, block 17025) to the breakpack article module 266 (forming at least part of the pack level sorting echelon 15100). The sorted packs (SPCK) are loaded into breakpack item container 264 (FIG. 30B, block 17040) or, in some non-contained versions, placed on or into a pallet (PAL) as described above. It is transported to the case level classification echelon (15000) where it will be ordered into ordered cases (CU).

When units (UNTs) are ordered, a case (CU) containing a unit (UNT) is removed by the container bot 110, e.g., the units (UNTs) are removed from the case (CU) and any pack (PCK). are transported to the breakpack item module 266 (forming at least part of the unit level sorting echelon 15200), wherein the units (UNTs) are placed in the pack (e.g., case removed and and/or unpackaged) (Figure 30B, block 17015) and sorted (Figure 30B, block 17020). Sorted units (SUNT) are transported on pallets (PAL), included in packs (PCKs) with other units for sorting by the pack level sorting echelon 15100, as described above. Cases (CUs) ordered for placement in the (PAL) and one or more breakpack item containers 264 are transported to the case level sorting echelon 15000 for ordering (FIG. 30B, block 17045).

The output of the plurality of sorting echelons 15000, 15100, 15200 is a pallet (PAL) each containing one or more of mixed unitized article units, mixed package groups, and mixed cases sorted in a predetermined order.

Recursive sorting of sorting echelons 15000, 15100, 15200 is described with respect to delivering product from storage and retrieval system 100; In another aspect, recursive sorting may be performed on products entering storage and retrieval system 100. For example, fulfillment orders may be known to controller 120 at any given time; However, one of the specific fulfillment orders may not be scheduled for fulfillment by a predetermined period of time. When products for a given fulfillment order are entered into the storage and retrieval system 100, the controller 120 uses sorting echelons 15000, 15100, and 15200 in a manner substantially similar to that disclosed herein to opportunistically store the products. Can be classified. However, sorted packs, sorted units and/or sorted cases may be placed in a storage array (rather than output from the system) until the sorted product is requested to fulfill a given fulfillment order.

It should be understood that the foregoing description is merely illustrative of aspects of the disclosed embodiments. Various alternatives and modifications may be made 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 alternatives, modifications and variations that fall within the scope of any claims appended hereto. Moreover, the mere fact that different features are recited in different dependent or independent claims does not mean that a combination of these features cannot be advantageously used, and such combinations are within the scope of the aspects of the disclosed embodiments.

Claims (51)

A warehouse system for storing and retrieving goods in containers, the warehouse system comprising:
A multi-tiered container storage array, each level of which has a transfer area and a storage area, the storage area comprising an array of storage shelves configured to support containers thereon, the transfer area being substantially continuous and the storage shelf of the array of storage shelves. a multi-layer container storage array arranged to communicatively connect to each other, wherein the transfer area includes a picking aisle and a container transfer deck connecting the picking aisles;
Distinguished from the container transfer deck, the containers that traverse the container transfer deck and the picking aisle at each level and are accessed to the breakpack workstation for each container storage location on the storage shelves at each level of the multi-tiered storage array are called breakpacks. at least one autonomously guided container transfer vehicle configured to transfer to an operator station;
At each level of the footwall, more than one level of breakpack article container stations distributed along each level with a corresponding breakpack article transfer deck;
At least one device configured to traverse and transport breakpacks from each level of the footwall to the respective breakpack article container station, along the corresponding breakpack article transfer deck, and between the corresponding breakpack article transfer decks at different levels of the footwall. autonomously guided brake pack goods transport vehicle; and
a controller configured to effect navigation of the at least one autonomously guided breakpack product transport vehicle between container storage locations, a breakpack operator station, and a breakpack product container located at a breakpack product container station on the footwall; warehouse system. 2. The warehouse system of claim 1, wherein the footwall is different and distinct from a multi-tiered container storage array. 2. The warehouse system of claim 1, wherein the at least one autonomous guided container transport vehicle is configured to transport a supply item container and a breakpack item container, respectively. 2. The method of claim 1, wherein the breakpack product transfer decks at each level of the footwall are each configured such that each footwall level has a breakpack product transfer deck that is separate and distinct from each container transfer deck coupled to a breakpack operator station. A warehouse system that is separate and distinct from the container transfer deck of the warehouse. 2. The container transport deck of claim 1, wherein the breakpack goods transfer deck is configured to have at least one autonomously guided breakpack goods transfer vehicle traverse the breakpack goods transfer deck, and wherein the breakpack goods transfer deck is traversed by the at least one autonomously guided container transport vehicle on the container transfer deck. A warehouse system configured to transport breakpack items for transport from an operator station to a corresponding breakpack item container. 2. The method of claim 1, wherein the autonomously guided brake pack product transport vehicle has a payload support, and from the payload support, the brake pack product unit payload carried thereon is transferred to each brake at each level of the footwall. A warehouse system configured to output to breakpack article containers at a pack article container station. 2. The method of claim 1, wherein the common portion and transfer area of the multi-tiered container storage array are communicatively connected to one or more footwalls, through one or more breakpack operator stations, each footwall being independent of each other footwall,
Each footwall is filled independently of each other,
Each footwall performs independent breakpack item container output,
A warehouse system, wherein each footwall is approached by an autonomously guided container transport vehicle, and the independent footwall goods container releases of each footwall are independent of each other footwall to provide output breakpack goods containers orthogonally to each other to be filled. 8. The method of claim 7, wherein each independent footwall has a different breakpack article container station, each having a different breakpack article independently filled to each other breakpack article container of each other independent footwall. A warehouse system arranged to support a container, whereby each other filled breakpack article container provides for the release of an independent breakpack article container from an independent footwall. 2. The system of claim 1, further comprising an intervening sorter arranged to communicatively couple the multi-layer array transfer area and the breakpack operator station, the intervening sorter comprising: from an autonomously guided container transport vehicle, upstream of the breakpack operator station; A warehouse system configured to sort supply containers. 10. The method of claim 9, wherein sorting of supply product containers by an intervening sorter upstream of the breakpack operator station comprises ordering of the supply product containers from a lower optimization order of the articles to a higher optimization order, and input to the breakpack operator station. arranged to facilitate executing a predetermined sequence of supply goods containers, disassembly of goods from the supply goods containers, and dispatch of at least one autonomously guided breakpack goods transfer vehicle from the breakpack operator station to fill the footwall. warehouse system. 10. The warehouse system of claim 9, wherein an intervening sorter upstream of the breakpack operator station is configured to define a plurality of sorting axes orthogonal to each other. 12. The warehouse system of claim 11, wherein at least one sorting axis in one direction has a parallel sorting axis. 2. The method of claim 1, wherein the at least one autonomously guided breakpack article transport vehicle traverses along a corresponding brakepack article transfer deck and between the corresponding brakepack article transfer decks of the footwall, transports the brakepack article to the brakepack article of the footwall. A brake downstream of the breakpack operator station that facilitates the ordering of the breakpack articles transported to each breakpack article container at each breakpack article container station from the lower optimized order of articles to the higher order, which implements the predetermined order of filling the containers. A warehouse system that specifies a pack sorter. 14. The warehouse system of claim 13, wherein the breakpack item sorter downstream of the breakpack operator station is configured to define a plurality of sorting axes orthogonal to each other. 15. The warehouse system of claim 14, wherein at least one sorting axis in one direction has a parallel sorting axis. A method of storing and retrieving goods in a container, the method comprising:
Providing a multi-tiered container storage array, each level having a transport area and a storage area, the storage area comprising an array of storage shelves configured to support containers thereon, the transport area being substantially continuous and the storage shelves comprising: arranged to communicatively connect the storage shelves of the array with each other, the transfer area comprising a picking aisle and a container transfer deck connecting the picking aisles;
transporting containers, by at least one autonomously guided container transport vehicle, to and from each container storage location of storage shelves at each level of the multi-tiered storage array to and from a breakpack workstation, the container transport deck and each at least one autonomously guided container transport vehicle traversing a level's picking aisle distinct from the container transfer deck, wherein at least one of the at least one autonomously guided container transport vehicles is located at each level of the multi-level storage array;
providing, at each level of the footwall, more than one level of breakpack article container stations distributed along each level with corresponding breakpack article transfer decks;
Each breakpack article at each level of the footwall, by means of at least one autonomously guided container transport vehicle, along the corresponding breakpack article transfer deck and between the corresponding breakpack article transfer decks at different levels of the footwall. Transferring the brake pack to the container station;
and effecting, by a controller, navigation of said at least one autonomously guided breakpack product transfer vehicle between breakpack product containers located at container storage locations, a breakpack operator station, and a breakpack product container station on a footwall. How to. 17. The method of claim 16, wherein the footwall is different and distinct from a multi-tiered container storage array. 17. The method of claim 16, wherein the at least one autonomous guided container transport vehicle transports a supply goods container and a breakpack goods container, respectively. 17. The method of claim 16, wherein the breakpack article transfer deck at each level of the footwall is separate and distinct from each container transfer deck coupled to the breakpack article operator station with each footwall level. 17. The method of claim 16, wherein the breakpack goods transfer deck is configured to be transported by at least one autonomously guided breakpack goods transfer vehicle traversing the breakpack goods transfer deck and at least one autonomously guided container transport vehicle on the container transfer deck. A method configured to transport a breakpack article from a breakpack operator station to a corresponding breakpack article container. 17. The method of claim 16, wherein the autonomously guided breakpack article transport vehicle has a payload support, from which the payload support conveys the breakpack article unit payload carried thereon to each of the breakpack article container stations at each level of the footwall. How to print a break pack product container. 17. The system of claim 16, wherein the common portion and transfer area of the multi-tiered container storage array are communicatively connected to one or more footwalls, through one or more of the breakpack operator stations, each footwall being independent of each other footwall;
Each footwall is filled independently of the other,
Each footwall performs independent breakpack item container release,
Wherein each footwall is approached by an autonomously guided container transport vehicle, and wherein the independent breakpack article containers of each footwall are independent of each other footwall to provide output breakpack article containers filled orthogonally to each other. 23. The method of claim 22, wherein each independent footwall has a different breakpack article container station, each is arranged to support a different breakpack article container, and each other independent brake of each other independent footwall A method whereby pack article containers are filled independently, such that each different filled breakpack article container defines an independent breakpack article container release of an independent footwall. 17. The method of claim 16, sorting supply containers upstream of the breakpack operator station from an autonomously guided container transport vehicle using an intervening sorter arranged to communicatively couple the multi-layer array transfer area and the breakpack operator station. A method further comprising: 25. The method of claim 24, wherein the sorting of the supply product containers by an intervening sorter upstream of the breakpack operator station ranks the supply product containers from a lower optimization order of the articles to a higher optimization order and the supply input to the breakpack operator station. A method arranged to facilitate dispatch of at least one autonomously guided breakpack material transfer vehicle from a breakpack operator station to perform a predetermined sequence of material containers, dismantle material from a supply container, and fill a footwall. 25. The method of claim 24, wherein an intervening sorter upstream of the breakpack operator station defines a plurality of sorting axes orthogonal to each other. 27. The method of claim 26, wherein at least one sorting axis in one direction has a parallel sorting axis. 27. The method of claim 26, wherein the at least one autonomously guided breakpack article transport vehicle traverses along a corresponding brakepack article transfer deck and between corresponding brakepack article transfer decks of the footwall, transporting the brakepack article to the breakpack article of the footwall. A breakpack operator station downstream that facilitates the ordering of breakpack articles transported to each breakpack article container at each breakpack article container station from a lower optimized order of articles to a higher optimized order, carrying out the prescribed order of filling the containers. Method for specifying a brake pack article sorter. 29. The method of claim 28, wherein the breakpack article sorter downstream of the breakpack operator station is configured to define a plurality of sorting axes orthogonal to each other. 30. The method of claim 29, wherein at least one sorting axis in one direction has a parallel sorting axis. An automated order fulfillment system, said system comprising:
With breakpack article container stations arranged along the container filling station area, each level has a container fill station area, and corresponding breakpack goods juxtaposed along the breakpack container stations in the container filling station area. a multi-layer breakpack article container filling array with a transfer deck; and
At least one autonomously guided breakpack article transfer vehicle, said at least one autonomously guided article transfer vehicle, said at least one autonomously guided article transfer vehicle, said at least one self-guided brakepack article transfer vehicle, said at least one autonomously guided article transfer vehicle Breakpack product transfer vehicles are located at each breakpack product container station at each level along the corresponding breakpack product transfer deck and between corresponding breakpack product transfer decks at different levels of the multi-level breakpack product container filling array. configured to traverse and transport breakpack goods, each breakpack goods container station being approached by and filled by at least one autonomously guided breakpack goods transport vehicle with a predetermined breakpack goods filling payload; At least one autonomously guided breakpack article transport vehicle arranged to support the pack article container,
The corresponding transport deck at each level is guided by the inter-level movement autonomously guided breakpack product transport vehicle path that traverses between the corresponding breakpack product transport deck at each level and the other breakpack product transport decks corresponding to each other level. communicatively connected to a different transfer deck corresponding to each different level of the multi-level breakpack product container filling array, such that at least one autonomously guided breakpack product transport vehicle is configured to operate at each different level from a corresponding breakpack product transfer deck. Autonomous guided brakepack goods transport path between levels to corresponding respective different brakepack goods transfer decks, and further, at one level, at least one autonomously guided brakepack goods transport vehicle is loaded on a predetermined predetermined brakepack goods transport vehicle. An automated order fulfillment system that transports breakpack product filling loads and fills breakpack product containers at each breakpack product container station at a different level. 32. The method of claim 31, wherein the corresponding breakpack article transfer deck of each level and the interlevel autonomously guided breakpack article transfer path comprises at least one interlevel detour route and at least one intralevel detour route. forming at least a two-dimensional matrix of autonomously guided breakpack goods transfer vehicle detour routes, comprising: wherein at least one autonomously guided breakpack goods transfer vehicle moves from an initial breakpack container station destination to an initial container station destination at a common level and another An automated order fulfillment system, wherein an automated order fulfillment system is configured to freely detour on-the-fly via at least one inter-level detour path and at least one intra-level detour path to a detour breakpack article container station destination in at least one of the levels. 33. The method of claim 32, wherein the corresponding breakpack article transfer deck of each level is non-deterministic and the detour path between at least one level is non-deterministic, such that the at least one autonomously guided brakepack article transfer vehicle is configured to: An automated order fulfillment system that allows free switching between a goods transfer deck and at least one inter-level detour (or vice versa). 33. The automated order fulfillment system of claim 32, wherein the at least one inter-level detour path is a ramp. 32. The method of claim 31, wherein the at least one autonomously guided breakpack material transport vehicle, alone or in combination, uses two-dimensional or three-dimensional cameras, wheel odometry, dead reckoning, electromagnetic distance sensors, or distance measurement using vision. perform attitude determination and localization through at least one of measurements and reference point detection, and raise or lower the at least one autonomously guided brakepack goods transport vehicle between levels along a path in the Z direction and longitudinal direction. Automated system for announcing vehicle attitude and localization at all and performing free transition of vehicle movement between the brake pack goods transfer deck and at least one inter-level detour route (or vice versa), with a substantially constant rate of movement at the time of transition. Order fulfillment system. According to clause 31,
A multi-tiered container storage array, each level of which has a transfer area and a storage area, the storage area comprising an array of storage shelves configured to support containers thereon, the transfer area being substantially continuous and the storage shelf of the array of storage shelves. a multi-layer container storage array arranged to communicatively connect to each other, wherein the transfer area includes a picking aisle and a container transfer deck connecting the picking aisles; and
further comprising at least one autonomous guided container transfer vehicle configured to traverse the container transfer deck and the picking aisle, to perform transfer of containers between the multi-tier storage array and the multi-tier breakpack article container filling array;
Wherein the multi-tier breakpack item container filling array is different and distinct from a multi-tier container storage array. 37. The automated order fulfillment system of claim 36, wherein the at least one autonomous guided container transport vehicle is configured to transport a supply item container and a breakpack item container, respectively. 37. The apparatus of claim 36, wherein a corresponding breakpack article transfer deck at each level of the multi-tier container storage array is separate and distinct from each container transfer deck, such that each level of the multi-tier container storage array is separate and distinct from each container transfer deck. An automated order fulfillment system that allows packs to have material transfer decks. 37. The method of claim 36, wherein the corresponding breakpack article transfer deck comprises: at least one autonomously guided breakpack article transfer vehicle traversing the corresponding breakpack article transfer deck, and at least one autonomously guided container delivery vehicle on the container transfer deck. An automated order fulfillment system configured to transport breakpack items from a breakpack operator station to a corresponding breakpack item container for transport by. According to clause 31,
brakepack operator station; and
An automated order fulfillment system comprising: an intervening sorter disposed upstream of a breakpack operator station and configured to sort supply containers entering the breakpack operator station. 41. The method of claim 40, wherein sorting of the supply product containers by an intervening sorter upstream of the breakpack operator station comprises: ordering of the supply product containers from a lower optimization order of the articles to a higher optimization order and input to the breakpack operator station. Executing a predetermined sequence of supply goods containers, disassembling goods from the supply goods containers, and dispatching at least one autonomously guided breakpack goods transfer vehicle from the breakpack operator station to fill the multi-level breakpack goods container filling array. An automated order fulfillment system deployed to facilitate. 41. The automated order fulfillment system of claim 40, wherein an intervening sorter upstream of the breakpack operator station is configured to define a plurality of sorting axes orthogonal to each other. 43. The automated order fulfillment system of claim 42, wherein at least one sort axis in one direction has a parallel sort axis. 41. The method of claim 40, wherein the at least one autonomously guided breakpack article transport vehicle traverses along a corresponding breakpack article transfer deck and transports the breakpack article between different levels of corresponding breakpack article transfer decks. Facilitating the ordering of breakpack articles transported to each breakpack article container at each breakpack article container station from a lower optimized order of articles to a higher optimized order, implementing a predetermined order of filling the breakpack article containers of the article containers. An automated order fulfillment system that provides for a breakpack item sorter downstream of the breakpack operator station. 45. The automated order fulfillment system of claim 44, wherein the breakpack item sorter downstream of the breakpack operator station is configured to define a plurality of sorting axes orthogonal to each other. 46. The automated order fulfillment system of claim 45, wherein at least one sort axis in one direction has a parallel sort axis. In an order fulfillment method in an automated order fulfillment system, the method includes:
providing a multi-level breakpack article container filling array, wherein each level has a container filling station area, with breakpack article container stations disposed along the container filling station area, and further comprising a breakpack container station in the container filling station area. having a corresponding breakpack article transfer deck juxtaposed along; and
At each level, by at least one autonomously guided breakpack goods transport vehicle, along the corresponding breakpack goods transfer deck and between the corresponding breakpack goods transfer decks at different levels of the multi-level breakpack goods container filling array. Traversing and transferring to each breakpack article container station, wherein each breakpack article container station is approached by and filled by at least one autonomously guided breakpack article transport vehicle with a predetermined breakpack article filling payload. arranged to hold a breakpack article container, the at least one autonomously guided breakpack article transport vehicle comprising: a payload for supporting at least one breakpack article unit for transport by the at least one autonomously guided breakpack article transport vehicle; It includes a step, having a support,
The corresponding breakpack goods transfer deck at each level autonomously guides the inter-level movement of breakpack goods traversing between the corresponding breakpack goods transfer deck at each level and the other breakpack goods transfer decks corresponding to each other level. communicatively connected by a transport vehicle path to another transfer deck corresponding to each different level of the multi-tiered breakpack item container filling array, such that at least one autonomously guided breakpack item transport vehicle is configured to drive from the corresponding breakpack item transfer deck Inter-level movement to each of the different breakpack goods transport decks corresponding to each different level, through an autonomously guided breakpack goods transport path, and further, at least one autonomously guided breakpack goods transport vehicle at one level. A method for transporting a predetermined fill load of breakpack articles loaded on a and filling breakpack article containers at each breakpack article container station at a different level. 48. The method of claim 47, wherein the corresponding breakpack article transfer deck at each level and the interlevel moving autonomously guided breakpack article transfer path comprises at least one interlevel detour path and at least one intralevel detour route. forming at least a two-dimensional matrix of self-guided breakpack goods transfer vehicle detour routes comprising paths, whereby at least one autonomously guided breakpack goods transfer vehicle has a common level and A method of freely detouring from at least one of the different levels to the breakpack goods container station destination via at least one of at least one inter-level detour route and at least one intra-level detour route. 49. The method of claim 48, wherein the corresponding breakpack article transfer deck of each level is non-deterministic and the detour path between at least one level is non-deterministic, such that the at least one autonomously guided breakpack article transfer vehicle is configured to: A method for freely switching between a goods transfer deck and at least one inter-level detour route (or vice versa). 49. The method of claim 48, wherein at least one inter-level detour path is a ramp. 48. The method of claim 47, wherein the at least one autonomously guided breakpack material transport vehicle, alone or in combination, uses two-dimensional or three-dimensional cameras, wheel odometry, dead reckoning, electromagnetic distance sensors, or distance measurement using vision. perform attitude determination and localization through at least one of measurements and reference point detection, and raise or lower the at least one autonomously guided brakepack goods transport vehicle between levels along a path in the Z direction and longitudinal direction. A method for performing a free transition of vehicle movement between a brakepack goods transfer deck and at least one inter-level detour route (or vice versa), with a substantially constant rate of movement at the time of transition, both with vehicle attitude and localization known therein.