Storage and retrieval system comprising grid frame structure and plurality of storage containers

Abstract

The invention provides a storage and retrieval system. The storage and retrieval system includes a grid frame structure (714) including a rail system (320) forming a grid pattern, the rail system (320) including a plurality of grid spaces (310), at least one load handling device (30) movable on the rail system (320), and a plurality of storage posts arranged adjacent to each other. A stack of a plurality of storage containers (200, 500) is disposed in each of the plurality of storage columns and below the rail system (320). The load handling device (30) comprises a lifting device arranged to lift one or more storage containers from the stack. Each storage container includes a base wall and opposing side and end walls extending from the base wall to form a box-like structure having an opening, and a lid for closing the opening of one or more storage containers to define a cooled transfer box (200). At least one of the base wall and / or the opposite side walls and / or the opposite end walls and / or the cover of the cooling carrying box comprises a recess containing a refrigerant having a freezing point in the range of-30 DEG C to 0 DEG C for storing frozen or refrigerated food products.

Description

Technical Field

[0001] The present invention relates to the field of automated storage and retrieval systems, including robotic load handling devices for handling storage containers stacked in the automated storage and retrieval systems, and more particularly to storage containers for automated storage and retrieval systems. Background Art

[0002] Storage and retrieval systems comprising three-dimensional storage grid structures in which storage containers / boxes are stacked on top of each other are well known. PCT publication WO2015 / 185628A (Ocado) describes a known storage and fulfillment system in which stacks of boxes or containers are arranged within a grid frame structure. The boxes or containers are accessed by a robot-controlled load handling device running on tracks located on top of the grid frame structure. This type of system is schematically shown in Figures 1 to 3.

[0003] As shown in Figures 1 and 2, stackable containers, referred to as boxes 10, are stacked on top of one another to form a stack 12. For the purpose of definition, the terms "box," "tote box," "container," and "storage container" are used interchangeably in the specification to represent the same features. The stack 12 is arranged in a grid frame structure 14 in a warehouse or manufacturing environment. The grid frame structure is composed of a plurality of storage columns or grid columns. Each grid unit in the grid frame structure has at least one grid column for storing a stack of containers. Figure 1 is a schematic perspective view of a grid frame structure 14, and Figure 2 is a top view of a stack 12 of boxes 10 arranged within the frame structure 14. Each box 10 typically contains a plurality of product items (not shown), and the product items within the box 10 may be the same, or may be different product types, depending on the application.

[0004] The grid frame structure 14 includes a plurality of upright members 16 supporting horizontal members 18, 20. A first set of parallel horizontal members 18 are arranged perpendicular to a second set of parallel horizontal members 20 to form a plurality of horizontal grid cells supported by the upright members 16. The members 16, 18, 20 are typically made of metal. The boxes 10 are stacked between the members 16, 18, 20 of the grid frame structure 14 such that the grid frame structure 14 prevents horizontal movement of the stack 12 of boxes 10 and guides vertical movement of the boxes 10.

[0005] The top layer of the grid frame structure 14 includes rails 22 arranged in a grid pattern across the top of the stack 12. Referring also to FIG. 3, the rails 22 support a plurality of load handling devices 30. A first set 22a of parallel rails 22 guides movement of the robotic load handling devices 30 from one side to the other side of the top of the grid frame structure 14 in a first direction (e.g., the X direction), and a second set 22b of parallel rails 22 arranged perpendicular to the first set 22a guides movement of the load handling devices 30 in a second direction (e.g., the Y direction) perpendicular to the first direction. In this manner, the rails 22 allow the robotic load handling devices 30 to move laterally in two dimensions in the horizontal XY plane, so that the load handling devices 30 can be moved to a position above any stack 12.

[0006] The known load handling device 30 shown in Figure 4 includes a carrier body 32 and is described in PCT Patent Publication No. WO2015 / 019055 (Ocado), which is incorporated by reference into the present application. Here, the load handling device 30 includes a wheel assembly, which includes a first set of wheels 34 and a second set of wheels 36, the first set of wheels 34 consisting of a pair of wheels on the front of the carrier 32 and a pair of wheels on the rear of the carrier 32, which are used to engage with a first set of guides or tracks to guide the movement of the device in a first direction, and the second set of wheels 36 consisting of a pair of wheels 36 on each side of the carrier 32, which are used to engage with a second set of guides or tracks to guide the movement of the device in a second direction. The carrier body of the load handling device includes an upper portion and a lower portion. The wheels are arranged around the periphery of a cavity or recess in the lower portion of the carrier body, referred to as a container receiving recess 40. As shown Figure 5 As shown in (a and b), the container receiving recess is sized to accommodate the container 10 when the container 10 is lifted by the crane mechanism. The crane mechanism or container lifting mechanism includes a lifting drive assembly or winch assembly, which includes a winch or crane mechanism for lifting a storage container or box (also called a tote) from above and a container gripping assembly or grabber device 39. The lifting mechanism is located at the upper part of the carrier body. The grabber device is formed as a frame including four corners. The winch crane assembly includes a lifting tether 38 wound on a spool or reel (not shown). Typically, the winch assembly includes four spools, each of the four spools carries a lifting tether, one end of the lifting tether is anchored to the spool and the other end is anchored to the corner of the grabber device.

[0007] The container gripping assembly 39 is configured to grip the top of the container 10 to lift it from a container stack in a storage system of the type taught in PCT Patent Publication No. WO2015 / 019055 (Ocado). The winch assembly is driven by a drive mechanism (not shown), which is generally referred to as a Z motor because the Z motor is configured to lift and lower the container gripping assembly in the Z direction when lifting and lowering the storage container. During the operation of the drive mechanism when lowering the container gripping assembly, the lifting tether is released from the spool. When the storage container is lifted off the guide rail below and enters the container receiving space of the load handling device, the carrier or load handling device can be moved laterally to different positions. When reaching the target position (e.g., another stack, an access point in the storage system, or a conveyor belt), the box or container can be lowered from the container receiving portion and released from the gripper device.

[0008] Once a customer order is received, a robotic load handling device operable to move on rails is instructed to pick a storage box containing the order items from a stack in the grid frame structure and transport the storage box to a picking station where the items can then be retrieved from the storage box. Typically, the load handling device transports the storage box or container to a box lifting device integrated into the grid frame structure. The mechanism of the box lifting device lowers the storage box or container to the picking station. At the picking station, the items are retrieved from the storage box. As taught in GB2524383 (Ocado Innovation Limited), picking can be done manually or by robots. After being retrieved from the storage box, the storage box is transported to a second box lifting device whereupon it is lifted to the grid level to be retrieved by the load handling device and transported back to its position within the grid frame structure. A control system and communication system tracks the position of the storage box and its contents within the grid frame structure. When individual containers are stacked in vertical layers, three-dimensional coordinates can be used to indicate their position in the grid frame structure or "beehive" to represent the position of the load handling device or container and the container depth (e.g., container at (X, Y, Z), depth W). Similarly, the position in the grid frame structure can be indicated in two dimensions to represent the position of the load handling device or container and the container depth (e.g., container depth (e.g., container at (X, Y), depth Z). For example, Z=1 identifies the topmost layer of the grid, i.e., the layer immediately below the rail system, Z=2 is the second layer below the rail system, and so on to the lowest layer of the grid.

[0009] In the storage and retrieval system according to the present invention, various items can be stored and retrieved. However, in the case where the items are grocery items of a perishable nature, provisions for storing perishable grocery items need to be provided in the storage and retrieval system. WO2021 / 209648 (Ocado Innovation Limited) teaches a multi-temperature storage system comprising: a storage structure comprising a plurality of upright members, a plurality of horizontal members supported by the upright members and forming a grid pattern, the grid pattern defining a plurality of grid cells and allowing containers to be arranged in stacks below the grid cells defined by the grid pattern, and a rail structure on top of the horizontal member. The rail structure is configured to allow a load handling device to move across the storage structure to retrieve containers from the stack. The multi-temperature storage system includes a temperature control tool, which is configured to maintain a first temperature zone within the storage structure at a first temperature and a second temperature zone within the storage structure at a second temperature. The temperature control tool includes a temperature control facility and a conduit providing a closed loop along which a temperature control fluid is configured to flow from the temperature control facility to a first temperature zone within the storage structure and from the first temperature zone within the storage structure to the temperature control facility. The temperature control tool is described as a refrigerated facility that cools air to a specified temperature and directs the cooled air along the conduit to one or more locations in the grid frame structure.

[0010] An advantage of a storage and retrieval system as taught in WO2015 / 185628A (Ocado) over other storage systems known in the art is the ability to densely pack items in storage, and a robotic load handling device operable on a grid frame structure is able to at least automatically retrieve items from storage in the grid frame structure to fulfill customer orders. However, the problem with providing temperature control means to direct cooled air to designated areas of the grid frame structure is not only the cost of cooling certain areas of the grid frame structure, but also that the designated areas will need to be adequately insulated to prevent the ingress of warm air from warmer areas of the grid frame structure (e.g., surrounding areas). Since low temperatures affect the storage capacity of the rechargeable power source, which is typically a battery, that powers the robotic load handling device on the grid frame structure, the multi-temperature storage and retrieval systems known in the art are very limited to storing refrigerated goods in the temperature range of 1°C to 4°C. Temperatures in the freezer area below this range, typically in the range of -25°C to -18°C, will severely affect the storage capacity of the battery, so that the battery cannot retain a charge for a sufficient period of time to have any useful purpose on the grid frame structure. Therefore, frozen goods (e.g., ice cream, frozen meat, etc.) are typically stored in separate areas in a typical distribution center or customer fulfillment center with a grid frame structure, and picking frozen goods to fulfill customer orders is very limited to manual operations, thereby eliminating the ability to automate the fulfillment of frozen items.

[0011] Therefore, there is a need for a multi-temperature storage and retrieval system that is capable of storing goods at a variety of storage temperatures, including controlled ambient, refrigerated and frozen temperatures, so as to utilize the high storage capacity of the grid frame structure and the automation of retrieving items from storage without suffering from the above-mentioned problems. Summary of the invention

[0012] The present invention alleviates the above problems by providing a passive cooling system, which includes one or more coolant packages located in one or more walls of an insulated storage container for storage in a grid frame structure. The use of one or more coolant packages enables temperature-sensitive goods to be stored in an insulated storage container within a predetermined temperature range. The coolant package includes a refrigerant that can be frozen to a predetermined temperature based on the freezing point of the refrigerant. An example of a refrigerant that provides a cooling effect is a eutectic mixture of a solvent and one or more mineral salts, which undergoes a phase change at a specific freezing point (or melting point) below the freezing point of the solvent. For example, the eutectic mixture may contain a glycol and / or may contain brine. Brine is particularly useful for use in the cooling of food because it is food safe. Commonly used coolant packages contain aqueous solutions of mineral salts. The type of mineral salt used in the aqueous solution affects the freezing point or melting point of the eutectic mixture, thereby affecting the temperature range in which the item can be stored in the insulated storage container. When incorporated into the storage container, heat from the storage container is absorbed by the refrigerant, causing the refrigerant to undergo a phase change as the refrigerant melts. This change of state occurs without a change in temperature, therefore, the rate of temperature change within the insulated storage container is reduced. The refrigerant is typically cooled in a refrigerator or freezer until the phase change material freezes, and depending on the mineral salts, the freezing point can be as low as -30°C when the refrigerant is a eutectic mixture. The cooling capacity of the refrigerant depends on the quality and quantity of the refrigerant in the insulated storage container. The quality of the refrigerant is judged by the stability of its temperature plateau. As the refrigerant thaws, the refrigerant absorbs heat at an approximately constant temperature, i.e., the temperature profile during the thawing phase is typically flat and continuous. The amount of refrigerant in the insulated storage container controls the amount of heat that can be extracted from the insulated storage container.

[0013] Providing a passive cooling system in a storage container allows the cargo to be stored within a wider temperature range that cannot be easily achieved with an active cooling system. Accordingly, the present invention provides a storage and retrieval system comprising: a grid frame structure comprising a track system and a plurality of storage columns arranged adjacent to one another, the track system comprising a first set of parallel rails or tracks and a second set of parallel rails or tracks, the second set of parallel rails or tracks extending transversely to the first set in a generally horizontal plane to form a grid pattern comprising a plurality of grid spaces; a plurality of storage containers arranged in a stack in each of the plurality of storage columns and located below the rail system, each of the plurality of storage containers including a base wall and opposing side walls and end walls extending from the base wall to form a box-like structure having an opening; at least one load handling device disposed on the track system, the load handling device being arranged to move laterally on the rails above the stack, the load handling device comprising a lifting device arranged to lift one or more containers or parts thereof from the stack, the lifting device comprising a container gripper assembly configured to releasably grip a storage container and a lift drive assembly configured to raise and lower the container gripper assembly; wherein one or more of the plurality of storage containers comprises a lid for closing an opening of the one or more storage containers to define a cooling tote; wherein at least one of the base wall and / or the opposing side wall and / or the opposing end wall and / or the cover of the cooling tote comprises a recess or cavity for containing a refrigerant; The freezing point of the refrigerant is in the range of -30°C to 0°C and is used for storing frozen or refrigerated food.

[0014] The refrigerant can be integrated into one or more walls of the storage container so that one or more walls or lids of the storage container can be used as an integrated coolant package. The base wall, the opposing side walls, and the opposing end walls form a box-like structure or shell within the internal storage space for storing goods or articles in the grid frame structure. Optionally, the refrigerant is contained in the lid of one or more cooling transport boxes. The advantage of incorporating the refrigerant into the lid is that the lid can be replaced from one or more cooling transport boxes when the refrigerant in the lid can no longer maintain the temperature in the cooling transport box within a predetermined temperature range. For the purpose of defining the present invention, the term "charge" is used to describe the condition when the refrigerant remains in a solidified state for a predetermined length of time. Therefore, when the refrigerant runs out of charge, it means that the refrigerant can no longer maintain the temperature in the cooling transport box within a predetermined temperature range. Since the size and shape of the storage container are generally consistent so that a plurality of storage containers can be stacked in the grid frame structure, one or more lids in the cooling transport box are easy to replace. Compared to integrating the refrigerant into one or more of the bottom wall and / or side walls of the cooling tote, the cover is a smaller component than the rest of the cooling tote, allowing multiple covers to be placed in a refrigeration system including a refrigeration or cooling chamber for charging without taking up too much space. The cover including the refrigerant can be referred to as a "refrigerant plate". The refrigerant can have a freezing point in the range of -30°C to -15°C, which defines the refrigerant plate as a freezer plate. Alternatively, the refrigerant can have a freezing point in the range of -5°C to -0°C, which defines the refrigerant plate as a chilled plate.

[0015] As an alternative to a cover including a refrigerant, the refrigerant may be contained within a plate to define a refrigerant plate, such that when the refrigerant has a freezing point in the range of -30°C to -15°C, the refrigerant plate is defined as a freezer plate, and when the refrigerant has a freezing point in the range of -5°C to 0°C, the refrigerant plate is defined as a refrigeration plate. Accommodating the refrigerant in a plate allows the refrigerant plate to be removably received within a recess of at least one of the base wall and / or opposing side wall and / or opposing end wall and / or the cover of the cooling tote. As an alternative to integrating the refrigerant into one or more walls of the storage container, accommodating the refrigerant in a refrigerant plate allows the refrigerant to be replaced by fully solidified or charged refrigerant when the refrigerant in the plate has been completely thawed or nearly completely thawed and is no longer able to effectively cool the contents of the storage container. There are different types of refrigerant plates, and each type of refrigerant plate depends on the type of refrigerant contained within the plate. For storing and cooling frozen goods, the refrigerant has a freezing point in the range of -30°C to -15°C (e.g., the freezing point may be -25°C, -20°C), and is defined as a freezing plate for the purpose of definition. For storing and cooling refrigerated goods, the refrigerant has a freezing point in the range of -5°C to 0°C (e.g., the freezing point may be -4°C, -3°C, -2°C, or -1°C), and is defined as a refrigerated plate for the purpose of definition.

[0016] For maintaining the temperature in the refrigerated zone, this amount corresponds to a temperature range of 2°C to 8°C, while for maintaining the temperature in the frozen or freezer zone, this amount corresponds to a temperature range of -30°C to -15°C. For storing goods in the refrigerated temperature range, preferably, the refrigerant has a freezing point in the temperature range of -5°C to 0°C, while for storing goods in the frozen temperature range, preferably, the refrigerant has a freezing point in the temperature range of -30°C to -15°C. In the case where the freezing point of the refrigerant is in the temperature range of -30°C to -15°C, the refrigerant may be a eutectic mixture. The advantage of using a eutectic mixture is that its freezing point can be tailored to the storage requirements of the goods in question. When the composition of the refrigerant is tailored to provide cooling for goods stored in the frozen temperature range, the cooling tote may be defined as a frozen tote. Accordingly, in the case where the composition of the eutectic mixture is adjusted to provide cooling for goods stored in the refrigerated temperature range, the cooling tote may be defined as a refrigerated tote.

[0017] In order to allow the cooling tote of the present invention to be stacked in a grid frame structure in an ambient temperature environment, optionally, at least a portion of at least one base wall, opposite side walls and / or opposite end walls and / or lids of one or more cooling tote boxes is thermally insulated. Optionally, at least a portion of at least one base wall, opposite side walls and / or end walls and / or lids of one or more cooling tote boxes include thermally insulating foam to reduce or prevent heat from the ambient environment outside the one or more cooling tote boxes from being transferred through at least one base wall, opposite side walls and / or lids of the one or more cooling tote boxes, which will warm the internal storage space of the one or more cooling tote boxes. The heat transfer through the walls of the cooling tote boxes not only heats the internal storage space of the cooling tote boxes, but also accelerates the thawing of the refrigerant in one or more walls of the cooling tote boxes from its charged state, reducing the ability of the refrigerant to cool the internal storage space of the cooling tote boxes. This reduces the effectiveness of the cooling box in storing and cooling items at temperatures below ambient temperature. If the item is a perishable grocery food, a temperature increase above the desired storage temperature of the perishable item for a predetermined length may deteriorate the perishable item to the point where the item may be classified as unsafe to eat, and in a worst case scenario result in the growth of harmful bacteria in the perishable item. The insulating foam also prevents cooling air from exiting the interior storage space of the cooling tote. Optionally, the insulating foam comprises polyurethane foam and / or polystyrene foam.

[0018] Optionally, at least one of the base wall, opposing side and end walls and / or lid of one or more cooling totes comprises a vacuum insulation core. Other means of preventing heat transfer from the surrounding environment into the interior storage space of the cooling tote is to provide a vacuum insulation core in at least one of the base wall, opposing side and end walls and / or lid of one or more cooling totes so as to prevent conduction and convection heat transfer through the walls of the cooling tote. Optionally, the vacuum insulation core may form part of a vacuum insulation panel.

[0019] The advantage of storing items in a grid frame structure is that a densely packed storage system can be provided, because storage containers can be densely packed together into a plurality of storage container stacks. The stack of storage containers can be as high as 21 storage containers in height, and since each storage container in the stack can weigh up to 35kg, this adds a lot of weight to the lower storage containers in the stack. The base wall, relative side walls and end walls of the cooling tote formed by insulating materials such as insulating foam have the problem of not having enough structural rigidity to support the weight of the plurality of storage containers above the stack. In order to prevent the wall of the cooling tote from being crushed by the weight of the storage container or cooling tote above the stack, optionally, the base wall of the box-like structure of each of one or more cooling totes and the relative side walls and relative end walls extending from the base wall of the box-like structure form an inner shell, and each of the one or more cooling totes further includes a rigid outer shell that accommodates the inner shell. When the cooling tote is stacked on top of another in the grid frame structure, the rigid outer shell of the cooling tote provides structural rigidity to compensate for the lower strength insulation material of the inner shell. The rigid shell may be made of any rigid material known in the art, such as metal, plastic material, and the like.

[0020] The more the refrigerant is exposed to the interior storage space of the cooling tote, the greater the heat transfer rate between the air in the interior storage space and the refrigerant, and thus the greater the cooling effect, i.e., more frigories of cooling power from the refrigerant are available to cool the interior storage space of the cooling tote. Frigories is a unit of heat extraction rate, equal to one calorie per hour. In order to maximize the exposure of the refrigerant in at least one of the base wall and / or the opposing side wall and / or the opposing end wall and / or the cover of the cooling tote, optionally, at least one of the base wall and / or the opposing side wall and / or the opposing end wall and / or the cover of each of the one or more cooling totes including the recess includes one or more cutouts extending into the interior of the box-like structure, so that at least a portion of the refrigerant plate is exposed to the interior space of the one or more cooling totes.

[0021] The refrigerant has a limited "cooling time" before it needs to be recharged in a refrigeration chamber or cooling chamber (i.e., refreezing). For the purposes of the definition according to the present invention, the term "cooling time" is interpreted as referring to the duration for which a refrigerant plate (e.g., a eutectic plate) provides cooling in one or more cooling boxes. In other words, it is the time that elapses when the refrigerant plate is in a cooling transport box. Typically, standard eutectic plates that provide a cooling effect in a temperature range of -30°C to -15°C have a cooling time with a predetermined cooling duration of up to 12 hours or even in the range of 24 hours to 30 hours before the eutectic plate needs to be recharged. In order to allow the refrigerant plate to be recharged, preferably, the refrigerant plate is removably accommodated in a recess in at least one of the base wall and / or opposing side wall and / or opposing end wall and / or cover of each of the one or more cooling transport boxes.

[0022] Since the cooling time of the refrigerant plate has a limited predetermined cooling duration, it is necessary to monitor the cooling time of the refrigerant plate when the cooling tote incorporating the refrigerant plate is placed in the grid frame structure in order to determine when the refrigerant plate needs to be recharged, otherwise there is a risk that the refrigerant will completely thaw in the cooling tote, rendering it unable to provide a cooling effect to the internal storage space and the contents of the cooling tote. Optionally, the storage and retrieval system according to the present invention further includes a control system, the control system including one or more processors and a memory storing instructions, the instructions being configured to determine the duration of the one or more cooling totes in the grid frame structure by: i) recording a start time when a refrigerant plate is placed in at least one of a base wall and / or an opposing side wall and / or an opposing end wall and / or a cover of each of one or more cooling totes; ii) determining a duration that has elapsed in the one or more cooling totes from the recorded start time to define a cooling time; and If the cooling time exceeds or approaches the predetermined cooling duration, a robotic load handling device operable on a track structure of the grid frame structure is instructed to remove one or more cooling totes from the grid frame structure.

[0023] The cooling time is defined as the time that has passed when the refrigerant is in at least one of the base wall and / or the opposite side wall and / or the opposite end wall and / or the cover of one or more cooling transport boxes. The cooling time depends on the quality and quantity of the refrigerant in the eutectic plate. Typically, the cooling time has a predetermined cooling duration in the range of 8 hours to 12 hours or 24 hours to 30 hours to provide a cooling effect of -30°C to -15°C or 2°C to 8°C. If the time has passed from the start time when the refrigerant plate is placed in at least one of the base wall, and / or the opposite side wall and / or the opposite end wall and / or the cover of each of the one or more cooling transport boxes, that is, the cooling time exceeds the predetermined cooling duration, the control system can instruct one or more robotic load handling devices that can be operated on the grid frame structure to retrieve the cooling transport box including the suspected refrigerant plate so that the refrigerant plate can be replaced with a charged refrigerant plate from the cooling station. The spent refrigerant panels can be recharged by placing them in the cooling chamber to refreeze any refrigerant that thawed in the spent refrigerant panels. Once the spent refrigerant panels are replaced with charged panels in the cooling tote, the cooling time restarts. Since the one or more cooling totes are subsequently stored in the grid frame structure once the one or more charged refrigerant panels are placed in the one or more cooling totes, the start time can be the time when the one or more cooling totes enter the grid frame structure.

[0024] Once the cooling time exceeds or approaches a predetermined cooling duration to provide a useful cooling effect in the cooling tote, optionally, one or more cooling totes are removed to a cooling station including a plurality of cryogen plates, the cooling station including a refrigeration system for cooling a plurality of cryogen plates within a temperature range of -25°C to -15°C or 2°C to 8°C, so that one or more cryogen plates in one or more retrieved cooling totes can be replaced by one or more cryogen plates from the cooling station.

[0025] In order to make the control system determine the state of the refrigerant plate in the cooling transport box, optionally, each of the plurality of refrigerant plates includes a tag for identifying each of the plurality of refrigerant plates. By being able to identify the refrigerant plate, the control system can assign a start time to a specific refrigerant plate when the refrigerant plate is placed in the cooling transport box, and store data associated with the identification and start time of the refrigerant plate in a database. The tag may include any one of a barcode, a 1-D barcode, a 2-D barcode, a QR code, or an RFID tag. Depending on the type of the tag, a radio frequency identification reader, a linear and / or matrix barcode reader, a payment card reader, a smart card reader, an infrared reader can be used to read the tag. In order to determine the type of the refrigerant plate in the cooling transport box, preferably, the identification includes data associated with whether the refrigerant plate is a freezing plate or a refrigeration plate. The tag can be read by an input device for determining the identification of each of the plurality of refrigerant plates in the cooling station or the cooling transport box or the grid frame structure.

[0026] The control system can then use the start time to determine the state of the cryogen plate when placed in the cooling tote. Optionally, the control system is configured to: i) assigning the identification of one or more refrigerant plates to one or more cooling totes; ii) tracking the position of one or more cooling totes within the grid frame structure; iii) storing the position of the one or more cooling totes in the grid frame structure in a database.

[0027] Preferably, the control system is configured to assign the identification of one or more refrigerant plates to one or more cooling totes depending on whether the cargo is refrigerated cargo or frozen cargo. Different types of refrigerant plates are used in the cooling totes depending on whether the cargo is frozen cargo or refrigerated cargo. One or more freezing plates are used in cooling totes storing frozen cargo, while one or more refrigerating plates are used in cooling totes storing refrigerated cargo. The identification of the refrigerant plate includes data associated with the type of refrigerant plate, and this is assigned to the one or more cooling totes depending on whether the cargo in the one or more cooling totes is frozen cargo or refrigerated cargo.

[0028] By tracking the position of the cooling totes stored in the grid frame structure, the control system can instruct the robotic load handler to retrieve the cooling tote whenever the cooling time of the refrigerant panels in the cooling tote has exceeded or is approaching its predetermined cooling duration. The position of the robotic load handler on the track system can be used to determine the position of the cooling tote in the grid structure in the XY plane. For example, the position of the robotic load handler in the horizontal plane on the track system can be determined using sensors at the intersection of the rails extending the X-axis and the Y-axis, and the vertical position of the cooling tote in the stack of storage containers can be determined based on the depth to which the cooling tote is lowered in a given stack.

[0029] Optionally, the control system is configured to monitor the status of one or more cooling totes in the grid frame structure by: i) retrieving data from a database associated with the identification of one or more refrigerant plates; ii) associating an identification of one or more refrigerant panels with one or more cooling totes in the grid frame structure; iii) determining the status of the one or more cryogen plates by comparing the cooling time of the one or more cryogen plates with their corresponding predetermined cooling durations.

[0030] Here, the control system monitors the status of one or more cooling totes in the grid frame structure by determining the length of time the cooling tote has been stored in the grid frame structure by comparing the length of time the refrigerant plate has been left in the cooling tote (i.e., the cooling time) with its predetermined cooling duration. If the cooling time exceeds or approaches its predetermined cooling duration, this is an indication to the control system that the refrigerant plate in the cooling tote needs to be charged (i.e., placed in a freezer). Data related to the identification of one or more refrigerant plates in the grid frame structure and the association of one or more cooling totes can be stored in a lookup table. Once the control system has identified a cooling tote that includes a refrigerant plate that needs to be recharged, optionally, the control system is configured to retrieve the cooling tote from the grid frame structure by: i) retrieving data associated with the position of the cooling tote in the grid frame structure from a lookup table; ii) instructing a robotic load handling device operable on a track system to use the position data to retrieve the cooling tote from the grid frame structure.

[0031] The data associated with the position of the cooling tote in the grid frame structure can be represented by X, Y and Z coordinates. Typically, the container gripper assembly is suitable for engaging with the top of the cooling tote, such as cooperating with the corresponding engagement feature in the edge of the top surface forming the cooling tote. Optionally, the cooling tote may include a plurality of openings or holes for engaging with the container gripper assembly. The individual storage containers including the cooling tote can be stacked in vertical layers, and three-dimensional coordinates can be used to indicate their positions in the grid frame structure or "beehive" to indicate the position and storage container depth of the robot load handling device or storage container (e.g., the container at (X, Y, Z), depth W). Similarly, the position in the grid frame structure can be indicated two-dimensionally to indicate the position and storage container depth of the robot load handling device or storage container (e.g., the container at (X, Y), depth Z). For example, Z=1 represents the top layer of the grid, i.e., the layer immediately below the rail system, and Z=2 is the second layer below the rail system, and so on to the lowest bottom layer of the grid. A first set of parallel rails guides movement of the robotic load handling device across the top of the grid frame structure in an X direction, and a second set of parallel rails arranged perpendicular to the first set of parallel rails guides movement of the robotic load handling device in a Y direction perpendicular to the first direction. Once the control system has identified the location of the cooling tote in the grid frame structure, the robotic load handling device can be instructed to retrieve the cooling tote from the grid frame structure using the location data stored in the database. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] Other features and aspects of the present invention will become apparent from the following detailed description of exemplary embodiments in conjunction with the accompanying drawings, in which: FIG. 1 is a diagram of an automated storage and retrieval system according to an exemplary embodiment of the present invention; FIG2 is a schematic diagram showing a top view of a stack of boxes arranged within the frame structure of FIG1 ; FIG3 is a schematic diagram of a system of known load handling devices operating on a grid frame structure; FIG4 is a schematic perspective view of a load handling device showing a container receiving space within a main body of the load handling device; Figure 5 (a) and 5(b) are schematic perspective cross-sectional views of the load handling device of FIG. 4 showing (a) a container received in a container receiving space of the load handling device and (b) the container receiving space of the load handling device; Figure 6 (a) is a schematic side view of a grabber arrangement of a load handling arrangement, and Figure 6 (b) is a schematic perspective view of a grabber device of a load handling device; Figure 7 is a schematic perspective view of an assembled cooling tote box; Figure 8 yes Figure 7 A schematic perspective view of a cooling tote of , wherein the cover is raised above the opening of the cooling tote; Fig. 9 and 10 are schematic perspective views of two specific embodiments of a cooling tote including a refrigerant plate stored in a lid of the cooling tote; Fig.11 and 12 are schematic perspective views of two specific embodiments of a cooling tote including a refrigerant plate stored in a base wall of the cooling tote; Fig.13 and 14 are schematic perspective views of two specific embodiments of a cooling tote including refrigerant panels stored in opposing side walls of the cooling tote; Fig.15 (a), (b) and (c) are schematic perspective views of refrigerant plates in different configurations in a cooling tote; Fig.16 is a schematic perspective view of a cart storing a plurality of cooling totes; Fig.17 It accommodates multiple Fig.16 A schematic perspective view of a cooling station for a cart is shown; Fig.18 (a) and 18(b) are illustrations of an automated storage and retrieval system including stacks of ambient storage containers and cooling totes within a grid frame structure; Fig.19 (a) and 19(b) are illustrations of an automated storage and retrieval system comprising cooling totes stacked in specific areas of a grid frame structure; Fig. 20 is a schematic diagram of a cooling control system according to a specific embodiment of the present invention; Fig.21 is an example of a flow chart giving a brief overview of the stages in preparing a cooling tote for storage in a grid frame structure; Fig. 22 is an example of a flow chart detailing the stages of detecting the status of a cooled tote stored in a grid frame structure. DETAILED DESCRIPTION

[0033] The present invention provides a storage and retrieval system in which storage containers arranged in a stack in a grid frame structure can be retrieved from the grid frame structure by a load handling device. The load handling device includes a lifting device and a clamping assembly for connecting and lifting the storage container. Figure 6A container clamping assembly 139, also referred to as a gripper device, is shown for releasably attaching to a storage container 10 below. The gripper device includes a gripper element 184, which includes a pair of wings that are foldable so that they can be received in corresponding holes or openings in the upper edge of the storage container. The wings are actuated into an open and closed configuration by a suitable actuating mechanism coupled to a drive gear. More specifically, the head of at least one of the wings includes a plurality of teeth meshed with the drive gear, so that when the gripper element 184 is actuated by the actuating mechanism, the rotation of the drive gear causes a pair of wings to rotate from a closed or folded configuration to an open expanded configuration. When in a folded or closed configuration, the size of the gripper element 184 is designed to be received in a corresponding hole in the upper edge of the container. The foot of each of the pair of wings includes a stop 188, such as a boss, so that when received in a corresponding hole in the upper edge of the container, the stop 188 engages with the underside of the upper edge when in the expanded open configuration, thereby locking to the container when the gripper device 139 is twisted upward toward the container receiving portion of the load handling device.

[0034] Figure 7 A cooling tote 200 is shown in accordance with the present invention. A cooling tote is a storage container 10 that can store frozen or refrigerated foods. Frozen items are typically stored at or below -18°C, and refrigerated items are stored between 2°C and 8°C. The cooling tote 200 is the same or substantially the same size and shape as a storage container 10 used to store ambient temperature items in a grid structure. The terms "ambient storage container" or "standard storage container" are used in this patent application to describe a storage container used to store items at ambient temperature, and to distinguish it from a cooling tote used to store frozen or refrigerated foods. Figure 7 The cooling tote shown includes a base wall 210, side walls 220 and end walls 230. The side walls 220 and end walls 230 extend upward from the base wall 210 to form a box-like structure ( Figure 8 ). The cooling tote 200 further includes a cover 240. The cover 240 includes holes or openings 242 arranged so that the gripper device 139 ( Figure 6 ) can engage and lock onto the cooling tote 200.

[0035] Figure 8 Shows Figure 7A cooling tote in which a lid 240 is lifted from the side walls and end walls of the tote. The cooling tote further includes holes 225 in the upper edges of the opposing side walls 220 and end walls 230. The holes 225 are positioned so that when the lid is on the cooling tote, the holes 225 are aligned with the holes 242 in the lid, which allows the gripper elements 184 of the gripper device 139 to engage and lock onto the cooling tote 200. The lid 240 includes an outer surface 244 and an inner surface 246. The outer surface 244 is exposed to the surrounding external environment. The size and shape of the inner surface 246 are designed so that it fits into the opening 250 of the cooling tote. Specifically, the size and shape of the inner surface 246 of the lid 240 is such that it fits tightly in the opening 250 to form an enclosed internal storage space, also referred to as an inner space. As now explained, due to the composition of the side walls, end walls, base wall and / or lid, and in addition by using Fig. 9 , refrigerated and / or frozen grocery items are kept cool in the interior space of the cooling transport box. The opposite sidewalls 220, the opposite end walls 230, the base wall 210 and / or the cover 240 include insulation materials, so that the heat from the surrounding environment outside the cooling transport box is prevented or reduced from being transferred through the base wall, the opposite sidewalls, the end wall and / or the cover to heat the interior space. The insulation material can be foam. It is particularly advantageous to use insulation foam because the efficiency of the bubbles in the foam to conduct heat is lower than that of solids, and the gas is trapped in the foam to prevent the gas from transferring heat by convection. Polyurethane and polystyrene foam are two such insulation foams that can be used. If the cooling transport box includes insulation materials, the base wall, the opposite sidewalls and the opposite endwalls can include a rigid shell shell (not shown) to provide enough structural rigidity to support the weight of multiple storage containers above the stack. The rigid shell shell can be made of metal or plastic. Alternatively or additionally, at least one of the base wall, the opposite sidewalls, the end wall and / or the cover can include a vacuum insulation core. Due to the absence or almost absence of air, the vacuum insulation core has no or almost no thermal conductivity. Specifically, the vacuum insulation core eliminates the heat transfer by convection. Using a vacuum insulation core means that at least one of the base wall, the opposite side wall, the end wall and / or the cover can be made very thin, thereby increasing the size of the interior space in the cooling tote. The opposite side wall, the end wall, the base wall and / or the cover can be made of a vacuum insulation panel, and the cover vacuum insulation panel includes a membrane wall for preventing ambient air from entering the panel and a rigid, highly porous material for supporting the membrane wall after the air has been discharged from the panel. The highly porous material can be, for example, fiberglass, perlite, aerogel or fumed silica. Chemicals can be added to the vacuum insulation core to collect any gas leaking through the membrane.

[0036] Fig. 9 The additional feature of the refrigerant plate 260 is shown. Figure 7 and8 The refrigerant plate includes a refrigerant for cooling the interior space of the cooling tote. Fig. 9 In the illustrated embodiment, a refrigerant plate 260 is housed within a lid 240 of a cooling tote. An advantage of storing the refrigerant plate in the lid is that, due to the higher density of cold air compared to hot air, the cold air exhausted from the refrigerant plate drops to the bottom of the cooling plate. Specifically, the refrigerant plate 260 is contained within a recess 248 in the lid 240. The recess 260 is located in an inner surface 246 of the lid. The refrigerant plate 260 is removably received within the recess 248 in the lid 240. There is a snap-fit ​​or push-fit arrangement between the refrigerant plate 260 and the recess 248, so that the refrigerant plate 260 can be snapped or pushed into the recess 248, and the refrigerant plate 260 is retained in the recess 248. The inner surface of the lid may additionally include clips, fasteners, etc. to hold the refrigerant plate 260 in place in the recess 248. As Fig. 9 As shown, one side of the refrigerant plate is completely exposed to the interior space of the cooling tote, thereby increasing the heat transfer between the air in the interior storage space and the refrigerant, thereby obtaining a greater cooling effect. Therefore, the refrigerant plate forms a part of the inner surface of the cover. Grocery items in the interior space of the cooling tote can therefore be in direct contact with the refrigerant plate 260 in the cover 240 and keep the items cool by thermal conduction. In addition, the refrigerant plate circulates cold air through the enclosed interior storage space, thereby keeping the food in the interior storage space cool by thermal convection.

[0037] Alternatively, the refrigerant plate may be slid into a recess in the cover, e.g. Fig.10 As shown. The refrigerant plate 260 can be received in the cavity 249 in the cover via a groove 247 in the cover 240, which forms an entrance to the cavity 249. The groove 247 has a width and a height so that the refrigerant plate 260 can slide through the groove 247 into the cavity 249. Fig. 9 In contrast to the embodiment shown in FIG. 1 , in which the refrigerant plate is snap-fitted into the recess 248 and retained in the recess 248, Fig.10 In the embodiment, the refrigerant plate 260 is held in place in the recess 249 by the inner surface 246 of the cover. The inner surface 246 of the cover includes cutouts 245 to allow cool air to flow into the interior space. Fig.10 Three cutouts 245 are shown, and each cutout is equal in size and shape. Any size and shape of cutouts may be used to allow cool air to flow from the refrigerant plate 260 to the interior space, however larger cutouts result in a more efficient cooling of the tote.

[0038] The refrigerant plate may alternatively be contained within the base wall of the cooling tote, e.g. Fig.11 and 12 shown. Fig.11One arrangement of a cooling tote is shown in which a refrigerant plate 260 is receivable within a pocket 218 in a base wall via a slot 217, which forms an entrance to the pocket 218. The slot 217 is located in the base wall 210. Once the refrigerant plate is positioned in the pocket 218, one side of the refrigerant plate 260 is fully exposed to the interior space of the cooling tote. Thus, the refrigerant plate forms part of the interior surface of the base wall. Thus, grocery items in the interior space of the cooling tote are in direct contact with the refrigerant plate, and the items are cooled by heat conduction. Fig.12 Another arrangement of a cooling tote is shown in which a refrigerant plate 260 can be received within a pocket 219 in the base wall, and the refrigerant plate 260 is snapped or pushed into the pocket 219. Clips or fasteners (not shown) can also be used to hold the refrigerant plate in place in the pocket 219. Once the refrigerant plate is positioned in the pocket, one side of the refrigerant plate is fully exposed to the interior space of the cooling tote. Thus, the refrigerant plate forms part of the inner surface of the base wall.

[0039] The refrigerant plates may alternatively be contained within the side walls of the cooling tote, e.g. Fig.13 and 14 In order for the side wall to accommodate the refrigerant plate, the side wall is stepped, which makes the upper part 236 of the side wall wider than the lower part 237 of the side wall. Fig.13 In the embodiment of the present invention, the refrigerant plate can be received in a recess 228 in the side wall 220 via a groove 227, which forms an entrance to the recess 228. The groove 227 is located in the side wall, which allows the refrigerant plate 260 to slide horizontally into the recess 228. The side wall 220 includes a sliding surface 225, on which the refrigerant plate can slide more easily into the recess 228. Adjacent to the sliding surface may be one or more protruding lips (not shown) to keep the refrigerant plate in place as the refrigerant plate slides into the recess, and also to keep the refrigerant plate in place once the refrigerant plate is completely in the recess. Alternatively, a clip or other fastening mechanism can be used to keep the refrigerant plate in place in the recess. When the refrigerant plate is in place in the recess 228, one side of the refrigerant plate 260 is completely exposed to the interior space of the cooling transport box to allow effective cooling of the interior space. Therefore, the refrigerant plate forms a part of the inner surface of the side wall.

[0040] Fig.14 Another arrangement of a cooling tote is shown in which a refrigerant plate 260 can be received in a pocket 229 in a side wall via a slot 223, which forms an entrance to the pocket 229. The slot is located in the side wall, which allows the refrigerant plate 260 to slide or drop vertically into the pocket 229. The refrigerant plate 260 is held in place in the pocket 229 in the side wall 220 by the inner surface 221 of the side wall 220. The inner surface 221 of the side wall 220 includes a Fig.10A cutout 261 similar to the cutout shown in FIG.

[0041] like Fig.13 and 14 As shown, two refrigerant plates 260 are located in the coolant tote, one in each of the opposing side walls 220. However, the cooling tote may include one, two, three, or four refrigerant plates 260, such as Fig.15 shown. Fig.15 The refrigerated tote of (a) comprises four refrigerant plates, one in the lid, one in each of the opposing side walls and one in the base wall. This creates an interior space suitable for storing frozen goods that may be thawed quickly. Fig.15 The refrigerated tote of (b) includes three refrigerant panels, one in the cover and one in each of the opposing side walls. Fig.15 The cooling tote of (c) includes a refrigerant plate in the cover. Thus, there are various configurations of cooling totes. In particular, the cover 240 of the cooling tote can be interchangeable, so that, if necessary, a cover without a recess can replace a cover with a recess, and vice versa.

[0042] In the above and Figures 7 to 15 In all embodiments of the cooling tote shown, the refrigerant plates are identical in size and shape. This means that when the refrigerant plate is about to run out of charge and will soon thaw and no longer be able to cool the interior of the cooling tote, or when the refrigerant plate runs close to the end of a predetermined cooling duration, the refrigerant plate can be removed and replaced with a charged refrigerant plate that will be fitted in an empty recess in the lid, opposing side walls, opposing end walls, or base wall of the cooling tote. There may be differences in the refrigerants in the refrigerant plates, for example water may be used as a refrigerant specifically for cooling a cooling tote for refrigerated grocery items suitable for refrigerators, and a mixture of mineral salts and water may be used as a refrigerant specifically for cooling a cooling tote for frozen grocery items.

[0043] like Fig.16 As shown, the refrigerant panels 260 that are removed from the cooling tote and need to be recharged are stored in a cart 320. The cart is configured so that it holds a plurality of refrigerant panels on multiple levels. Fig.16 In the embodiment, the cart has three horizontal layers, and each horizontal layer accommodates approximately twenty refrigerant plates 260. This particular arrangement provides space-efficient storage of refrigerant plates when charging, but other arrangements may be used. On the cart, each refrigerant plate is separated from adjacent refrigerant plates.

[0044] The refrigerant plate 260 for recharging is transported to the cooling station 420 while on a cart, such as Fig.17As shown. The cooling station includes a refrigeration system for cooling the refrigerant plates in a temperature range of -30°C to 0°C, so that an uncharged refrigerant plate in the cooling box can be replaced by one or more refrigerant plates from the cooling station. The cart 320 storing the uncharged refrigerant plates 260 rolls into the cooling station via the doorway 430, and the cart with the refrigerant plates is stored in the cooling station 420 while the refrigerant plates are charged. It is important that the refrigerant is completely frozen and solidified before the refrigerant plates are used. If it is not completely frozen, the refrigerant will have a lower ability to absorb heat, its cooling capacity will be reduced, and therefore it will need to be recharged more quickly. The freezing temperature of the refrigerant plate should be at least 5°C lower than the melting temperature of the refrigerant. Because each refrigerant plate is separated from the adjacent refrigerant plates on the cart 320, cold air is allowed to circulate between the refrigerant plates, thereby reducing the charging time or the time it takes for the refrigerant plates to freeze. The charge or freezing state of the refrigerant plate can be checked by shaking the refrigerant plate; any movement from a liquid or semi-liquid state means that the charge state is not complete and the refrigerant is not frozen. Alternatively, the refrigerant plate 260 can be stored in the cooling station 420 for a predetermined amount of time that ensures that the refrigerant plate is completely frozen. The predetermined amount of time can be between 2 and 5 hours or between 6 and 24 hours, such as 12 hours or 18 hours. Once the refrigerant plates are fully charged or frozen, they can replace any uncharged refrigerant plates in the pockets in one or more cooling totes.

[0045] Cooling totes that are the same size and shape as standard storage containers can be intermixed with surrounding storage containers or stored separately from standard storage containers on the grid frame structure. Fig.18A cooling tote 200 is shown stored in a grid frame structure 714 along with surrounding storage containers 500. The grid frame structure 714 includes a track system 320 including a first set of parallel rails or tracks 322a and a second set of parallel rails or tracks 322b extending transversely to the first set in a substantially horizontal plane to form a grid pattern including a plurality of grid spaces 310. The load handling device 30 is movable and operable on the tracks of the track system 320. Below the track system 320 are a plurality of storage columns in which the environmental storage containers 500 and the cooling tote 200 are arranged in stacks. The cooling tote 200 is stacked and interspersed within the grid frame structure such that between 0% and 100% of a particular stack includes a cooling tote. Since the cooling tote uses passive cooling rather than active cooling, the grid frame structure 714 does not need to be altered to accommodate the cooling tote. In addition, the passive cooling of the cooling tote means that the power supply of the load handling device will not be degraded by low temperatures as in an active cooling system. In fact, the load handling device can use a gripping device to retrieve the cooling totes from the grid in the same manner as the ambient storage containers. Therefore, incorporating cooling totes 200 into the grid frame structure 714 so that they are mixed in the stack with the surrounding totes 500 provides an economical and efficient way to store and retrieve refrigerated and frozen groceries. Fig.19 An alternative arrangement of a grid frame structure is shown, wherein a cooling tote 200 is arranged in a specific portion 600 on one side of the grid frame structure. The cooling tote is therefore isolated from the surrounding storage containers and is partitioned into the region of the grid frame structure. By arranging the cooling tote in this manner, any cold air lost from the cooling tote helps to keep the adjacent cooling tote cool, thereby keeping the cooling tote cooler over a longer period of time. Therefore, the predetermined cooling duration is increased. The predetermined cooling duration may be between 8 and 12 hours or between 24 and 30 hours. Although the cooling tote is stacked in a region or portion 600 of the grid frame structure, any load handling device 30 can retrieve the cooling tote. Other arrangements of the cooling tote in the grid frame structure are also possible, for example, positioning the cooling tote 200 around the periphery of the grid frame structure.

[0046] While the above description describes refrigeration panels that can be received in the base wall, side walls, end walls, and lid, the refrigerant may alternatively be integrated into the cooling tote, such that charging of the refrigerant may also include placing at least a portion of the cooling tote (e.g., the lid) into the cooling station. In this case, when the refrigerant panel charge is depleted and has thawed or is approaching its predetermined cooling duration, the lid may be removed from the cooling tote and placed in a cooling station such as Fig.16 transported to Fig.17The cooling station is recharged in the cooling tote before being placed on the cooling tote for cooling the items in the interior space of the cooling tote. Since the size and shape of the cooling tote are substantially uniform so that the cooling tote can be stacked in a grid frame structure, the cover of the cooling tote is easy to replace. Cooling control system

[0047] Fig. 20 A schematic diagram of a cooling control system 700 according to an embodiment of the present invention is shown, the cooling control system 700 including a control system 702, an input device 704, a user interface device 706, and a database 708. The control system 702 controls the operation of the cooling control system and includes one or more processors 702a, a memory 702b (e.g., a read-only memory and a random access memory), and a communication bus 702c. A local user interface 706 (e.g., a smart phone, a tablet, a smart watch, a notebook computer, etc.) is communicatively coupled to the control system 702 via a communication network on a wired or wireless transmitter / receiver. For example, the communication network can be a local area network (LAN), a wide area network (WAN), or any other type of network. One or more processors of the control system can execute instructions stored in ROM and / or RAM to at least partially provide the functionality of the scheduling system described herein. One or more processors of the control system are communicatively coupled to the wireless / wired transmitter receiver via a communication bus. A cloud (not shown) can form part of the control system, which allows processing and storage of data to be performed in the cloud.

[0048] In order to identify one or more refrigerant plates in the cooling tote, each refrigerant plate includes a label 710, which includes data associated with the identification of its corresponding refrigerant plate. The label 710 can be in the form of a barcode, such as a 2D barcode, a QR code, an RFID tag. The identification of the refrigerant plate includes data associated with the cooling capacity of the refrigerant contained in the plate, and this depends on the goods stored in the cooling tote. In order to keep frozen goods in a frozen state, the refrigerant plate generally provides cooling in a temperature range of -30°C to -15°C and is defined as a freezing plate. Similarly, in order to keep refrigerated goods in a refrigerated state, the refrigerant plate generally provides cooling in a temperature range of 2°C to 8°C and is defined as a refrigeration plate. In order to determine different types of refrigerant plates in the cooling tote and associate different types of refrigerant plates with the cooling capacity of the cooling tote, the identification of the refrigerant plate includes data associated with the type of refrigerant plate.

[0049] A suitable input device 704 (e.g., a barcode reader) can be used to read the tag, and the data associated with the identification of the refrigerant plate is input into the control system 702 via the input device 704 and subsequently stored in the database 708. Optionally, the cooling transport box may include a dedicated tag 712 for identifying the cooling transport box in the grid frame structure discussed above. As with the refrigerant plate, the data associated with the identification of the cooling transport box is read by a suitable input device (not shown), and the data is subsequently stored in the database. The identification of the cooling transport box may also be associated with the cooling capacity of the cooling transport box. Similar to the refrigerant plate, the identification of the cooling transport box may be defined as a refrigerated transport box for providing cooling capacity in a temperature range of -30°C to -15°C, and the identification of the cooling transport box may be defined as a refrigerated transport box for providing cooling capacity in a temperature range of -5°C to 0°C. The control system is configured to associate the identification of the cooling transport box with the identification of the type of refrigerant plate in the cooling transport box so as to determine the cooling capacity of the cooling transport box (i.e., a refrigerated transport box or a cooling transport box). Tagging of the cooling tote is not required, as one or more processors of the control system may execute instructions to track the location of the robotic load handling device carrying the cooling tote when the robotic load handling device is instructed to deposit the cooling tote for storage in the grid frame structure 714. However, adding a tag to the cooling tote provides confirmation to the control system that the identified refrigerant panel is in the correct cooling tote.

[0050] Fig.21 The flowchart 720 shown in provides a brief overview of the various stages of preparing a cooling tote for storage in a grid frame structure. In use, when the cooling tote is being prepared for storage of one or more items or goods (such as refrigerated or frozen grocery items) at a temperature below ambient temperature, one or more processors 702a of the control system 702 are directed to receive data associated with the identification of the refrigerant plate via the input device 704 to determine the type of refrigerant plate to be used to cool the cooling tote, and this is largely dependent on the cooling capacity required for the cooling tote. This is in Fig.21 7. The step 724 of reading the label on the refrigerant plate by the input device 704 is shown. Data associated with the identification of the refrigerant plate is stored in the database 708. As described above, the preparation of the cooling box occurs at a cooling station, which includes a refrigeration system and a cooling chamber for cooling a plurality of refrigerant plates. The refrigeration system is controlled to ensure that the refrigerant in the refrigerant plate is completely frozen before being used in the cooling box (also known as "charging" the refrigerant plate). The charging of the refrigerant plate depends on whether the refrigerant plate provides a freezing cooling effect or a refrigerated cooling effect in the cooling tote.

[0051] Once the identity of the refrigerant plate is identified, the refrigerant plate is placed in a recess in at least one base wall and / or opposing side wall and / or opposing end wall or lid of the cooling tote 728. In addition to identifying the type of refrigerant plate, the input device can also be used to read a label 726 on the cooling tote that includes the refrigerant plate. This Fig.21 , indicating that it is an optional step. Data associated with the identification of the cooling transport box is then stored in a database. The control system is configured to assign the identification of the refrigerant plate to the identification of the cooling transport box that includes the refrigerant plate. When the identification of the refrigerant plate is placed in a cooling transport box that has been recorded in the database, a start time is recorded by the control system. The start time provides an indication of the cooling time of the refrigerant in the cooling transport box. This process is repeated when other refrigerant plates are placed in different cooling boxes. A lookup table is thereby generated, which includes data associated with the identification of the refrigerant plate, the identification of the cooling transport box, and the start time when the refrigerant plate is placed in the cooling transport box and / or enters the grid frame structure. Once the refrigerant plate is placed in the cooling transport box, the cooling transport box is transferred to the grid frame structure (in Fig.21 The grid structure is referred to as a "grid" in the text file 730. The start time may optionally include a time when a cooling tote including a refrigerant plate enters the grid frame structure. As an alternative or in addition to recording the identification of the cooling tote via a tag on the cooling tote, the identification of the cooling tote may also include the location at which the cooling tote is stored in the grid frame structure. For example, the position of the robotic load handling device on the track system may be used to determine the position of the cooling tote in the grid structure in the XY plane. For example, a sensor at the intersection of rails extending the X-axis and the Y-axis may be used to determine the position of the robotic load handling device in the horizontal plane on the track system, and the vertical position of the cooling tote in the stack of storage containers may be determined based on the depth to which the cooling tote is lowered in a given stack.

[0052] One or more cooling totes according to the present invention are configured so that one or more cooling totes can be stored in a stack of storage containers in an ambient temperature environment. However, the refrigerant plates in the cooling tote remain charged or frozen to provide a useful cooling effect for a limited period of time, referred to as a predetermined cooling duration. Once the predetermined cooling duration has expired or is about to expire, the cooling efficiency of the refrigerant plates will decrease, and the refrigerant plates will need to be recharged or replaced with newly charged plates. Fig. 22800, which details the stages of monitoring the status of the cooling tote stored in the grid frame structure. The processing steps begin with the control system identifying the cooling tote 822 in the lookup table and calculating the cooling time 824 from the start time discussed above. In practice, the control system continuously monitors the cooling time and compares the cooling time with its corresponding predetermined cooling duration in the lookup table. Any cooling time that has exceeded its predetermined cooling duration or is approaching its predetermined cooling duration is shown as a "red" flag in the lookup table, and an indication is provided to the control system that the refrigerant plate in the cooling tote needs to be recharged or replaced at the cooling station.

[0053] In determining whether the refrigerant plate needs to be recharged or recharged at the cooling station, one or more processors of the control system execute instructions to determine 826 whether the cooling time is greater than a predetermined cooling duration. If the answer to this question is "yes", the control system identifies the grid frame structure (in Fig. 22 828 in the grid frame structure). As described above, the identification of the cooling tote can include the location of the cooling tote in the grid frame structure. Such data can be found in the lookup table discussed above. Once the identity of the suspected cooling tote is identified, the control system is configured to provide instructions to the robotic load handling device that can be operated on the track to retrieve the cooling tote from the grid frame structure 830 and move the cooling tote to a cooling station 832. At the cooling station, the exhausted refrigerant plate is replaced with a charged refrigerant plate 834, and the process is repeated. Fig. 22 The process described in 830 is used to identify the refrigerant panels in the cooling tote and associate the identification of the refrigerant panels with the cooling tote. Once the cooling tote has been replenished with the charged refrigerant panels, the control system is configured to return the cooling tote to the grid frame structure for storage 836. The method steps are repeated in a continuous cycle for other cooling totes stored in the grid frame structure, etc.

[0054] Typically, a refrigerant plate, particularly one based on a eutectic mixture, can maintain its cooling time for a predetermined cooling duration of 8 to 12 hours or 24 to 30 hours, depending on the type of eutectic mixture. For some grocery items or goods in storage, this is a sufficient one-time storage time to fulfill a customer order without returning the cooled tote to the cooling station. Such items or goods include convenience grocery items or goods, such as milk, butter as refrigerated items, and ice cream as frozen items or goods.

[0055] Although the control system has been described in conjunction with a refrigerant plate, the refrigerant plate may equally well be at least a portion of a cooling transport box, in particular a lid of the cooling transport box. Therefore, the processing steps of identifying the refrigerant plate and determining the cooling time of the refrigerant plate may be applied to the lid of the cooling transport box. The lid of the cooling transport box represents the smallest volume portion of the cooling transport box and therefore does not take up a large amount of space in the cooling station. As described above, the refrigerant may be integrated into the lid of the cooling transport box. Therefore, instead of charging the refrigerant plate in the cooling station, the cooling station may be configured to charge a plurality of lids. Since the dimensions of the cooling transport boxes are generally uniform, the lids may be replaced between different cooling transport boxes. This allows a plurality of lids to be charged at the cooling station, and the control system is configured to instruct the robotic load handling device to retrieve the cooling transport box from the grid frame structure once the cooling time of the refrigerant in the lid has reached or approaches its predetermined cooling duration. Once at the cooling station, the process of replacing the lid of the cooling transport box with the charged lid from the cooling station is as shown. Fig.21 Likewise, the control system monitors the state of the refrigerant in the cover by generating a lookup table with the recorded start time of placing the cover on the cooling tote and the time that has elapsed since the start time, i.e., the cooling time. It is also reasonable in the present invention that the entire cooling tote - rather than the cover - can be charged at the cooling station. A plurality of cooling totes with integrated refrigerant can be charged at the cooling station.

Claims

1. A storage and retrieval system comprising: a grid frame structure comprising a track system and a plurality of storage columns arranged adjacent to one another, the track system comprising a first set of parallel rails or tracks and a second set of parallel rails or tracks, the second set of parallel rails or tracks extending transversely to the first set in a generally horizontal plane to form a grid pattern comprising a plurality of grid spaces; a plurality of storage containers arranged in a stack in each of the plurality of storage columns and below the rail system, each of the plurality of storage containers comprising a base wall and opposing side and end walls extending from the base wall to form a box-like structure having an opening; at least one load handling device disposed on the rail system, the load handling device being arranged to move laterally over the stack on the rails, the load handling device comprising a lifting device arranged to lift one or more storage containers or parts thereof from the stack, the lifting device comprising a container gripper assembly configured to releasably grip a storage container and a lift drive assembly configured to raise and lower the container gripper assembly; wherein one or more of the plurality of storage containers comprises a lid for closing an opening of the one or more storage containers to define a cooling tote; wherein at least one of the base wall and / or the opposing side wall and / or the opposing end wall and / or the cover of the cooling tote comprises a recess for containing a refrigerant; The freezing point of the refrigerant is in the range of -30°C to 0°C and is used for storing frozen or refrigerated food.

2. The storage and retrieval system of claim 1, wherein the refrigerant comprises a eutectic mixture having a freezing point in the range of -30°C to -15°C for cooling frozen food.

3. The storage and retrieval system of claim 1, wherein the refrigerant has a freezing point in the range of -5°C to 0°C for cooling refrigerated food.

4. The storage and retrieval system of any one of the preceding claims, wherein the refrigerant is contained within a lid of the one or more cooling totes.

5. A storage and retrieval system according to any one of the preceding claims, wherein: At least a portion of the at least one base wall, opposing side walls, opposing end walls, and / or the lid of the one or more cooling totes is made of insulating foam.

6. The storage and retrieval system of claim 5, wherein the insulating foam comprises polyurethane foam and / or polystyrene foam.

7. The storage and retrieval system of any one of the preceding claims, wherein at least one of the base wall, opposing side walls, opposing end walls and / or the lid of the one or more cooling totes comprises a vacuum insulation core.

8. The storage and retrieval system of claim 7, wherein the vacuum insulation core forms part of a vacuum insulation panel.

9. A storage and retrieval system according to any one of the preceding claims, wherein: The base wall and opposing side walls and end walls extending from the base wall of the box-like structure of each of the one or more cooling totes form an inner shell, and each of the one or more cooling totes further includes a rigid outer shell containing the inner shell.

10. A storage and retrieval system according to any one of the preceding claims, wherein: The refrigerant is contained within the plate to define a refrigerant plate, such that when the refrigerant has a freezing point in the range of -30°C to -15°C, the refrigerant plate is defined as a freezing plate, and when the refrigerant has a freezing point in the range of -5°C to -0°C, the refrigerant plate is defined as a refrigeration plate.

11. The storage and retrieval system of claim 10, wherein the at least one base wall and / or opposing side walls and / or opposing end walls and / or the cover of each of the one or more cooling totes comprising the recess comprises one or more cutouts extending into the interior of the box-like structure such that at least a portion of the refrigerant plate is exposed within the interior space of the one or more cooling totes.

12. The storage and retrieval system of claim 10 or 11, wherein the refrigerant plate is removably received within the recess of at least one of the base wall and / or opposing side wall and / or opposing end wall and / or cover of each of the one or more cooling totes.

13. The storage and retrieval system of claim 10, wherein the refrigerant plate is a lid of the cooling tote.

14. A storage and retrieval system according to any one of the preceding claims, wherein: The cooling tote includes a plurality of openings for engaging the container holding assembly.

15. The storage and retrieval system of any one of claims 10 to 14, further comprising a control system comprising one or more processors and a memory storing instructions, the instructions, when executed by the one or more processors, being configured to determine a duration of the one or more cooling totes in the grid frame structure by: i) recording a start time when a refrigerant plate is placed in at least one of a base wall and / or an opposing side wall and / or an opposing end wall and / or a cover of each of said one or more cooling totes; ii) determining a duration that has elapsed in the one or more cooling totes from the recorded start time to define a cooling time; and If the cooling time exceeds or approaches a predetermined cooling duration, a robotic load handling device operable on the rail structure is instructed to remove the one or more cooling totes from the grid frame structure.

16. The storage and retrieval system of claim 15, wherein: The start time is the time at which the one or more cooling totes enter the grid frame structure.

17. A storage and retrieval system as claimed in claim 15 or 16, wherein: The one or more cooling totes are removed to a cooling station comprising a plurality of cryogen plates, the cooling station comprising a refrigeration system for cooling the plurality of cryogen plates within a temperature range of -30°C to 0°C, such that the one or more cryogen plates in the one or more retrieved cooling totes can be replaced by one or more cryogen plates from the cooling station.

18. The storage and retrieval system of any one of claims 15 to 17, wherein each of the plurality of refrigerant panels includes a tag readable by an input device for establishing an identity of each of the plurality of refrigerant panels in the cooling station or cooling tote or grid frame structure.

19. The storage and retrieval system of claim 18, wherein the label comprises any one of a barcode, a 1-D barcode, a 2-D barcode, or a QR code, or an RFID tag.

20. The storage and retrieval system of claim 18 or 19, wherein: The identification includes data associated with whether the refrigerant plate is a freezer plate or a refrigeration plate.

21. The storage and retrieval system of claim 20, wherein: The control system is configured to: i) assigning an identification of one or more refrigerant plates to the one or more cooling totes; ii) tracking the position of the one or more cooling totes within the grid frame structure; iii) storing the position of said one or more cooling totes within said grid frame structure in a database.

22. The storage and retrieval system of claim 21, wherein: The control system is configured to assign an identification of one or more refrigerant panels to the one or more refrigerated totes depending on whether the cargo is refrigerated cargo or frozen cargo.

23. The storage and retrieval system of claim 20, wherein: The control system is configured to monitor the status of one or more cooling totes in the grid frame structure by: i) retrieving data from a database associated with the identification of one or more refrigerant plates; ii) associating an identification of the one or more refrigerant panels with one or more cooling totes in the grid frame structure; iii) determining the status of the one or more refrigerant plates by comparing the cooling time of the one or more refrigerant plates with their corresponding predetermined cooling time durations.

24. The storage and retrieval system of claim 23, wherein: Data associated with the association of identification of the one or more refrigerant panels with one or more cooling totes in the grid frame structure is stored in a lookup table.

25. The storage and retrieval system of claim 24, wherein: The control system is configured to retrieve the cooling tote from the grid frame structure by: i) retrieving data associated with the location of the cooling tote in the grid frame structure from a lookup table; ii) instructing a robotic load handling device operable on the track system to retrieve the cooling tote from the grid frame structure using the position data.

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