Chilled and frozen storage zones in commercial product storage structures

Abstract

There is provided an automated storage and retrieval system. In one form, the system may include: a storage structure including multiple levels with each level including multiple storage locations configured to store containers containing eaches and being accessible to mobile robots; a first storage zone in the storage structure configured to store containers at a first temperature; a second storage zone in the storage structure configured to store containers at a second temperature greater than the first temperature, at least a portion of the second storage zone being located above the first storage zone; and an insulated workstation in one of the first and second storage zones with the first insulated workstation configured to allow transfer of eaches to or from mobile robots.

Description

CHILLED AND FROZEN STORAGE ZONESIN COMMERCIAL PRODUCT STORAGE STRUCTURESCross-Reference to Related Application(sJ

[0001] This application claims the benefit of and priority to U.S. Application No. 63 / 627,323, filed January 31, 2024, which is incorporated herein by reference in its entirety.Technical Field

[0002] This invention relates generally to storage and retrieval systems, and more particularly, to the arrangement of chilled and frozen storage zones in such systems.Background

[0003] Some storage and retrieval systems operate at storage facilities that store many different types of goods and merchandise. Different types of merchandise may be stored at different temperatures or temperature ranges. Frozen goods may be stored at frozen temperatures, chilled goods may be stored at chilled temperatures, and other goods may be stored at ambient temperatures. In some storage and retrieval systems, mobile robots may be used to transfer goods from their storage locations to other areas where the goods may be collected and assembled into orders.

[0004] It is desirable that frozen goods and chilled goods be stored at storage facilities in an efficient manner. It is desirable that such goods be stored in an efficient manner so as to reduce refrigeration costs. Also, there is a need to accommodate individuals picking goods at the storage facilities, who want to avoid working in an excessively cold environment. Further, there is a need to account for the use of mobile robots in determining the storage and picking of frozen and chilled goods at storage facilities.Brief Description of the Drawings

[0005] Disclosed herein are embodiments of systems, apparatuses and methods using an automated storage and retrieval system. This description includes drawings, wherein:

[0006] FIG. 1 is a perspective view of a storage structure in accordance with some embodiments;

[0007] FIG. 2 is a perspective view of the storage structure of FIG. 1;

[0008] FIG. 3 is a partial perspective view of the storage structure of FIG. 1;

[0009] FIG. 4 is a partial perspective view of the storage structure of FIG. 1;

[0010] FIG. 5 is a partial top view of a level in accordance with some embodiments;

[0011] FIG. 6 is a partial front view of the storage structure of FIG. 1;

[0012] FIG. 7 is a partial side view of the storage structure of FIG. 1;

[0013] FIG. 8 is a partial side view of the storage structure of FIG. 1;

[0014] FIG. 9 is a partial top view of a ground level of the storage structure of FIG. 1;

[0015] FIG. 10 is a perspective view of the storage structure of FIG. 1;

[0016] FIG. 11 is a partial perspective view of the storage structure of FIG. 1;

[0017] FIG. 12 is a partial perspective view of a tunnel in accordance with some embodiments;

[0018] FIG. 13 is a partial perspective view of the tunnel of FIG. 12;

[0019] FIG. 14 is a partial perspective view of the tunnel of FIG. 12 at a storage structure in accordance with some embodiments;

[0020] FIG. 15 is front view of a vertical pathway in accordance with some embodiments;

[0021] FIG. 16 is a perspective view of a double door in accordance with some embodiments;

[0022] FIG. 17 is a perspective view of the double door of FIG. 16; and

[0023] FIG. 18 is a flow diagram in accordance with some embodiments.

[0024] Elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions and / or relative positioning of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of various embodiments of the present invention. Also, common but well- understood elements that are useful or necessary in a commercially feasible embodiment are often not depicted in order to facilitate a less obstructed view of these various embodiments of the present invention. Certain actions and / or steps may be described or depicted in a particular order of occurrence while those skilled in the art will understand that such specificity with respect tosequence is not actually required. The terms and expressions used herein have the ordinary technical meaning as is accorded to such terms and expressions by persons skilled in the technical field as set forth above except where different specific meanings have otherwise been set forth herein.Detailed Description

[0025] The following description is not to be taken in a limiting sense but is made merely for the purpose of describing the general principles of exemplary embodiments. Reference throughout this specification to “one form,” “one embodiment,” “an embodiment,” “some embodiments”, “an implementation”, “some implementations”, “some applications”, or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. Thus, appearances of the phrases “in one embodiment,” “in an embodiment,” “in some embodiments”, “in some implementations”, and similar language throughout this specification do not all refer to the same embodiment.

[0026] The terms “top” and “bottom,” “upper” and “lower” and “vertical” and “horizontal as may be used herein are by way of example and illustrative purposes only and are not meant to limit the description of the embodiments inasmuch as the referenced item can be exchanged in position and orientation. Also, as used herein, the terms "substantially" and / or "about" mean that the specified dimension or parameter may be varied within an acceptable manufacturing tolerance for a given application.

[0027] Generally speaking, pursuant to various embodiments, systems, apparatuses and methods are provided herein involving automated storage and retrieval systems. In one form, the system includes: a storage structure including a plurality of levels, each level including a plurality of storage locations configured to store containers containing eaches, the storage locations being accessible to a plurality of mobile robots; a first storage zone in the storage structure configured to store containers at a first temperature; a second storage zone in the storage structure configured to store containers at a second temperature greater than the first temperature, at least a portion of the second storage zone being located above the first storage zone; and a first insulated workstationin one of the first and second storage zones, the first insulated workstation configured to allow transfer of one or more eaches to or from a first mobile robot.

[0028] In some implementations, the system further includes a workroom adj acent the first insulated workstation configured to allow an operator to access the first insulated workstation to transfer the one or more eaches to or from the first mobile robot. In some implementations, the first insulation workstation includes: a housing separating the first mobile robot from the workroom; and at least one opening in the housing to allow the operator access to an interior of the first insulated workstation. In some implementations, the workroom is positively pressurized to maintain the workroom at a third temperature greater than the second temperature. In some implementations, the first insulated workstation further includes a first pathway and a second pathway; the first pathway configured for movement of mobile robots from the one of the first and second storage zones entering the first insulated workstation; and the second pathway configured for movement of mobile robots exiting the first insulated workstation to the one of the first and second storage zones. In some implementations, the first insulated workstation is a picking workstation configured to allow transfer of an each from a purchase container entering the picking workstation to an order container exiting the picking workstation. In some implementations, the first insulated workstation is a decanting workstation configured to allow deposit of an each stored in the workroom to the first mobile robot in the first insulated workstation. In some implementations, the system further includes: a second insulated workstation in the other of the first and second storage zones, the second insulated workstation configured to allow transfer of one or more eaches to or from a second mobile robot. In some implementations, a first portion of the second storage zone occupies the same level as the first storage zone; and a second portion of the second storage zone occupies a level above the first storage zone. In some implementations, the system further includes: a first set of containers configured for use in the first storage zone; and a second set of containers configured for use in the second storage zone. In some implementations, a subset of the plurality of mobile robots are configured for use only in the first storage zone. In some implementations, the system further includes: an ambient zone outside the storage structure and part of a storage facility including the storage structure, the ambient zone being connected to the second storage zone by at least insulated pathway. In some implementations, the system further includes: an insulated climbing channel configured formovement of mobile robots between levels of the first storage zone and the second storage zone, the insulated climbing channel having access openings to the first storage zone and the second storage zone. In some implementations, the system further includes: a first door and a second door in series and configured to provide access to and from the workroom, each of the first door and the second door being movable between open and closed positions, the first door and the second door configured so that only one door can be in an open position at a time. In some implementations, the system further includes a third storage zone in the storage structure configured to store containers at a fourth temperature greater than the first and second temperatures, at least a portion of the third storage zone being located above the second storage zone.

[0029] In another form, there is provided a method of transferring eaches including: accessing, by a plurality of robots, a plurality of storage locations at a storage structure having a plurality of levels, each level including storage locations configured to store containers containing eaches, wherein the storage structure includes a first storage zone configured to store containers at a first temperature, and wherein the storage structure includes a second storage zone configured to store containers at a second temperature greater than the first temperature, at least a portion of the second storage zone being located above the first storage zone; and providing or receiving, by a first mobile robot, a transfer of one or more eaches to or from the first mobile robot at a first insulated workstation in one of the first and second storage zones.

[0030] In some implementations, the method further includes: providing a workroom adjacent the first insulated workstation configured to allow an operator to access the first insulated workstation to transfer the one or more eaches to or from the first mobile robot. In some implementations, the method further includes positively pressurizing the workroom to maintain the workroom at a third temperature greater than the second temperature. In some implementations, the first insulated workstation is a picking workstation configured to allow transfer of an each from a purchase container entering the picking workstation to an order container exiting the picking workstation. In some implementations, the first insulated workstation is a decanting workstation configured to allow deposit of an each stored in the workroom to the first mobile robot in the first insulated workstation. In some implementations, the method further includes providing or receiving, by a second mobile robot, a transfer of one or more eaches to orfrom the second mobile robot at a second insulated workstation in the other of the first and second storage zones.

[0031] In another form, there is provided an automated storage and retrieval system including: a storage structure including a plurality of levels, each level including a plurality of storage locations configured to store containers containing eaches, the storage locations being accessible to a plurality of mobile robots; a storage zone in the storage structure configured to store containers at a first temperature; an ambient zone configured to be maintained at a second temperature greater than the first temperature; and an insulated pathway connecting the storage zone to the ambient zone.

[0032] In another form, there is provided an automated storage and retrieval system including: a storage structure including a plurality of levels, each level including a plurality of storage locations configured to store containers containing eaches, the storage locations being accessible to a plurality of mobile robots; a first storage zone in the storage structure configured to store containers at a first temperature; a second storage zone in the storage structure configured to store containers at a second temperature greater than the first temperature, at least a portion of the second storage zone being located above the first storage zone; and an insulated climbing channel configured for movement of mobile robots between levels of the first storage zone and the second storage zone, the insulated climbing channel providing access to the mobile robots to the levels of the first storage zone and the second storage zone.

[0033] In one aspect, and without limitation, this disclosure is directed generally to solutions to increase efficiency and reduce cost related to the refrigeration storage of the automated storage and retrieval system (ASRS) by providing a lower frozen space and a chilled upper space. For example, instead of sequentially extending the frozen and chilled sections in a horizontal direction at the facility, this disclosure proposes an ASRS layout with a frozen section at lower levels and a chilled section, at least partially, at upper section of a storage structure. The disclosure also provides an approach for picking and / or decanting the frozen and chilled goods with this structural layout. In one aspect, this approach generally involves keeping certain mobile robots within the frozen / chilled environment as much as practicable while keeping individuals (such as pickers) in an ambient (or chilled) environment as much as practicable.

[0034] FIGS. 1-4 show part of an order fulfillment facility 100 (or storage facility) that utilizes and is part of an ASRS. More specifically, as part of the ASRS, Figures 1-4 show a storage structure 102 that is generally intended to store frozen and chilled products, in contrast to other products that may be stored at an ambient temperature. In one form, it is contemplated that this storage structure 102 is a part of and is connected to the rest of the storage facility 100. As described further below, the frozen and chilled products are preferably stored in a frozen storage zone and in a chilled storage zone, respectively.

[0035] The storage structure 102 includes a number of storage locations 104. In particular, the storage structure 102 includes a y-z array of storage locations 104 in horizontal rows and level changing towers (or vertical towers or climbing channels) along the rows. As explained below, mobile robots may travel between storage levels in the z-direction within the level changing towers 105. Rows of storage locations 104 may be arranged to face each other, separated by horizontal pathways 106. In one form, it is contemplated that the horizontal pathways may be aisles 106. An aisle 106 is preferably sufficiently wide to allow a mobile robot traveling within the aisle 106 to transfer totes to or from the storage locations 104 on either side of the aisle 106.

[0036] The storage structure 102 further includes decks 108 (or transit planes or areas) spaced apart at different horizontal levels of the storage structure 102. The decks 108 may extend between the aisles 106 so that mobile robots can maneuver in the x-y plane of each deck 108 to travel between different aisles 106. The spacing between decks 108 may be different in various embodiments. In addition to providing access to the aisles 106, the decks 108 may allow transfers by mobile robots to or from a workstation 110.

[0037] FIG. 5 shows a partial and simplified overhead view of a level 116 in the storage structure 102. This overhead view shows aisles 106 with storage locations 104 to either side of the aisle 106. It further shows mobile robot 128 that can traverse the aisles 106 and access the storage locations 104. The mobile robot 128 can also travel along decks 108 to allow it to turn and to allow it to exit one aisle 106 and enter a different one.

[0038] In some embodiments, workstations 110 are equipped to receive mobile robots. For example, a first mobile robot at a workstation 110 may carry product containers (or totes) with items for fulfilling product requests. A second mobile robot at the workstation 110 may carry order containers (or totes) within which items from the product totes are placed to fulfill productrequests. Workers (or pickers) at a workstation 110 manually transfer items from a product tote to an order tote. Further details relating to the general structure and operation of embodiments of storage structures, workstations, and mobile robots are disclosed in U.S. Patent No. 9,139,363; U.S. Patent No. 10,040,632; U.S. Patent 10,435,241; U.S. Patent No. 10,984,375; U.S. Patent No. 10,952,533; U.S. Patent No. 11,142,398; U.S. Patent No. 11,267,651; and U.S. Patent No. 11,332,311 ; which patents are all incorporated by reference herein in their entirety.

[0039] As noted above, the order fulfdlment facility 100 includes a number of mobile robots for transferring totes or other product containers to and from workstations 110 and to and from storage locations 104. In certain embodiments, mobile robots may be self-guided so as to move horizontally within aisles 106 to transfer totes or other product containers between the mobile robots and storage locations 104. For example, a track system including horizontal rails may be affixed within the aisles 106 at different vertical levels. The horizontal rails provide access to storage shelves on either side of an aisle 106 in the x-direction on a given level. As noted above, the storage structure 102 may include level changing towers 105 within which the mobile robots may travel vertically in the z-direction between levels of storage locations 104.

[0040] Accordingly, in some forms, there is disclosed a storage structure 102 with pathways 106 and decks 108, and with mobile robots configured to move along the pathways 106 and decks 108 in the storage structure 102. The storage structure 102 may be part of an order fulfillment facility 100 that includes storage locations 104 for storing containers containing goods / items / eaches, with the storage locations 104 being accessible to mobile robots by a horizontal pathway 106. The term each generally refers to an individual unit of a product or merchandise item. Further, mobile robots are configured to access the storage locations 104 to deposit or retrieve containers at the storage locations 104.

[0041] As shown in FIGS. 6-9, the storage structure 102 includes a layout of various storage zones and workstations. The storage structure 102 includes a frozen storage zone 112 in the storage structure 102 that is configured to store containers at a first temperature. It also includes a separate area for the storage of chilled products. More specifically, it includes a chilled storage zone 114 in the storage structure 102 configured to store containers at a second temperature greater than the first temperature. It is also contemplated that the frozen storage zone 112 and the chilledstorage zone 114 are separated by an insulation barrier 1 15 to maintain their respective temperatures.

[0042] Each zone 112 and 114 may be composed of multiple stratified levels 116. In some forms, it is contemplated that each level 116 may have a dedicated temperature control device. In one form, it is contemplated that this temperature control device may be an evaporator 122. Further, in some forms, each stratified level 116 may be separated from another one by an insulated layer 120.

[0043] Further, it is contemplated that at least a portion of the chilled storage zone 114 is located at a level above the frozen storage zone 112. For example, in FIG. 4, in one form, the frozen storage zone 112 is located at the right and bottom portion of the storage structure 102, i.e., generally in the lower righthand quadrant of the figure. It may occupy the lower levels on the right half of the storage structure 102. In contrast, in this example, the chilled storage zone 114 is located in the remaining three quadrants of the storage structure 102. It occupies the remaining levels directly above the frozen storage zone and also occupies all of the levels on the lefthand side of the storage structure 102. This vertical stratification (with the frozen zone below the chilled zone) helps the zones maintain their respective temperatures as the colder air has less tendency to rise.

[0044] In alternative forms, it is contemplated that the storage structure 102 may include an ambient storage zone in lieu of one of the other two zones. This ambient storage zone would allow the storage of products at an ambient temperature, which would be greater than frozen or chilled temperatures. As one alternative, an ambient storage zone might be located at level(s) 116 directly above the frozen storage zone 112 (in effect replacing the chilled storage zone 114). As another alternative, an ambient storage zone might be located at level(s) 116 directly above a chilled storage zone 114 (without a bottommost frozen storage zone 112).

[0045] In another alternative form, an ambient storage zone might be included in addition to the other two zones. For example, in one arrangement, the frozen storage zone 112 may be located on the bottommost level(s), at least a portion of the chilled storage zone 114 may be located on intermediate level(s) 116 above the frozen storage zone 112, and, in turn, at least a portion of an ambient storage zone may be located on upper level(s) 116 above the chilled storage zone 114. For instance, as one example, an ambient storage zone might occupy the uppermost level of storagestructure 102 in FIGS. 1-4. Again, this arrangement takes advantage of thermal stratification to help the zones maintain their respective temperatures as the colder air has less tendency to rise. Further, in one form, it is contemplated that climbing channel(s) 105 could extend vertically through all three zones.

[0046] FIG. 6 shows workstations 110 with operators 113 at a ground level of the storage structure 102. A portion of the exterior of the storage structure 102 has been excluded in order to provide a better view of possible locations for the workstations 110. In one form, it is contemplated that the operators 113 are human individuals, and it is desirable to provide them with a comfortably temperate environment. However, in other forms, it is contemplated that the operators may be in the form of robots (such as, for example, stationary robots) or robotic devices (such as, for example, robotic arms).

[0047] The ground level may be a desirable workstation location due to the arrival of shipments at the ground level, but other locations are also possible. As stated, it is generally contemplated that mobile robots can move both along horizontal pathways (aisles) 106 and along vertical pathways (climbing channels) 105 within the storage structure 102. Therefore, they can move to workstations 110 at the ground level. Further, in one form, as addressed below, it is contemplated that mobile robots may move from the chilled storage zone 114 (at the top of FIG. 6) to an ambient zone in another part of the facility 100 via a horizontal tunnel 118.

[0048] FIGS. 7 and 8 show a side view of a layout of the storage structure 102. In FIG. 8, where some external detail has been removed, operators 113 are shown at workstations 110. In this view, it is generally contemplated that the lower levels that are encapsulated in the heavy black outline are part of the frozen storage zone 112. Conversely, the upper levels are part of the chilled storage zone 114. The disposition of the frozen storage zone 112 below the chilled storage zone 114 allows stratification of the chilled / frozen air. There is an insulation barrier 115 (or thermal break) between the frozen storage zone 112 and the chilled storage zone 114.

[0049] In addition, there is preferably an insulation layer 120 between levels 116 within a zone to help control the temperature in each level 116. It is generally contemplated that any suitable form of insulation material may be used. Further, each level 116 preferably includes its own evaporator 122 so that the temperature of each level 116 can be controlled independently of other levels 116. The use of a separate evaporator 122 for each level 116 allows the selective useof as much of each zone as is needed for the amount of storage. For example, if there is a limited amount of frozen items, these frozen items may be stored at lower levels of the frozen storage zone 112, and the upper levels need not be used and therefore need not be maintained at a frozen temperature by evaporators 122.

[0050] As shown, in this exemplary layout, the workstations 110 are included in the frozen storage zone 112. In contrast, it is generally contemplated that the workrooms 124 and 126 where the operators are working are maintained at an ambient temperature, although, in some forms, the workrooms 124 and 126 may be maintained at a chilled temperature. It is generally contemplated that there is also an insulation barrier 115 between the frozen storage zone 112 and the workrooms 124 and 126. The workstations 110 may be insulated workstations to help maintain the difference in temperature between the frozen storage zone 112 and the workrooms 124 and 126. The workrooms 124 and 126 are adjacent the workstations 110 and are configured to allow an operator 113 to access the workstations 110 to transfer the one or more eaches to or from the mobile robot 128. This access is generally represented by the dashed lines in FIG. 8. Although in this example, the workstations 110 are located in the frozen storage zone 112, it is also contemplated that they may be located in the chilled storage zone 114 in other embodiments, as addressed below.

[0051] In this particular layout, it is generally contemplated that the workstations 110 are insulated workstations in one of the frozen and chilled storage zones. However, in other forms, not all of the workstations 110 need to be insulated workstations, such as, for example, when a workroom 124 or 126 is maintained at a chilled temperature and the workstation 110 is in a chilled storage zone. The workstations 110 are configured to allow transfer of one or more eaches to or from a mobile robot 128.

[0052] In this regard, in one form, it is contemplated that mobile robots 128 may retrieve purchase containers (or totes) from storage locations 104 in the frozen and chilled storage zones 112 and 114. For example, mobile robots 128 in the chilled storage zone 114 may travel vertically down a climbing channel 105 to the workstations 110 that are located in the frozen storage zone 112. They may travel to the workstations 110 where the operators 113 may pick each(es) from the purchaser containers 127 and transfer the each(es) to order containers 129. Operators 113 make transfers to and from the mobile robots 128 at the workstations 110. In some forms, as shown in FIG. 9, there may be two lanes for mobile robots 128: one lane for incoming mobile robots 128with purchase containers 127 and a second lane for outgoing mobile robots 128 with order containers 129.

[0053] In one form, a workstation 110 may include a housing 130 that separates the mobile robot 128 from a workroom 124 and 126. Further, the workstation 110 may include at least one opening in the housing 130 to allow an operator 113 access to the interior of the workstation 110 (shown by dashed lines in FIG. 8). It is generally contemplated that there is limited air flow through the opening(s) because the workstations 110 are preferably low to the ground and cold air does not tend to move upward. Optionally, in one form, these opening(s) may be covered by automated and / or manual doors that can open to allow an operator 113 to access the interior of the workstation 110 and to access a mobile robot 128 carrying a purchase container. For example, in this optional form, sensors may detect movement of the operator’s hand or movement of a mobile robot 128 to open or close an automated door.

[0054] Although one example of an insulated workstation 110 has been described, it should be evident that many other forms are possible. The workstation 110 should be of a form to seek to limit the transfer of air between the frozen and ambient zones. For example, in another form, mobile robots 128 may briefly enter the workroom 124 or 126 from the workstation 110, where an operator 113 performs a transfer, and may then immediately return to the workstation 110. It is generally contemplated that the workstation 110 will be isolated as much as practicable so as to prevent air circulation and destratification.

[0055] In this regard, it is contemplated that the workrooms 124 and 126 preferably are maintained at pressure conditions that help limit the transfer of air between the zones. In one form, the workrooms 124 and 126 may be sealed, as addressed further below, or maintained at a desired positive pressure. The sealed nature of the workrooms 124 and 126 helps minimize cold air flowing from workstations 110 into the workrooms 124 and 126, allowing the operators 113 to work in comfort.

[0056] Optionally, each workroom 124 and 126 may be configured so that positive pressure is introduced into the workrooms 124 and 126. For example, a small flow of dry freezer air may be warmed and used to positively pressurize the operator workrooms 124 and 126. A blower device / heater combination 134 is shown whereby air may be warmed and flow from the frozen storage zone 112 to the workrooms 124 and 126. The pressurization may be accomplishedby a blower device that can be used to provide a high-pressure flow of air, such as, for example, centrifugal blowers or squirrel cage blowers. The pressurization may be fairly minor in terms of both flow and pressure, and the blower device may be followed by a heater. In one form, the freezer air is preferably dry, possibly with a dewpoint of -20C or lower, and when it is warmed for operator comfort, it retains this low moisture content and therefore has no tendency to form frost. Accordingly, the workrooms 124 and 126 may be positively pressurized to maintain them at an ambient temperature (or, in some forms, a chilled temperature) that is greater than the frozen zone temperature.

[0057] In this exemplary layout, the left side of FIG. 8 is intended to be a picking side in workroom 124, while the right side is intended to be a decanting side in workroom 126. The picking workstation 110A (on the left side) is configured to allow transfer of an each from a purchase container 127 entering the picking workstation 110A to an order container 129 exiting the picking workstation 110A. It is generally contemplated that the purchaser and order containers 127 and 129 are carried by mobile robots 128. The decanting workstation 110B (on the right side) is configured to allow deposit of an each stored in the workroom 126 to the mobile robot 128. It is generally contemplated that workroom 126 may contain pallets 136 of goods / items / eaches that are being transferred to mobile robots 128 individually or in containers. Although this layout shows one example, it should be understood that picking and decanting workstations 110A and HOB may be arranged in other desired ways.

[0058] FIG. 9 shows a top view in which the frozen storage zone 112 and the chilled storage zone are each shown encapsulated within a heavy black outline. The chilled storage zone 114 is adjacent to the frozen storage zone 112 but is preferably separated by an insulation barrier. Further, it should be understood that a portion of the chilled storage zone 114 also extends above the frozen storage zone 112 (as can be seen in FIG. 8). Each zone 112 and 114 includes its own storage locations 104 and decks 108. In this layout, the picking side is at the top of FIG. 9, while the decanting side is at the bottom of FIG. 9.

[0059] As shown in FIG. 9, in this exemplary layout, there are six workstations 110, although other numbers and arrangements of workstations 110 are also possible. There is a picking workstation 110A in the frozen storage zone 112 that is adjacent a picking workroom 124 A, and there is a decanting workstation 110B in the frozen storage zone 112 that is adjacent a decantingworkroom 126A. Further, in this layout, there are two picking workstations 110A in the chilled storage zone 114 that is adjacent a picking workroom 124B, and there are two decanting workstations HOB in the chilled storage zone 114 that is adjacent a decanting workroom 126B.

[0060] In one form, it is contemplated that some or all of the workstations 110 may include a first pathway 138 and a second pathway 140 for the mobile robots 128. The first pathway 138 may be configured for movement of mobile robots 128 from the one of the frozen and chilled storage zones 112 and 114 entering the workstation 110. The second pathway 140 may be configured for movement of mobile robots 128 exiting the workstation 110 to the one of the frozen and chilled storage zones 112 and 114. In one form, it is contemplated that the operator may have access to a purchase container 127 that a mobile robot 128 is bringing to the workstation 110 and may also have access to an order container 129 that another mobile robot 128 is taking from the workstation 110. In this regard, a workstation 110 may include a housing 130 with a first opening to access purchase containers 127 and a second opening to access order containers 129.

[0061] In one form, the picking workrooms 124 A and 124B and the decanting workrooms 126A and 126B are preferably maintained at an ambient temperature for the comfort of the operators. In some forms, they may be maintained at a chilled temperature. It is generally contemplated that the decanting workrooms 126A and 126B may contain pallets 136 of goods / items / eaches for transfer to mobile robots 128. In this regard, eaches may be transferred individually to mobile robots 128, or they may be transferred in containers. Further, it is generally contemplated that the boundaries between frozen, chilled, and ambient zones contain insulation barriers to help maintain the temperatures in the different zones.

[0062] Further, in one form, the four workrooms 124 A, 124B, 126A, and 126B are preferably sealed and under certain pressure conditions. In one form, it is contemplated that the two workrooms 124A and 126A adjacent the frozen storage zone 112 may be maintained at a higher pressure than the two workrooms 124B and 126B adjacent the chilled storage zone 114. This pressure differential may be desirable to limit or minimize the outflow of frozen or chilled air from the respective workstations. In this regard, in one form, it is contemplated that some or all of the four doors between the workrooms and exiting the workrooms may be double doors 148 that form a sort of airlock, as described further below, to maintain the sealed nature of the workrooms.

[0063] FIGS. 10 and 11 show views of the storage structure 102 and the four workrooms 124A, 124B, 126A, and 126B. As shown in FIG. 10, workroom 126A is a decanting workroom that is associated with decanting to the frozen storage zone 112, and workroom 126B is a decanting workroom that is associated with decanting to the chilled storage zone 114. The picking workrooms 124A and 124B are on the other side of the storage structure 102. As shown in FIG. 11, workrooms 124A and 124B are picking workrooms that are associated with picking of the frozen storage zone 112 and the chilled storage zone 114, respectively.

[0064] Additional features relating to the containers (totes) and to the mobile robots are contemplated so as to maintain the intended temperatures in the various zones. In one form, the containers may be dedicated to the frozen storage zone 112 or to the chilled storage zone 114 so as to spend all or a predominant amount of time in those zones. In other words, a first set of containers may be configured for use in the chilled storage zone 114, while a second set of containers may be configured for use in the frozen storage zone 112. Similarly, the mobile robots 128 may be dedicated to the frozen or chilled storage zones 112 and 114 so as to spend all or a predominant amount of time in those zones. For example, in one form, a subset of the mobile robots 128 may be configured to operate in the frozen storage zone 112. In some forms, it is contemplated that the time such mobile robots 128 may spend in an ambient zone may be limited or minimized.

[0065] FIGS. 12-14 show another feature intended to help maintain intended temperatures in chilled and ambient zones. In some forms, it is contemplated that the movement of mobile robots 128 may only be between chilled and frozen zones or between chilled and ambient zones. It may be desirable to limit or eliminate movement of mobile robots 128 between frozen and ambient zones because of the temperature differential.

[0066] FIGS. 12-14 show a tunnel 118 that is generally intended to connect the chilled storage zone 114 in the storage structure 102 to an ambient zone in a different part of the storage facility. In other words, it is contemplated that an ambient zone (maintained at a greater temperature than the chilled storage zone 114) may be connected to the chilled storage zone 114 by at least one insulated pathway 118. For example, FIGS. 1-3, 10, and 11 show two insulated pathways 118 extending out horizontally from the storage structure 102 that would connect to an ambient zone in another part of the facility.

[0067] In some forms, it is contemplated that the tunnel 118 may have a tube-like structure with walls 143 defining a generally rectangular cross-section that is sized to enclose mobile robots 128 and allow them to pass through the tunnel 118. Further, it is generally contemplated that the tunnel 118 will enclose the mobile robots 128 in a close-fitting and secure manner to reduce heat transfer, and preferably, the tunnel length is, at least, double the height of the tunnel 118. Optionally, automatic door(s) 144 (or hatch(es)) may be included at one or both ends of the tunnel 118 so as to minimize the transfer of heat between zones. In some forms, these door(s) 144 may be maintained in a closed position, and sensors (such as motion sensors, weight sensors, etc.) may be used to activate the door(s) 144 to allow mobile robots 128 to enter and pass through the tunnel 118. Although FIGS. 12 and 13 appear to show the tunnel 118 with an open top portion, this top portion was shown as transparent to illustrate a mobile robot 118 inside for ease of understanding. It is generally contemplated that the tunnel 118 includes four walls 143 that fully enclose mobile robots 118 passing through it.

[0068] FIG. 15 shows a feature intended to help maintain intended temperatures in chilled and frozen zones. More specifically, it is generally contemplated that the vertical pathways (climbing channels) 105 configured for movement of mobile robots 128 between the frozen storage zone 112 and the chilled storage zone 114 are insulated. A vertical pathway / climbing channel acts as a form of elevator shaft for the mobile robots 128 and provides access to different levels. It is generally contemplated that any suitable insulation material may be used to insulate the vertical pathway 105 generally along part of all of its length. In one form, it is desirable to introduce a thermal break at the interface between temperature zones and / or to introduce a small amount of heat to the metal parts to prevent frost formation.

[0069] In one form, it would be beneficial to provide side panels (insulated or not) 146 to prevent airflow from the evaporators 122 that are cooling the levels 116 from entraining air from one temperature zone to the next. For example, in one form, these side panels may be in the form of non-insulated or insulated doors 146 (or other insulated features) along the vertical pathway 105 at locations / openings where mobile robots 128 will enter a level 116 from the vertical pathway 105. This insulation helps reduce the transfer of air from one level 116 to another one. Like the tunnel 118, in some forms, these door(s) 146 may be automated and maintained in a closedposition, and sensors (such as motion sensors, weight sensors, etc.) may be used to activate the door(s) 146 to allow mobile robots 128 to enter and pass through the door(s) 146.

[0070] FIGS. 16 and 17 show a feature that helps maintain the workrooms 124 and 126 in a sealed condition and at desired pressures. This feature is in the form of a double door 148 that operates as a sort of airlock. For example, FIGS. 16 and 17 show a double door 148 between a decanting workroom 126A and an external area 150 where pallets 136 of goods may be stored and arranged. As will be understood, the double door 148 of the workroom 126A will need to be opened in order to move full pallets 136 into the workroom 126A and to move empty pallet 136 out of the workroom 126A.

[0071] The double door 148 generally includes two doors that are arranged in series with respect to one another. There is an interior door adjacent to and providing access to the workroom 126, and there is an exterior door that is adjacent to and providing access to the pallet area 150. The two doors are configured so that only one of the doors may be open at a time. For example, an individual opens the exterior door, enters the vestibule 152 between the two doors with a pallet 136, the exterior door closes, the interior door opens, and the individual proceeds through the interior door into the workroom 126A with the pallet 136. In other words, the double door 148 includes a first door and a second door in series and configured to provide access to and from a workroom 124 or 126 with each of the first door and the second door being movable between open and closed positions and with the first door and the second door configured so that only one door can be in an open position at a time.

[0072] It is contemplated that a double door 148 may be used in several locations relative to the workrooms. As just described, the double door 148 may be located at an exit to a workroom 124 or 126. In another form, it is contemplated that double doors 148 may be located between workrooms 124 or 126. Two workrooms may be maintained at different pressures making a double door 148 between them desirable. For example, with reference to FIG. 9, a double door 148 may be located between decanting workroom 126A and decanting workroom 126B, and a double door 148 may be located between picking workroom 124A and picking workroom 124B. Sensors may be used to open and / or close one or both of the interior door and exterior door.

[0073] FIG. 18 shows a process 200 for transferring eaches involving mobiles robots and insulated workstations. It is generally contemplated that the transfer occurs at a store structurewith a frozen storage zone and a chilled storage zone. Further, it is generally contemplated that the storage structure, zones, and workstations may involve some or all of the components described above. The above description is incorporated herein.

[0074] At block 202, a storage structure is provided with frozen and chilled storage zones. It is generally contemplated that the storage structure will include a frozen storage zone configured to store containers at a first temperature. It is further generally contemplated that the storage structure will include a chilled storage zone configured to store containers at a second temperature greater than the first temperature with at least a portion of the chilled storage zone being located above the frozen storage zone.

[0075] At block 204, containers of eaches are stored in storage locations in the frozen storage zone. At block 206, the storage locations in the frozen storage zone are accessed by mobile robots. Similarly at block 208, containers of eaches are stored in storage locations in the chilled storage zone, and at block 210, the storage locations in the chilled storage zone are accessed by mobile robots. It is generally contemplated that the mobile robots may access the storage locations at a storage structure having multiple levels with each level including storage locations configured to store containers containing eaches.

[0076] At block 212, eaches (which includes containers holding eaches) are transferred at an insulated workstation, such as workstations 110 described above. More specifically, eaches are transferred to or from mobile robots at the insulated workstation, which is located in one of the frozen or chilled storage zones. In one form, it is contemplated that one mobile robot may allow an operator to take one or more eaches delivered by the mobile robot. At block 214, eaches are received at the insulated workstation by another mobile robot. In one form, it is contemplated that this other mobile robot may allow an operator to transfer one or more eaches to this mobile robot.

[0077] In one form, it is contemplated that the insulated workstation may be a picking workstation configured to allow transfer of an each from a purchase container entering the picking workstation to an order container exiting the picking workstation. In another form, it is contemplated that the insulated workstation may be a decanting workstation configured to allow deposit of each(es) (or a container of eaches) stored in an operator workroom to the first mobile robot in the first insulated workstation. In some forms, it is contemplated that there are insulated workstations in each of the frozen and chilled storage zones and that mobile robots are providingor receiving transfers of each(es) at the insulated workstations in both the frozen and chilled storage zones.

[0078] At block 216, a workroom is provided adjacent to the insulated workstation where an operator may access the workstation to transfer eaches to and from mobile robots. As should be understood, the steps of this process 200 may be performed in any order, and in some forms, it is likely that the workroom is provided before some of the other steps described above. Optionally, at block 218, the workroom is positively pressurized to help maintain the temperature in the workroom. In some forms, it is contemplated that the workroom is kept at an ambient temperature for the comfort of the operator(s) working in the workroom.

[0079] Those skilled in the art will recognize that a wide variety of other modifications, alterations, and combinations can also be made with respect to the above-described embodiments without departing from the scope of the invention, and that such modifications, alterations, and combinations are to be viewed as being within the ambit of the inventive concept.

Claims

CLAIMSWhat is claimed is:

1. An automated storage and retrieval system comprising: a storage structure including a plurality of levels, each level including a plurality of storage locations configured to store containers containing eaches, the storage locations being accessible to a plurality of mobile robots; a first storage zone in the storage structure configured to store containers at a first temperature; a second storage zone in the storage structure configured to store containers at a second temperature greater than the first temperature, at least a portion of the second storage zone being located above the first storage zone; and a first insulated workstation in one of the first and second storage zones, the first insulated workstation configured to allow transfer of one or more eaches to or from a first mobile robot.

2. The automated storage and retrieval system of claim 1, further comprising a workroom adjacent the first insulated workstation configured to allow an operator to access the first insulated workstation to transfer the one or more eaches to or from the first mobile robot.

3. The automated storage and retrieval system of claim 2, wherein the first insulation workstation comprises: a housing separating the first mobile robot from the workroom; and at least one opening in the housing to allow the operator access to an interior of the first insulated workstation.

4. The automated storage and retrieval system of claim 2, further comprising a blower configured to direct air flow into the workroom to positively pressurize and maintain the workroom at a third temperature greater than the second temperature.

5. The automated storage and retrieval system of claim 1 , wherein: the first insulated workstation further comprises a first pathway and a second pathway; the first pathway configured for movement of mobile robots from the one of the first and second storage zones entering the first insulated workstation; and the second pathway configured for movement of mobile robots exiting the first insulated workstation to the one of the first and second storage zones.

6. The automated storage and retrieval system of claim 1, wherein the first insulated workstation is a picking workstation configured to allow transfer of an each from a purchase container entering the picking workstation to an order container exiting the picking workstation.

7. The automated storage and retrieval system of claim 2, wherein the first insulated workstation is a decanting workstation configured to allow deposit of an each stored in the workroom to the first mobile robot in the first insulated workstation.

8. The automated storage and retrieval system of claim 1, further comprising: a second insulated workstation in the other of the first and second storage zones, the second insulated workstation configured to allow transfer of one or more eaches to or from a second mobile robot.

9. The automated storage and retrieval system of claim 1, wherein: a first portion of the second storage zone occupies the same level as the first storage zone; and a second portion of the second storage zone occupies a level above the first storage zone.

10. The automated storage and retrieval system of claim 1, further comprising: a first set of containers configured for use in the first storage zone; and a second set of containers configured for use in the second storage zone.

11. The automated storage and retrieval system of claim 1, wherein:a subset of the plurality of mobile robots are configured for use only in the first storage zone.

12. The automated storage and retrieval system of claim 1, further comprising: an ambient zone outside the storage structure and part of a storage facility including the storage structure, the ambient zone being connected to the second storage zone by at least insulated pathway.

13. The automated storage and retrieval system of claim 1, further comprising: an insulated climbing channel configured for movement of mobile robots between levels of the first storage zone and the second storage zone, the insulated climbing channel having access openings to the first storage zone and the second storage zone.

14. The automated storage and retrieval system of claim 2, further comprising: a first door and a second door in series and configured to provide access to and from the workroom, each of the first door and the second door being movable between open and closed positions, the first door and the second door configured so that only one door can be in an open position at a time.

15. The automated storage and retrieval system of claim 1, further comprising: a third storage zone in the storage structure configured to store containers at a fourth temperature greater than the first and second temperatures, at least a portion of the third storage zone being located above the second storage zone.

16. A method of transferring eaches comprising: accessing, by a plurality of robots, a plurality of storage locations at a storage structure having a plurality of levels, each level including storage locations configured to store containers containing eaches, wherein the storage structure includes a first storage zone configured to store containers at a first temperature, and wherein the storage structure includes a second storage zoneconfigured to store containers at a second temperature greater than the first temperature, at least a portion of the second storage zone being located above the first storage zone; and providing or receiving, by a first mobile robot, a transfer of one or more eaches to or from the first mobile robot at a first insulated workstation in one of the first and second storage zones.

17. The method of claim 16, further comprising: providing a workroom adjacent the first insulated workstation configured to allow an operator to access the first insulated workstation to transfer the one or more eaches to or from the first mobile robot.

18. The method of claim 17, further comprising positively pressurizing the workroom to maintain the workroom at a third temperature greater than the second temperature.

19. The method of claim 16, wherein the first insulated workstation is a picking workstation configured to allow transfer of an each from a purchase container entering the picking workstation to an order container exiting the picking workstation.

20. The method of claim 17, wherein the first insulated workstation is a decanting workstation configured to allow deposit of an each stored in the workroom to the first mobile robot in the first insulated workstation.

21. The method of claim 16, further comprising: providing or receiving, by a second mobile robot, a transfer of one or more eaches to or from the second mobile robot at a second insulated workstation in the other of the first and second storage zones.

22. An automated storage and retrieval system comprising: a storage structure including a plurality of levels, each level including a plurality of storage locations configured to store containers containing eaches, the storage locations being accessible to a plurality of mobile robots;a storage zone in the storage structure configured to store containers at a first temperature; an ambient zone configured to be maintained at a second temperature greater than the first temperature; and an insulated pathway connecting the storage zone to the ambient zone.

23. An automated storage and retrieval system comprising: a storage structure including a plurality of levels, each level including a plurality of storage locations configured to store containers containing eaches, the storage locations being accessible to a plurality of mobile robots; a first storage zone in the storage structure configured to store containers at a first temperature; a second storage zone in the storage structure configured to store containers at a second temperature greater than the first temperature, at least a portion of the second storage zone being located above the first storage zone; and an insulated climbing channel configured for movement of mobile robots between levels of the first storage zone and the second storage zone, the insulated climbing channel providing access to the mobile robots to the levels of the first storage zone and the second storage zone.