WO2025181122A2

WO2025181122A2 - Storage and retrieval system

Info

Publication number: WO2025181122A2
Application number: PCT/EP2025/055129
Authority: WO
Inventors: Keith HABBEN; Larry SKEEN-SMITH; Jainam DOSHI
Original assignee: Ocado Innovation Ltd
Current assignee: Ocado Innovation Ltd
Priority date: 2024-02-28
Filing date: 2025-02-26
Publication date: 2025-09-04
Anticipated expiration: 2026-08-28
Also published as: GB2638700A; GB202402815D0; WO2025181122A3

Abstract

A storage and retrieval system comprising: an enclosure comprising a temperature control system configured to control the air temperature inside the enclosure, wherein the enclosure houses a grid and a plurality of storage containers located in stacks beneath the grid; a container access station; and a plurality of load handling devices arranged to move along the grid and configured to move the containers between the stacks and container access station. The container access station comprises: a source container drop-off location disposed within the enclosure and arranged to receive containers from the load handling devices, a source container presentation location disposed outside the enclosure and arranged to present containers, a source container pick-up location disposed within the enclosure and arranged to provide containers to the load handling devices, and a source container conveyor system arranged to convey containers from the source container drop-off location to the source container pick-up location via the source container presentation location; a destination container drop-off location disposed within the enclosure and arranged to receive containers from the load handling devices, a destination container presentation location disposed outside the enclosure and arranged to present containers, a destination container pick-up location disposed within the enclosure and arranged to provide containers to the load handling devices, and a destination container conveyor system arranged to convey containers from the destination container drop-off location to the destination container pick-up location via the destination container presentation location; wherein the source container conveyor system and the destination container conveyor system are arranged to convey containers through one or more openings formed in a side wall of the enclosure and comprise linear sections and direction change sections, the direction change sections being disposed outside of the enclosure. Or, the enclosure is provided with an opening; wherein the container access station comprises one or more conveyor systems that extend through the opening in the enclosure, and a cover unit; wherein the cover unit comprises: a frame module arranged to extend over at least a portion of the opening and to define one or more conveyor apertures through which containers can be conveyed by the conveyor systems; and an insulation jacket that is arranged to substantially occlude a gap between the storage enclosure and the frame module.

Description

STORAGE AND RETRIEVAL SYSTEM

Field of the invention

The disclosure herein relates to automated storage and retrieval systems. More specifically but not exclusively, it relates to a storage and retrieval system using stackable containers stored in a workspace located beneath a grid, where the containers, holding objects, are transported using load handling devices travelling on top of the grid.

Background

Some commercial and industrial activities require systems that enable the storage and retrieval of a large number of different products. One known type of system for the storage and retrieval of items in multiple product lines involves arranging storage bins or containers in stacks on top of one another, the stacks being arranged in rows. The storage bins or containers are accessed from above, removing the need for aisles between the rows and allowing more containers to be stored in a given space.

GB2520104A, the contents of which are incorporated herein by reference, describes a system in which stacks of containers are arranged within a frame structure. The containers are accessed by robotic load handling devices operative on tracks located on the top of the frame structure. A system of this type is illustrated schematically in Figures 1 to 4 of the accompanying drawings.

The process of adding an item to storage containers is referred to as a decant operation, as inbound items are removed from any shipping containers and/or packaging and decanted into some separate storage means. Storage and retrieval system therefore typically include one or more decant stations at which decant operations are performed, wherein the decant station is arranged to receive storage containers and to enable items to be added to the contents of the storage containers. Then, to fulfil a customer order, one or more storage containers containing outbound items are delivered to a picking station, at which the ordered products are picked out of the containers, e.g. by a manual picker or by a robotic picking device.

Within the context of a grocery selling business, it is desirable to automate the storage and retrieval of a wide range of food items. While the above storage and retrieval system has been commonly deployed for the storage and retrieval of ambient food items and chilled food items, there are challenges associated with the automated storage and retrieval of frozen food items, which require lower temperatures than ambient and chilled goods for safe storage (typically -18°C or lower). In the case where picking stations are manned by human pickers, each picker would typically be required to wear a significant level of personal protective equipment (PPE) and/or work in very short shifts to mitigate the effects of working at freezing temperatures. It is against this background that the present invention has been devised.

This application claims priority from GB patent application GB2402815.1 filed on 28 February 2024, the contents being herein incorporated by reference.

Summary of the invention

According to a first aspect, there is provided a storage and retrieval system. The storage and retrieval system comprises an enclosure comprising a temperature control system configured to control the air temperature inside the enclosure, wherein the enclosure houses a grid and a plurality of storage containers located in stacks beneath the grid, a container access station, and a plurality of load handling devices arranged to move along the grid and configured to move the containers between the stacks and container access station. The container access station comprises a source container dropoff location disposed within the enclosure and arranged to receive containers from the load handling devices, a source container presentation location disposed outside the enclosure and arranged to present containers, a source container pick-up location disposed within the enclosure and arranged to provide containers to the load handling devices, and a source container conveyor system arranged to convey containers from the source container drop-off location to the source container pick-up location via the source container presentation location. The container access station further comprises a destination container drop-off location disposed within the enclosure and arranged to receive containers from the load handling devices, a destination container presentation location disposed outside the enclosure and arranged to present containers, a destination container pick-up location disposed within the enclosure and arranged to provide containers to the load handling devices, and a destination container conveyor system arranged to convey containers from the destination container drop-off location to the destination container pick-up location via the destination container presentation location. The source container conveyor system and the destination container conveyor system are arranged to convey containers through one or more openings formed in a side wall of the enclosure and comprise linear sections and direction change sections, the direction change sections being disposed outside of the enclosure.

The source container conveyor system and the destination container conveyor system may each comprise a grid interface portion disposed within the enclosure and a container interaction portion disposed outside the enclosure. The grid may define grid spaces and each stack of containers may then be disposed beneath a grid space. The load handling devices may be configured to raise and lower containers to and from each stack through the corresponding grid spaces. Each grid interface portion may be arranged beneath a plurality of the grid spaces, with each of the drop-off locations and pick-up locations exposed beneath a corresponding grid space in order to allow the load handling devices operating on the grid to transfer containers between the load handling devices and each of the drop-off locations and pick-up locations.

The container access station may comprise a further source container drop-off location disposed within the enclosure and arranged to receive containers from the load handling devices, the further source container drop-off location being disposed in series with the source container drop-off location. The further source container drop-off location may be disposed within the enclosure. The source container conveyor system may be arranged to convey containers through the further source container drop-off location to the source container drop-off location.

The container access station may comprise a further source container pick-up location disposed within the enclosure and arranged to provide containers to the load handling devices, the further source container pick-up point being disposed in series with the source container pick-up point. The further source container pick-up location may be disposed within the enclosure. The source container conveyor system may be arranged to convey containers through the further source container pick-up location to the source container pick-up location.

The storage and retrieval system may be configured to store containers comprising source containers and destination containers, the storage and retrieval system being configured to transfer items from source containers to destination containers. For example, the storage and retrieval system may be configured to store a stock of items of a particular item type in a source container, and to consolidate the items comprised in a single order in a destination container.

Preferably, the linear sections of the source container conveyor system and the destination container conveyor system within the enclosure are parallel. The destination container presentation location and the source container presentation location may be adjacent, and preferably diagonally adjacent.

The source container conveyor system may comprise an outgoing linear section that conveys containers from the source container drop-off location towards the source container presentation location, and an ingoing linear section that conveys containers from the source container presentation location towards the source container drop-off location. Preferably, the outgoing linear section and the incoming linear section are parallel, and more preferably are immediately adjacent.

The destination container conveyor system may comprise an outgoing linear section that conveys containers from the destination container drop-off location towards the destination container presentation location, and an ingoing linear section that conveys containers from the destination container presentation location towards the destination container drop-off location. Preferably, the outgoing linear section and the ingoing linear section are parallel, and more preferably are immediately adjacent.

The destination container conveyor system may comprise one or more direction change sections that direct containers towards the destination container presentation location. The destination container presentation location is preferably adjacent to the source container presentation location such that the one or more direction change sections directs containers towards the source container conveyor system.

The destination container conveyor system may comprise one or more direction change sections that directs containers from the destination container presentation location towards the destination container pick-up location. The source container conveyor system may comprise one or more direction change sections that direct containers from the source container presentation location towards the source container pick-up location.

According to a second aspect, there is provided a storage and retrieval system. The storage and retrieval system comprises an enclosure comprising a temperature control system configured to control the air temperature inside the enclosure, wherein the enclosure houses a grid and a plurality of storage containers located in stacks beneath the grid, a container access station; and a plurality of load handling devices arranged to move along the grid and configured to move the containers between the stacks and the container access station. The enclosure is provided with an opening, and the container access station comprises one or more conveyor systems that extend through the opening in the enclosure. The storage and retrieval system further comprises a cover unit, wherein the cover unit comprises a frame module arranged to extend over at least a portion of the opening and to define one or more conveyor apertures through which containers can be conveyed by the conveyor systems, and an insulation jacket that is arranged to substantially occlude a gap between the storage enclosure and the frame module.

The insulation jacket may be attached to both the frame module and the storage enclosure, and to extend between the frame module and the storage enclosure. The insulation jacket may be arranged to extend around the opening and connect to a periphery of the frame module so as to substantially occlude the gap between the storage enclosure and the frame module.

The insulation jacket may be extendible. The insulation jacket may be capable of moving between an extended configuration and a contracted configuration. A horizontal dimension of the extendible insulation jacket may be at a maximum when in the extended configuration and at a minimum when in the contracted configuration. The insulation jacket may comprise a layer of material that is sufficiently flexible to allow the extendible insulation jacket to collapse/fold (i.e. in the manner of a concertina) when contracted.

The frame module may further comprise one or more doors, each of the one or more doors being arranged to move between a closed configuration in which the door closes one or more of the conveyor apertures and an open configuration in which the door does not close the conveyor aperture. The frame module may further comprise one or more actuator mechanisms that are arranged to move each of the one or more doors between the closed configuration and the open configuration.

The frame module may further comprise one or more linear conveyor sections, each of the linear conveyor sections being aligned with one of the conveyor apertures. The linear conveyor sections may be any of supported by and integral to the frame module. Each of the linear conveyor sections may be arranged to convey containers through the corresponding conveyor aperture.

Each one or more conveyor systems may comprise a grid interface portion disposed within the storage enclosure and a container interaction portion disposed outside the storage enclosure, and each of the linear conveyor sections of the frame module may then be arranged to provide an interface between the grid interface portion and the container interaction portion of one of the conveyor systems. Each one or more conveyor systems may be arranged to receive containers from the load handling devices at a drop-off location disposed within the enclosure and to convey container from the drop-off location to a pick-up location disposed within the enclosure via a presentation location disposed outside the enclosure.

In each of the above aspects, the container access station may be configured to operate as either a pick station, at which items are picked out of the containers presented by the container access station, and a decant station, at which items are added to the containers presented by the container access station. In some arrangements, the container access station may be configured to operate as a pick station at which items are picked from a source container presented by the container access station and added to a destination container that is also presented by the container access station. The storage and retrieval system may then be configured to store a stock of items of a particular item type in each of the source containers, and to consolidate the items comprised in a single order into a destination container.

In each of the above aspects, the storage and retrieval system may further comprise rails or tracks arranged to form the grid and on which the load handling devices are arranged to move. The storage and retrieval system may comprise two substantially perpendicular sets of tracks or rails arranged to form the grid. The storage and retrieval system may comprise a first set of substantially parallel rails or tracks and a second set of substantially parallel rails or tracks extending substantially perpendicularly to the first set in a substantially horizontal plane. The storage and retrieval system may comprise a set of uprights, the uprights supporting the tracks, the uprights and tracks together defining a framework.

In each of the above aspects, the load handling devices may comprise a body mounted on wheels, a first set of wheels being arranged to engage with at least two tracks of the first set of tracks, the second set of wheels being arranged to engage with at least two tracks of the second set of tracks, the first set of wheels being independently moveable and driveable with respect to the second set of wheels such that when in motion only one set of wheels is engaged with the grid at any one time thereby enabling movement of the load handling device along the tracks to any point on the grid by driving only the set of wheels engaged with the tracks, the load handling devices further comprising means for removing or replacing containers from the stacks. Other variations and advantages will become apparent from the following description.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other aspects of the invention will now be described, by way of example only, and with reference to the accompanying drawings, in which:

Figure 1 is a schematic perspective view of a frame structure for housing a plurality of stacks of bins in a known storage system;

Figure 2 is a schematic plan view of part of the frame structure of Figure 1;

Figure 3a is a schematic perspective view of one form of load handling device for use with the frame structure of Figures 1 and 2;

Figures 3b is a schematic perspective cut away view of the load handling device of Figure 3a showing a container-receiving recess of the load handling device;

Figures 3c is a schematic perspective cut away view of the load handling device of Figure 3a showing a container accommodated within the container-receiving recess of the load handling device;

Figure 4 is a schematic perspective view of a known storage system comprising a plurality of load handler devices of the type shown in Figures 3(a), 3(b) and 3(c), installed on the frame structure of Figures 1 and 2;

Figure 5 is a schematic top-down view of a container access station 100 suitable for use in a storage and retrieval system 1 such as that illustrated in Figures 1 and 4;

Figure 6 is a schematic perspective view of the container access station 100 of Figure 5 from outside a storage enclosure;

Figure 7 is a schematic perspective view of the container access station 100 of Figure 5 from within a storage enclosure;

Figure 8 is a schematic sectional view of a portion of the container access station 100 of Figure 5;

Figure 9 is a schematic sectional view of a portion of the container access station 100 of Figure 5;

Figures 10a and 10b are perspective view of a frame module suitable for use in a container access station.

In the figures, like features are denoted by like reference signs where appropriate. Detailed Description

The following embodiments represent preferred examples of how the invention may be practiced, but they are not necessarily the only examples of how this could be achieved. These examples are described in sufficient detail to enable those skilled in the art to practice the invention. Other examples may be utilised and structural changes may be made without departing from the scope of the invention as defined in the appended claims. Moreover, direction references and any other terms having an implied orientation are given by way of example to aid the reader's understanding of the particular examples described herein. They should not be read to be requirements or limitations, particularly as to the position, orientation, or use of the invention unless specifically set forth in the appended claims. Similarly, connection references (e.g., attached, coupled, connected, joined, secured, and the like) are to be construed broadly and may include intermediate members between a connection of elements and relative movement between elements. As such, connection references do not necessarily infer that two elements are directly connected and in fixed relation to each other, unless specifically set forth in the appended claims. Similarly, wording such as "movement in the n- direction" and any comparable wording, where n is one of x, y or z, is intended to mean movement substantially along or parallel to the n-axis, in either direction (i.e., towards the positive end of the n- axis or towards the negative end of the n-axis).

Figure 1 is a schematic perspective view of a known storage and retrieval system 1 comprising a plurality of stacks 3 of storage containers 2 stored in a workspace located beneath a grid 4, and Figure 2 is a top-down view showing a single stack 3 of storage containers 2 within the grid 4. As shown in Figure 1, the stackable storage containers 2, known as bins, are stacked on top of one another to form the stacks 3. The grid 4 defines grid spaces 5 and each stack 3 of containers 2 is disposed beneath and aligned with a grid space 5 such that the containers 2 in a stack 3 can be accessed through a grid space 5. Each storage container 2 typically holds a plurality of product items (not shown), and the product items within a storage container 2 may be identical, or may be of different product types depending on the application.

The grid 4 is part of a frame structure 6 that comprises a plurality of upright members 7 that support horizontal members 8, 9. A first set of parallel horizontal members 8 is arranged perpendicularly to a second set of parallel horizontal members 9 to form a plurality of horizontal grid structures supported by the upright members 7. The members 7, 8, 9 are typically manufactured from metal. The containers 2 are stacked between the members 7, 8, 9 of the frame structure 6, so that the frame structure 6 guards against horizontal movement of the stacks 3 of containers 2, and guides vertical movement of the containers 2. The top level of the frame structure 6 then comprises the grid 4. The grid 4 comprises rails or tracks 10a, 10b supported on the upright members 7 and arranged in a grid pattern above the stacks 3. Referring additionally to Figures 3a, 3b, 3c and 4, the tracks 10a, 10b support a plurality of load handling devices 20. A first set of parallel tracks 10a guide movement of the load handling devices 20 in a first direction (X) across the top of the grid 4, and a second set of parallel tracks 10b, arranged perpendicular to the first set 10a, guide movement of the load handling devices 20 in a second direction (Y), perpendicular to the first direction. In this way, the tracks 10a, 10b allow movement of the load handling devices 20 in two dimensions in the X-Y plane, so that a load handling device 20 can be moved into position above any of the stacks 102.

As shown in Figures 3a, 3b and 3c, each load handling device 20 comprises a vehicle 21 which is arranged to travel in the X and Y directions on the tracks 10a, 10b of the grid 4, above the stacks 3. A first set of wheels 22, consisting of a pair of wheels 22 on the front of the vehicle 21 and a pair of wheels 22 on the back of the vehicle 21, are arranged to engage with two adjacent tracks of the first set of tracks 10a. Similarly, a second set of wheels 23, consisting of a pair of wheels 23 on each side of the vehicle 21, are arranged to engage with two adjacent tracks of the second set of tracks 10b. Each set of wheels 22, 23 can be lifted and lowered, so that either the first set of wheels 22 or the second set of wheels 23 is engaged with the respective set of tracks 10a, 10b at any one time.

When the first set of wheels 22 is engaged with the first set of tracks 10a and the second set of wheels 23 are lifted clear from the second set of tracks 10b, the first set of wheels 22 can be driven, by way of a drive mechanism (not shown) housed in the vehicle 21, to move the load handling device 20 in the X direction. To move the load handling device 20 in the Y direction, the first set of wheels 22 are lifted clear of the first set of tracks 10a, and the second set of wheels 23 are lowered into engagement with the second set of tracks 10b. The drive mechanism can then be used to drive the second set of wheels 23 to achieve movement in the Y direction. In this way, one or more load handling devices 20 can move around on the grid 4 above the stacks 3 under the control of a central control system (not shown).

Figure 4 shows a storage system 1 as described above with reference to Figures 1 and 2, the system 1 having a plurality of load handling devices 20 active on the grid 4 above the stacks 3. Each load handling device 20 comprises a container-lifting device 24, 25 configured to raise and lower containers 2. In the example illustrated in Figures 3a, 3b and 3c, the container-lifting device 24, 25 comprises winch cables or tethers 24 that are arranged to extend in a vertical direction, whose upper ends are attached to the vehicle 21 and whose lower ends are connected to a releasable container-engaging assembly 25. The container-engaging assembly 25 comprises engaging devices (which may, for example, be provided at the corners of the assembly 25) configured to releasably engage with features of the containers 2. For instance, the containers 2 may be provided with one or more apertures in their upper sides with which the engaging devices can engage. Alternatively or additionally, the engaging devices may be configured to hook under rims or lips of the containers 2, and/or to clamp or grasp the containers 2. The cables 24 may be wound up or down to raise or lower the containerengaging assembly 25, as required. One or more motors or other means may be provided to effect or control the winding up or down of the cables 24. The cables 24 and the one or more motors may together form a raising and lowering assembly configured to raise and lower the container-engaging assembly 25.

The wheels 22, 23 are arranged around the periphery of a cavity or recess, known as a containerreceiving recess 26, provided by the vehicle 21. The recess is sized to accommodate a container 2 when it is lifted by the container-lifting device 24, 25, as shown in Figure 3c. When in the recess 26, the container 2 is lifted clear of the tracks 10a, 10b beneath, so that the vehicle 21 can move laterally to a different location. On reaching the target location, for example another stack or an access point in the storage system, the container 2 can be lowered from the container receiving recess 26 and released from the container-lifting device 24, 25. In this way, each load handling device 20 is able to lift a storage container 2 from beneath the grid 4 of a storage system of the type shown in Figure 1, and transport the storage container 2 to another location within the system.

Figures 5 to 8 then show an arrangement suitable for use in a storage and retrieval system 1 such as that illustrated in Figures 1 and 4 when the grid 4 is disposed within a storage enclosure 30 that defines a temperature-controlled storage volume 31. The arrangement comprises a container access station 100 that interfaces with the grid 4 within the storage enclosure 30.

For the sake of clarity, only the container access station 100 and a portion of one side wall 32 of the storage enclosure 30 is shown in Figures 5 to 8. However, it should be understood that the storage and retrieval system 1 comprises the grid 4, the stacks 3 of storage containers 2 stored in a workspace located beneath the grid 4, and the load handling devices 20 operating on the grid. The storage enclosure 30 then comprises a number of side walls that surround the grid 4 and a ceiling or roof that extends between the sides walls so as to enclose the grid 4 within the storage volume 31. The container access station 100 then extends through an opening 33 in the storage enclosure 30 such that a grid interface portion 101 of the container access station 100 is disposed within the storage enclosure 30 and a container interaction portion 102 of the container access station 100 is disposed outside the storage enclosure 30. The grid interface portion 101 of the container access station 100 is arranged to interface with the load handling devices 20 operating on the grid 4 and the container interaction portion 102 of the container access station 100 is arranged to allow access to the contents of the containers 2. In particular, the grid interface portion 101 of the container access station 100 is disposed within the storage enclosure 30 such that at least a portion of the container interaction portion 102 is located beneath a portion of the grid 4.

Such an arrangement provides that containers can be stored within a temperature-controlled storage volume, whilst also providing that the contents of the containers can be accessed from outside the temperature-controlled storage volume. This arrangement is particularly advantageous when implementing the automated storage and retrieval of frozen items as it provides that the interior of the storage enclosure can be retained at a lower temperature than the exterior, so that interaction with the contents can take place in a less challenging environment. For example, when used to store frozen food items, the temperature within the storage volume defined within the storage enclosure 30 is preferably about -18°C or lower, e.g. between -30°C and -18°C. The container access station can then be used to implement the picking of items from the containers in a higher temperature environment, reducing the health risks for a manual picker and easing the operating conditions for a robotic picking device.

As described above, the storage enclosure 30 comprises walls that surround the grid 4 and the containers 2 located in the stacks 3 beneath the grid (not shown). The storage and retrieval system 1 then further comprises a temperature control system (not shown) that is configured to control the temperature inside the storage enclosure 30. By way of example, the temperature control system may comprise a refrigeration system arranged to maintain the air temperature within the storage enclosure 30 at a target temperature suitable for freezing food items, e.g. below 0°C. Such a refrigeration system may comprise one or more refrigeration units, a plurality of temperature sensors and a controller arranged to control the refrigeration units in response to inputs received from the temperature sensors. By way of further example, WO2016193419A1 discloses a temperature- controlled storage system in which containers are stored in stacks beneath a grid.

To minimise heat transfer through the walls of the storage enclosure 30, the walls of the storage enclosure 30 are preferably formed from or comprise a thermally insulating material, e.g. foam insulation. A side wall 32 of the storage enclosure 30 then comprises an opening 33 through which the container access station 100 extends such that the grid interface portion 101 of the container access station 100 is disposed within the storge enclosure 30 and the container interaction portion 102 of the container access station 100 is disposed outside the storage enclosure 30. The container interaction portion 102 of the container access station 100 is then disposed within a further enclosure (not shown). By way of example, the further enclosure may be a building that surrounds both the storage enclosure 30 and a volume outside of the storage enclosure 30 within which the container interaction portion 102 of the container access station 100 is located. By way of further example, the further enclosure may adjoin the storage enclosure 30 and thereby define a separate volume in which the container interaction portion 102 of the container access station 100 is located.

In the arrangement illustrated in Figures 5 to 8, the container access station 100 is arranged to allow items to be picked from a source container and deposited in to a destination container, with both the source container and the destination container being retrieved from and returned to the stacks 3 beneath the grid 4 for storage. For example, a source container could be a container that holds a stock of items of a particular item type, whilst a destination container could be a container that is used to consolidate the items comprised in a single order. The container access station 100 therefore comprises a source container conveyor system 103 and a destination container conveyor system 104 that are each arranged to convey containers through the opening 33 formed in the side wall 32 of the storage enclosure 30. In the arrangement illustrated in Figures 5 to 8, the source container conveyor system 103 and the destination container conveyor system 104 are each arranged to convey containers horizontally through the opening 33 formed in the substantially vertical side wall 32 of the storage enclosure 30.

The source container conveyor system 103 comprises a source container drop-off location 105 disposed within the storage enclosure 30 and arranged to receive containers 2 from the load handling devices 20, a source container presentation location 106 disposed outside the storage enclosure 30 and arranged to present containers 2 such that the contents of the container 2 can be accessed, and a source container pick-up location 107 disposed within the storage enclosure 30 and arranged to provide containers 2 to the load handling devices 20 operating on the grid 4. The source container conveyor system 103 is then arranged to convey containers 2 from the source container drop-off location 105 to the source container pick-up location 107 via the source container presentation location 106.

The destination container conveyor system 104 then comprises a destination container drop-off location 108 disposed within the storage enclosure 30 and arranged to receive containers 2 from the load handling devices 20, a destination container presentation location 109 disposed outside the storage enclosure 30 and arranged to present containers 2 such that the contents of the containers can be accessed, a destination container pick-up location 110 disposed within the storage enclosure 30 and arranged to provide containers 2 to the load handling devices 20 operating on the grid. The destination container conveyor system 104 is then arranged to convey containers 2 from the destination container drop-off location 108 to the destination container pick-up location 110 via the destination container presentation location 109.

The source container drop-off location 105, the source container pick-up location 107, the destination container drop-off location 108 and the destination container pick-up location 110 are each provided by a termination (e.g. end point) of the corresponding container conveyor system 103, 104. However, in the arrangement illustrated in Figures 5 to 8, the source container conveyor system 103 further comprises an additional source container drop-off location 111 and an additional source container pick-up location 112. The additional source container drop-off location 111 is disposed within the storage enclosure 30, between the source container drop-off location 105 and the source container presentation location 106, and in series with the source container drop-off location 105. The source container conveyor system 103 is therefore arranged to convey source containers through the additional source container drop-off location 111 to the source container presentation location 106. The additional source container pick-up location 112 is also disposed within the storage enclosure 30, between the source container presentation location 106 and the source container pick-up location 107, and in series with the source container pick-up location 107. The source container conveyor system 103 is therefore arranged to convey source containers through the additional source container pick-up location 112 to the source container pick-up location 107. This arrangement allows for a greater throughput of source containers through the grid interface portion 101 of the container access station 100. This is particularly advantageous when using the container access station 100 to consolidate orders consisting of multiple item types into a single destination container, as multiple source containers would then need to be delivered to the container access station 100 for each destination container.

As described above, the grid 4 defines grid spaces 5 and the load handling devices 20 are configured to raise and lower containers 2 through the grid spaces 5. Each of the drop-off locations 105, 108, 111 and pick-up locations 107, 110, 112 are therefore exposed beneath a corresponding grid space 5 in order to allow the load handling devices 20 operating on the grid 4 to transfer containers 2 between the load handling devices 20 and each of the drop-off locations 105, 108, 111 and pick-up locations 107, 110, 112.

As shown in Figures 6 and 7, the source container drop-off location 105, the additional source container drop-off location 111, the source container pick-up location 107, the additional source container pick-up location 112, the source container presentation location 106, the destination container drop-off location 108, the destination container pick-up location 110, and the destination container presentation location 109 each comprise a section of conveyor. However, the source container drop-off location 105, the additional source container drop-off location 111, the source container pick-up location 107, the additional source container pick-up location 112, the destination container drop-off location 108 and the destination container pick-up location 110 each further comprise chute guides 113 that assist in guiding containers that are lowered/raised by the load handling devices 20 operating on the grid 4 at these drop-off and pick-up locations.

The grid interface portion 101 of the container access station 100 therefore comprises the source container drop-off location 105, the additional source container drop-off location 111, the source container pick-up location 107, the additional source container pick-up location 112, the destination container drop-off location 108 and the destination container pick-up location 110, whilst the container interaction portion 102 of the container access station 100 comprises the source container presentation location 106 and the destination container presentation location 109.

As indicated by the arrows in Figure 5, the source container conveyor system 103 and the destination container conveyor system 104 each comprise a plurality of linear conveyor sections (shown using straight arrows) and a plurality of direction change conveyor sections (shown using bent arrows). In particular, the source container conveyor system 103 comprises outgoing linear conveyor sections (shown using arrows pointing in the positive X-direction) that are arranged to convey containers from the source container drop-off location 105 and the additional source container drop-off location 111 towards the source container presentation location 106, ingoing linear conveyor sections (shown using arrows pointing in the negative X-direction) that are arranged to convey containers 2 away from the source container presentation location 106 to the additional source container pick-up location 112 and the source container pick-up location 107, and direction change conveyor sections that are arranged to redirect containers between the source container drop-off location 105 and the source container pick-up location 107. The destination container conveyor system 104 then comprises outgoing linear conveyor sections (shown using arrows pointing in the positive X-direction) that are arranged to convey containers 2 from the destination container drop-off location 108 towards the destination container presentation location 109, ingoing linear conveyor sections (shown using arrows pointing in the negative X-direction) that are arranged to convey containers 2 away from the destination container presentation location 109 to the destination container pick-up location 110, and direction change conveyor sections that are arranged to redirect containers between the destination container drop-off location 108 and the destination container pick-up location 110.

In the arrangement illustrated in Figures 5 to 8, all of the direction change conveyor sections are disposed outside of the storage enclosure 30. This arrangement provides that only the relatively simple linear conveyor sections need be robust enough to function in the more extreme environment present within the storage enclosure 30, whilst the more complex direction change conveyor sections need only function in the less extreme environment outside of the storage enclosure 30. For example, the linear conveyor sections may each comprise a section of roller conveyor, belt conveyor or chain conveyor, whilst the direction change conveyor sections may comprise a section of pop-up rollers, belts, chains etc. or omni wheel conveyor. In the arrangement illustrated in Figures 5 to 8, the direction change conveyor sections are arranged to receive a container travelling in a first direction and discharge/dispatch the container in a second direction, the second direction being perpendicular to the first direction.

In the arrangement illustrated in Figures 5 to 8, the outgoing linear conveyor sections of the source container conveyor system 103 are parallel with and immediately adjacent to (i.e. without any significant separation) the ingoing linear conveyor sections of the source container conveyor system 103. The outgoing linear conveyor sections of the destination container conveyor system 104 are then parallel with and immediately adjacent to (i.e. without any significant separation) the ingoing linear conveyor sections of the destination container conveyor system 104. This arrangement of the linear conveyor sections within the storage enclosure 30 minimises the space consumed under the grid 4. It also provides that the drop-off and pick-up locations are immediately adjacent to one another such that load handling devices 20 operating on the grid 4 can deposit an outgoing container at a drop-off location and then promptly collect an ingoing container from a pick-up location, thereby optimising the utilisation of the load handling devices 20.

Direction change conveyor sections of the source container conveyor system 103 are then arranged to redirect containers that have travelled along the outgoing linear conveyor sections back along the ingoing linear conveyor sections towards the source container pick-up location 107. Correspondingly, direction change conveyor sections of the destination container conveyor system 104 are arranged to redirect containers that have travelled along the outgoing linear conveyor sections back along the ingoing linear conveyor sections towards the destination container pick-up location 110.

In the arrangement illustrated in Figures 5 to 8, the linear conveyor sections of the source container conveyor system 103 and the destination container conveyor system 104 each comprise a bridging conveyor section 114 that extends at least partially through opening 33 in the storage enclosure 30, and connects the grid interface portion 101 disposed within the storage enclosure 30 to the container interaction portion 102 disposed outside of the storage enclosure 30. The inclusion of these bridging conveyor section 114 allow each of the outgoing linear conveyor sections and the ingoing linear conveyor sections to be provided as modules of standard/fixed dimensions, with the length of the bridging conveyor section 114 then being adapted to account for the different thicknesses of side wall 32 etc. Preferably, at least a portion of each bridging conveyor section 114 is suspended or has fixed end supports so that it projects through a conveyor aperture 122 of the frame module 121.

In the arrangement illustrated in Figures 5 to 8, the destination container presentation location 109 is adjacent to the source container presentation location 109 to minimise the distance between them, and thereby optimise the efficiency with which items can be transferred from a source container to a destination container. In particular, the destination container presentation location 109 is diagonally adjacent to the source container presentation location 106 such that a picker P, manual or robotic, can operate in the corner space defined between the destination container presentation location 109 and the source container presentation location 106. Direction change portions of the destination container conveyor system 104 are therefore arranged to direct containers conveyed from the destination container drop-off location 108 towards the source container conveyor system 103, before redirecting the containers back towards the destination container pick-up location 110.

In the arrangement illustrated in Figures 5 to 8, the storage enclosure 30 is provided with a single opening 33 through which the container access station 100 extends between the interior of the storage enclosure 30 and the exterior, rather than having separate openings for the conveyor sections that pass through the opening 33. Such an arrangement simplifies the construction of the storage enclosure 30 and simplifies the installation of the container access station 100. However, the size of such a single opening for the entire container access station 100 must be larger than the combined size of several separate openings for the individual conveyors. The container access station 100 therefore further comprises a cover unit 120 that is arranged to reduce heat transfer through the opening 33 in the storage enclosure 30. The cover unit 120 comprises a frame module 121 arranged to extend over at least a portion of the opening 33 in the storage enclosure 30 and to define one or more conveyor apertures 122, with each incoming and outgoing linear conveyor extending through one of the conveyor apertures 122, and an insulation jacket 123 that is attached to the storage enclosure 30, is arranged to extend around the opening 33 and connects to a periphery of the frame module 121 so as to substantially, and preferably entirely, occlude a gap between the storage enclosure 30 and the frame module 121.

The insulation jacket 123 is extendible such that it can extend and contract in order to adjust to the length of the space between the frame module 121 and the side wall 32 of the storage enclosure 30. In particular, the insulation jacket 123 is capable of moving between an extended configuration and a contracted configuration. A horizontal dimension of the extendible insulation jacket 123 is then at a maximum when in a fully extended configuration and at a minimum when in the fully contracted configuration. Figure 9 illustrates schematically a cross-section through an exemplary arrangement of a cover unit

120 suitable for use in a container access station 100 such as that described above. In this exemplary arrangement, the extendible insulation jacket 123 comprises insulating material that is sufficiently flexible to allow the extendible insulation jacket 123 to collapse/fold (i.e. in the manner of a concertina) when contracted, such that the insulation jacket 123 can extend between a contracted configuration and an extended configuration. This arrangement provides that the position of the frame module 121 can be adjusted relative to the side wall 32 of the storage enclosure 30 without increasing the thermal loss through the container access station 100, which provides for greater flexibility in the dimensions of the storage enclosure 30, and particularly the thickness of the side wall 32, and in the positions of the source container conveyor system 103 and the destination container conveyor system 104 relative to the side wall 32.

In the exemplary arrangement of Figure 9, the frame module 121 itself comprises linear conveyor sections 124 of the source container conveyor system 103 and the destination container conveyor system 104. These linear conveyor sections 124 are at least supported by, and are preferably integral to, the frame module 121. This arrangement simplifies the installation of the container access station 100 by providing that the frame module 121 and the linear conveyor sections of the source container conveyor system 103 and the destination container conveyor system 104 can be installed as separate units that interface with one another, as opposed to requiring the installation of the frame module

121 and the subsequent installation of a conveyor section that passes through the frame module 121.

The frame module 121 then further comprises one or more doors 125, each of the one or more doors 125 being arranged to move between a closed configuration in which the door 125 closes one or more of the conveyor apertures 122, as shown in Figure 9, and an open configuration in which the door 125 does not close the conveyor apertures 122. The frame module 121 then comprises an actuator mechanism (not shown) that moves the doors 125 between the closed configuration and the open configuration. By way of example, each door 125 could comprise a motor-driven roller shutter that can be extended from a housing in order to close off one of more of the conveyor apertures 122 and retracted back in to the housing in order to open the conveyor apertures 122. By way of further example, each door 125 could comprise a vertical sliding door that can be raised and lowered in order to move the door 125 between the closed and open configurations.

Figures 10a and 10b illustrate an exemplary arrangement of a frame module 221 suitable for use in a container access station 100 such as that described above. In the exemplary arrangement of Figures 10a and 10b, the frame module 221 defines two conveyor apertures 222 and comprises a door 225 that is arranged to cover both conveyor apertures 222 when in the closed configuration, as shown in Figure 10b. The frame module 221 also comprises a motor-driven lift mechanism 226 that is arranged to move the door 225 between a lower position in which the door 225 is in the open configuration, as shown in Figure 10a, and an upper position in which the door 225 is in the closed configuration. The frame module 221 then further comprises integral linear conveyor sections 224, each of the linear conveyor sections 224 being aligned with one of the conveyor apertures 222.

The exemplary arrangement of Figures 10a and 10b is intended to be combined as a pair with another, corresponding frame module 221, with one of the frame modules 221 being used with the source conveyor system 103 and the other frame module 221 being used with the destination conveyor system 104. In particular, for each frame module 221, one of the conveyor apertures 222 defined by the frame modules 221 provides an aperture through which containers travelling along the outgoing linear conveyor sections can pass through the cover unit 120, whilst the other of the conveyor apertures 222 defined by the frame modules 221 provides an aperture through which containers travelling along the ingoing linear conveyor sections can pass through the cover unit 120.

When installed, one end of an insulation jacket (not shown) is connected to a periphery of the frame module 221 and an opposing end of the insulation jacket is attached to the side wall 32 surrounding the opening, thereby occluding the gap between the storage enclosure 30 and the frame module 221. When the container access station 100 is in active use, the door 225 will be in the open configuration, such that containers can pass between the grid interface portion 101 and the container interaction portion 102 through the conveyor apertures 222. Then, when the container access station 100 is inactive, the door 225 can be moved in to the closed configuration, thereby covering the conveyor apertures 222 and at least minimising thermal loss through the opening 33 in the side wall 32.

It will be understood that the above description of is given by way of example only and that various modifications may be made by those skilled in the art. Although various embodiments have been described above with a certain degree of particularity, or with reference to one or more individual embodiments, those skilled in the art could make numerous alterations to the disclosed embodiments without departing from the scope of this invention. By way of example, it will be appreciated that the features described hereinabove may all be used together in a single system. In other embodiments of the invention, some of the features may be omitted. The features may be used in any compatible arrangement.

By way of further example, in the arrangements illustrated in the Figures the conveyors and each section of each conveyor is illustrated as a roller conveyor. However, each conveyor and/or each section of conveyor could comprise any of a roller conveyor device, a chain conveyor device, a slat conveyor device etc.

Claims

1. A storage and retrieval system comprising:

An enclosure comprising a temperature control system configured to control the air temperature inside the enclosure, wherein the enclosure houses a grid and a plurality of storage containers located in stacks beneath the grid; a container access station; and a plurality of load handling devices arranged to move along the grid and configured to move the containers between the stacks and container access station; wherein the container access station comprises: a source container drop-off location disposed within the enclosure and arranged to receive containers from the load handling devices, a source container presentation location disposed outside the enclosure and arranged to present containers, a source container pickup location disposed within the enclosure and arranged to provide containers to the load handling devices, and a source container conveyor system arranged to convey containers from the source container drop-off location to the source container pick-up location via the source container presentation location; a destination container drop-off location disposed within the enclosure and arranged to receive containers from the load handling devices, a destination container presentation location disposed outside the enclosure and arranged to present containers, a destination container pick-up location disposed within the enclosure and arranged to provide containers to the load handling devices, and a destination container conveyor system arranged to convey containers from the destination container drop-off location to the destination container pickup location via the destination container presentation location; wherein the source container conveyor system and the destination container conveyor system are arranged to convey containers through one or more openings formed in a side wall of the enclosure and comprise linear sections and direction change sections, the direction change sections being disposed outside of the enclosure.

2. The storage and retrieval system according to claim 1, wherein the container access station comprises a further source container drop-off location disposed within the enclosure and arranged to receive containers from the load handling devices, the further source container drop-off location being disposed in series with the source container drop-off location.

3. The storage and retrieval system according to any of claims 1 and 2, wherein the container access station comprises a further source container pick-up location disposed within the enclosure and arranged to provide containers to the load handling devices, the further source container pick-up point being disposed in series with the source container pick-up point.

4. The storage and retrieval system according to any of claims 1 to 3, wherein the linear sections of the source container conveyor system and the destination container conveyor system within the enclosure are parallel.

5. The storage and retrieval system according to any of claims 1 to 4, wherein the destination container presentation location and the source container presentation location are adjacent.

6. The storage and retrieval system according to any of claims 1 to 5, wherein the source container conveyor system comprises an outgoing linear section that conveys containers from the source container drop-off location towards the source container presentation location, and an ingoing linear section that conveys containers from the source container presentation location towards the source container drop-off location.

7. The storage and retrieval system according to any of claims 1 to 6, wherein the destination container conveyor system comprises an outgoing linear section that conveys containers from the destination container drop-off location towards the destination container presentation location, and an ingoing linear section that conveys containers from the destination container presentation location towards the destination container drop-off location.

8. The storage and retrieval system according to any of claims 1 to 7, wherein the destination container conveyor system comprises one or more direction change sections that direct containers towards the destination container presentation location.

9. The storage and retrieval system according to any of claims 1 to 8, wherein the destination container conveyor system comprises one or more direction change sections that directs containers from the destination container presentation location towards the destination container pick-up location.

10. The storage and retrieval system according to any of claims 1 to 9, wherein the source container conveyor system comprises one or more direction change sections that directs containers from the source container presentation location towards the source container pick-up location.

11. A storage and retrieval system comprising: an enclosure comprising a temperature control system configured to control the air temperature inside the enclosure, wherein the enclosure houses a grid and a plurality of storage containers located in stacks beneath the grid; a container access station; and a plurality of load handling devices arranged to move along the grid and configured to move the containers between the stacks and the container access station; wherein the enclosure is provided with an opening; wherein the container access station comprises one or more conveyor systems that extend through the opening in the enclosure, and a cover unit; wherein the cover unit comprises: a frame module arranged to extend over at least a portion of the opening and to define one or more conveyor apertures through which containers can be conveyed by the conveyor systems; and an insulation jacket that is arranged to substantially occlude a gap between the storage enclosure and the frame module.

12. The storage and retrieval system according to claim 11, wherein the insulation jacket is attached to both the frame module and the storage enclosure, and extends between the frame module and the storage enclosure.

13. The storage and retrieval system according to any of claims 11 and 12, wherein the insulation jacket is capable of moving between an extended configuration and a contracted configuration.

14. The storage and retrieval system according to any of claims 11 to 13, wherein the frame module further comprises one or more doors, each of the one or more doors being arranged to move between a closed configuration in which the door closes one or more of the conveyor apertures and an open configuration in which the door does not close the conveyor aperture.

5. The storage and retrieval system according to any of claims 11 to 14, wherein the frame module further comprises one or more linear conveyor sections, each of the linear conveyor sections being aligned with one of the conveyor apertures.