Item transfer system and storage and retrieval system

Abstract

An item transfer system includes a storage container with a U-shaped insert (57) that is nested within the storage container (51). The item transfer system also includes an item transfer station (68) having a lifting device (74) for vertically moving the insert out of the storage container to a raised position and an item moving device (78) for moving the insert out of the storage container to a raised position. An item moving device (78) is used for horizontally moving the item onto the insert and / or horizontally removing the item from the insert when the insert is in the raised position.

Description

Technical Field

[0001] The present invention relates to automated systems for transferring items into and out of storage containers and to automated storage and retrieval systems. Background Art

[0002] Some commercial and industrial activities require systems that can store and retrieve a large number of different products. WO2015 / 019055A1 describes a storage and retrieval system in which stacks of storage containers are arranged in a grid storage structure. The storage containers are accessed from above by a load handling device running on rails or tracks located on top of the grid storage structure.

[0003] Items stored in the storage and retrieval system are stored in storage containers. Items can be products stored directly in the storage container. Items can also be sub-containers designed to fit within the storage container. Sub-containers can contain products for storage, or assembled orders to be shipped to customers.

[0004] Given the wide range of products that can be stored in storage and retrieval systems, automating the transfer of products into and out of storage containers is difficult and is typically performed manually. Sub-containers are typically transferred into and out of storage containers manually or by specially designed machines that are specifically configured to handle sub-containers and storage containers.

[0005] In order to improve efficiency, it is desirable to provide a system for automating the transfer of items into and / or out of storage containers. It is also desirable that the system be able to handle the loading and / or unloading of different types of items, including products and sub-containers. Summary of the invention

[0006] The invention is defined in the appended claims.

[0007] The present invention provides an item transfer system. The item transfer system includes a container unit. The container unit includes: a storage container with a top opening; and an insert configured to be nested in the storage container. The insert includes an insert base and a pair of opposite insert side walls extending upward from the insert base to define an insert channel, the insert channel having a pair of end openings opposite to each other in a horizontal direction, for allowing items to enter and leave the insert channel in a horizontal direction. The item transfer system further includes an item transfer station. The item transfer station includes: a lifting device, the lifting device is configured to vertically move the insert out of the storage container to a raised position where the insert base is located above the storage container, and to vertically move the insert from the raised position back into the storage container; and an item moving device, the item moving device is configured to horizontally move the item onto and / or out of the insert base via the end opening when the insert is in the raised position.

[0008] The container unit and item transfer station of the present invention allow for an automated, flexible, and versatile item transfer system in which one or more than one type of items can be transferred into and / or out of the container unit 50. Because the items can be moved into or out of the insert 57 by lifting the insert 57 and moving the items only in the horizontal direction, there is no need to transfer the items by picking them up, and therefore there is no need to consider how different types of items (which may have different shapes, sizes, weights, flexibility, fragility, etc.) need to be clamped and lifted in the automated system. Therefore, there is no need to provide specialized equipment for picking each different type of item. Therefore, the present invention provides a system for transferring different types of items into and / or out of storage containers that is essentially independent of the type of item being transferred.

[0009] Furthermore, the use of inserts allows the item transfer system to be used with existing storage containers in existing storage systems without the need to redesign the storage containers. Furthermore, the use of inserts with upwardly extending sidewalls allows the inserts to be engaged and lifted from above. Alternative systems in which the inserts are pushed upward from below may require holes to be formed in the base of the storage container, which would be unwelcome because the storage container would not be able to contain leaks. The insert sidewalls also help prevent items from falling from the insert base when the insert is in the raised position.

[0010] The U-shaped insert channel also allows access to and visibility of items within the container unit from above. This may be useful for systems where the container unit is used to store products and the products are picked from the container unit at a picking station to assemble customer orders. Picking is usually done by humans and is increasingly automated using robotic arms. In both cases, access to and visibility of items from above may be required (e.g., for a machine vision system).

[0011] The lifting device can be configured to engage the insert sidewall to move the insert vertically into and out of the storage container. Each insert sidewall can include a handle extending horizontally. The handle can extend horizontally in an outward direction. The lifting device can be configured to engage the handle to move the insert vertically. The lifting device can include a pair of opposing lifting members that are configured to engage the handle to move the insert vertically. The handle can include an engagement feature (e.g., a protrusion or a recess) that engages with a corresponding engagement feature of the lifting member when lifting the insert.

[0012] The handles of the insert may extend outward. The storage container may include a pair of opposing side walls, each side wall including a cutout extending downward from a top surface (e.g., a rim) of the side wall, the cutouts being configured such that when the insert is nested in the storage container, each handle protrudes into a space defined by each cutout. In this manner, the handles do not take up volumetric storage space within the storage container or within the insert channel, which allows the insert channel to be larger to hold more items or larger items.

[0013] The storage container may include a container sidewall. When the insert is nested in the storage container, the insert sidewall may be adjacent to the container sidewall so that the insert sidewall forms a portion of the outer sidewall of the container unit. The container sidewall may be configured to define two opposing side openings. For example, the storage container may include two higher opposing container sidewalls and two shorter opposing container sidewalls arranged in a rectangular shape to define two opposing side openings. When the insert is nested in the storage container, at least a portion (e.g., an upper portion) of each insert sidewall may be configured to occupy a corresponding side opening so that the insert sidewall and the container sidewall form a substantially adjacent structure.

[0014] The insert sidewalls can be configured to interlock the container sidewalls (e.g., the taller container sidewalls) in a vertical direction when the insert is nested within the storage container. For example, each insert sidewall can include a downwardly extending protrusion that is configured to be received in a corresponding recess or cutout in the container sidewall.

[0015] The insert may be open at the top, or at least include a top opening.

[0016] The insert base may be flat. The insert sidewalls may be flat. The bottom surface of the insert base may include one or more ribs extending between the insert sidewalls to strengthen the insert base.

[0017] The insert base may be made of or coated with a material that provides a low friction surface to allow items to slide across the surface of the insert base relatively easily. For example, the coefficient of friction of a particular item sliding on the low friction surface of the insert base may be lower than the coefficient of friction of the same item sliding on the container base.

[0018] The item moving device may include one or more pushing members, which are configured to move in a direction parallel to the longitudinal axis of the end opening extending through the insert passage, so as to push the item horizontally onto the insert base and / or away from the insert base via one of the end openings. Each pushing member can selectively move in a direction parallel to the longitudinal axis of the insert passage using any suitable actuator (e.g., electrical, hydraulic or pneumatic actuator). Each pushing member can be configured to move between an open position for allowing the pushing member to be positioned relative to the item and a closed position for pushing the item. Each pushing member can be configured to pivotally rotate between an open position and a closed position, for example, using any suitable rotary actuator.

[0019] The item moving device may include a first pushing member and a second pushing member spaced apart from the first pushing member in a direction parallel to the longitudinal axis of the inserter channel. The first pushing member and the second pushing member may be configured to move in a direction parallel to the longitudinal axis of the inserter channel to substantially simultaneously push the first item horizontally onto the inserter base and push the second item horizontally away from the inserter base.

[0020] The item moving device may be a robotic arm, such as a Cartesian robotic arm or an articulated robotic arm. The robotic arm may be configured to push the item horizontally onto and / or off the inserter base via one of the end openings.

[0021] The item transfer station may further include an alignment mechanism configured to center the items around a longitudinal axis that passes through the end opening of the insert passage. The alignment mechanism may include a pair of alignment members symmetrically located on either side of the longitudinal axis adjacent to one of the end openings of the insert passage. The alignment members may be configured to move toward each other in a direction perpendicular to the longitudinal axis to center the items located therebetween.

[0022] The item transfer station may further include an inbound item conveyor associated with the raised position of the insert. The inbound item conveyor may be configured to transport the items to the lifting device. The item moving device may be configured to move the items horizontally away from the inbound item conveyor, so that when the insert is in the raised position, the items are received on the insert base via one of the end openings. The inbound item conveyor may include a conveying surface on which the items are transported. When the insert is in the raised position, the conveying surface of the inbound item conveyor may be located at substantially the same height as the insert base, or higher than the insert base. The inbound item conveyor may be configured to transport the items to a position adjacent to one of the end openings of the insert channel.

[0023] The item transfer system may further include a central inbound item conveyor and a plurality of item transfer stations, each item transfer station including an inbound item transfer conveyor. The inbound item conveyors of the plurality of item transfer stations may be configured to transport items from the central inbound item conveyor to a lifting device of its corresponding item transfer station.

[0024] The item transfer station may further include an outbound item conveyor associated with the raised position of the insert. The outbound item conveyor may be configured to transport items away from the lifting device. The item moving device may be configured to move the items horizontally away from the insert base so that when the insert is in the raised position, the items are received on the outbound item conveyor via one of the end openings. The outbound item conveyor may include a conveying surface on which the items are transported. When the insert is in the raised position, the conveying surface of the outbound item conveyor may be located at substantially the same height as the insert base, or lower than the insert base. The outbound item conveyor may be configured to receive items at a position adjacent to one of the end openings of the insert channel.

[0025] The item transfer system may further include a central outbound item conveyor and a plurality of item transfer stations, each item transfer station including an outbound item conveyor. The outbound item conveyors of the plurality of item transfer stations may be configured to transport items from the lifting devices of their respective item transfer stations to the central outbound item conveyor.

[0026] Where the item transfer station includes both an inbound item conveyor and an outbound item conveyor, the inbound item conveyor may be configured to transport items to a position adjacent to one of the end openings of the insert passage, and the outbound item conveyor may be configured to receive items at a position adjacent to the other end opening of the insert passage. The item moving device may be configured to horizontally move items from the inbound item conveyor to the insert base via one of the end openings, and horizontally move items from the insert base to the outbound item conveyor via the other end opening.

[0027] The item transfer station may further include a box removal platform and a robot arm, and the robot arm is configured to remove the box of the boxed item before the item is horizontally moved to the inserter base. The box removal platform may include a cutting area and a suction area, and the cutting area includes one or more cutting blades protruding upwards from the top surface of the box removal platform, and the suction area includes a hole extending through the box removal platform and a suction tool for generating downward suction. The robot arm may be configured to move the boxed item above the cutting area to cut the bottom of the box. Then, the robot arm may be configured to slide the boxed item horizontally onto the inserter base while passing through the suction area, to remove the bottom from the rest of the box, which makes the bottom of the item slide directly onto the inserter base. Then, the robot arm may be configured to lift the rest of the box from the item, so that the boxed item will be left on the top of the inserter base.

[0028] The item transfer station may further include a stacking mechanism for stacking a second item on top of a first item on an insert base. The stacking mechanism may include a stacking plate configured to move between a retracted position and an extended position. The lifting device is further configured to lower the insert from a raised position to a stacking position. After the first item is horizontally moved onto the insert base using the item moving device when the insert is in the raised position, the insert is then lowered to the stacking position. The second item may be horizontally moved onto the stacking plate using the item moving device, and the stacking plate is moved to an extended position above the first item. The stacking plate is then moved to a retracted position to leave the second item on top of the first item.

[0029] The lifting device can be configured to move the insert vertically between the storage container and a plurality of elevated positions. The item transfer station includes one or more item moving devices, which are configured to move items horizontally onto and / or out of the insert base via an end opening at each elevated position. Each elevated position can have an associated item moving device, or a single item moving device can be associated with a plurality of elevated positions. Each elevated position can have an associated inbound item conveyor and / or an associated outbound item conveyor, the inbound item conveyor being configured to transport items to the lifting device, and the outbound item conveyor being configured to transport items away from the lifting device. For each raised position, one or more item moving devices may be configured to move items horizontally away from an associated inbound item conveyor so that the items are received on the insert base via one of the end openings, and / or one or more item moving devices may be configured to move items horizontally away from the insert base so that the items are received on the associated outbound item conveyor via one of the end openings.

[0030] The item transfer station may further include: an inbound container conveyor configured to transport the container units to the lifting device; and an outbound container conveyor configured to transport the container units away from the lifting device.

[0031] The storage and retrieval system may further include a storage area in which the plurality of container units are arranged in a plurality of vertical stacks. The storage and retrieval system may be configured to transport the container units from the storage area to the item transfer station and / or from the item transfer station to the storage area. The container units may be transported from the storage area to the item transfer station via an inbound container conveyor and from the item transfer station to the storage area via an outbound container conveyor.

[0032] The storage area may include a storage structure. The storage structure may include a track structure mounted on a top of the frame. The track structure may include a first set of tracks and a second set of tracks, the first set of tracks extending in a first direction, the second set of tracks extending in a second direction, the second direction being substantially perpendicular to the first direction to form a grid pattern defining a plurality of grid cells. Each stack of container units may be arranged below a grid unit. The storage and retrieval system may further include one or more load handling devices, each load handling device including: a drive assembly configured to move the load handling device horizontally on the track structure; a container holding device that releasably holds the container unit from above; and a lifting mechanism for lifting and lowering the container holding device.

[0033] The storage structure may include an entry column and an exit column below the grid unit. The item transfer station may include an inbound container conveyor configured to convey container units from the exit column and the lifting device, and an outbound container conveyor configured to convey from the lifting device to the entry column. The load handling device may deliver the container unit from the grid unit above the exit column to the outbound container conveyor. The load handling device may pick up the container unit from the entry column that is conveyed to the entry column via the outbound item conveyor.

[0034] The container holding device of the load handling device may include a gripper. Each storage container may include a feature configured to engage with the gripper to allow the container unit to be lifted by the container holding device. Example features include protrusions and / or recesses and / or holes. For example, each storage container may include a rim with a hole configured to receive and engage with the gripper of the container holding device.

[0035] The items to be moved onto and / or off the insert base may be any of the following: products, product sub-containers for containing products, trash, delivery sub-containers for containing customer orders. A sub-container is a container configured to fit on an insert within a storage container. BRIEF DESCRIPTION OF THE DRAWINGS

[0036] The present invention will now be described, by way of example only, with reference to the accompanying drawings, in which like reference numerals are used for like features, and in which: Figure 1 is a perspective view of a container unit including an insert nested within a storage container; Figure 2 yes Figure 1 a container unit wherein the insert is elevated above the storage container; Figure 3A yes Figure 1 A top perspective view of an insert; Figure 3B yes Figure 1 A bottom perspective view of an insert; Figure 4A is a perspective view of a variation of a container unit including an insert nested within a storage container; Figure 4B yes Figure 4A A perspective view of a container unit of FIG. 1 , wherein the insert is raised above the storage container; Figure 5 is a perspective view of a portion of an item transfer station; Figure 6 yes Figure 5 an item transfer station wherein the insert is raised to a raised position; Figures 7A-7C is a series of figures showing the operation of a first item moving device for moving items horizontally away from an insert; Figures 8E-8F is a series of figures showing the operation of a second item moving device for horizontally moving items onto and / or off an insert; Figures 9A-9D is a series of figures illustrating the operation of a third item moving device for horizontally moving items onto and / or off an insert; Fig.10 is a perspective view of an item transfer station including a stacking mechanism that allows items to be stacked on top of each other in an insert; Figures 11A-11F is a series of drawings showing the operation of the stacking mechanism; Fig.12 is a perspective view of a first example item transfer station for loading products and / or product sub-containers into container units; Fig.13 is a perspective view of a second example item transfer station for removing trash from a container unit; Fig.14 is a perspective view of a third example item transfer station for removing trash and / or empty product sub-containers from a container unit; Fig.15 is a perspective view of a fourth example item transfer station for loading products and / or product sub-containers into a container unit and / or for removing empty sub-containers from a container unit; Fig.16 is a perspective view of a fifth example item transfer station for loading products and / or product sub-containers into container units and removing trash and / or empty sub-containers from container units; Fig.17 is a perspective view of a sixth example item transfer station for loading delivery containers onto and / or removing delivery containers from a container unit; Fig.18 is a perspective view of a seventh example item transfer station for loading multiple types of items onto and / or removing multiple types of items from a container unit; Fig.19 is a perspective view of an eighth item transfer station including a robotic arm and a decartoning platform for decartoning boxed products prior to moving them into an insert base; Figures 20A-20E It is shown Fig.19 A series of illustrations showing how the item transfer station operates; Fig.21 It is a three-dimensional diagram of the grid storage structure and container units; Fig. 22 yes Fig.21 A schematic plan view of a track on top of a storage structure; Fig.23 Shown in Fig.21 a load handling device on top of the storage structure; Fig.24 is a perspective view of a single load handling device with a lifting mechanism in a lowered configuration; Fig.25 yes Fig.24 A schematic cross-sectional view of a load handling device of FIG. 1 with the lifting mechanism in a lowered configuration; Fig.26 It is connected to the item transfer station Fig.21 A three-dimensional diagram of the storage structure. DETAILED DESCRIPTION Container Unit

[0037] Figure 1 A container unit 50 is shown. The container unit 50 includes a storage container 51 and an insert 57 nested within the storage container 51. The term "container unit" will be used in this specification to refer to a combination of an insert 57 nested within the storage container 51.

[0038] The storage container 51 has a rectangular container base 52 and a container sidewall 53 extending upward from the base 52 to define a top opening 54. The storage container 51 may include features that allow the storage container 51 to be handled by a load handling device (described later).

[0039] Figure 2 The insert 51 is shown in a position vertically above the storage container 51, and Figure 3A and Figure 3B An isolated insert 57 is shown from the top perspective and the bottom perspective, respectively. The insert 57 includes a rectangular insert base 58 and two opposing insert side walls 60 extending upward from the insert base 58. The insert base 58 and the insert side walls 60 are substantially flat and form a U-shape that defines a horizontally extending insert channel 63 having two opposing end openings 64a, 64b that are opposite to each other in a horizontal direction. The U-shaped insert also defines a horizontal longitudinal axis 65 that passes through the end openings 64a, 64b. The insert 57 is open at the top (or at least includes a top opening).

[0040] The width and length dimensions of the insert base 58 are designed so that the insert 57 can be inserted into the storage container 52 via the top opening 55 of the storage container 52. The dimensions of the insert base 57 are also preferably designed so that the width and length are similar to the width and length of the container base 52. The insert sidewalls 60 preferably do not extend above the top of the storage container 51. The insert base 58 and the sidewalls 60 can be substantially rigid and can be made of, for example, a metal material. The insert base 58 can be made of or coated with a material that provides a low friction surface to allow items to slide over the surface of the insert base 58 relatively easily. For example, the coefficient of friction of a particular item sliding on the low friction surface of the insert base 58 can be lower than the coefficient of friction of the same item sliding on the container base 52.

[0041] Each insert sidewall 60 includes a handle 61 extending horizontally outward (i.e., in a direction away from the longitudinal axis 65 of the insert channel 63). The insert 57 can be lifted out of the storage container 51 and lowered back into the storage container 51 by engaging the handle 61 and lifting and lowering the insert 57 relative to the storage container 51, respectively. Each handle 61 includes one or more handle recesses 62 extending vertically upward from the bottom surface of the handle 61 for receiving corresponding protrusions of the lifting device 74 (described later). The recesses 62 are shown as extending vertically completely through the handle 61, but alternatively, they can extend vertically only partially through the handle 61.

[0042] When the insert 57 is nested within the storage container 51, the insert handle 61 protrudes horizontally into the space defined by the cutout 55 extending downward from the top of the container sidewall 53 in the container sidewall 53. In this way, the handle 61 does not take up volumetric storage space within the storage container 51 or within the insert channel 63, which allows the insert channel 63 to be larger to hold more items or larger items. The handle 61 preferably does not protrude horizontally past the outer surface of the container sidewall 53.

[0043] like Figure 3B As shown, the bottom surface of the insert base 58 includes a plurality of ribs 59 extending therethrough in a direction perpendicular to the longitudinal axis 65 of the insert passage 63 to help strengthen and reinforce the insert base 58 .

[0044] In use, the items stored in the container unit 50 are carried in the insert 57, rather than directly in the storage container 51. Therefore, when the insert 57 is lifted out of the storage container 51, any items stored in the container unit 50 are also lifted out with the insert 57.

[0045] Figure 4A A variation of the container unit 50 is shown in which an insert 57 is nested in a storage container 51 and Figure 4B The insert 57 is shown in a position vertically above the storage container 51. In this variation, the insert side wall 60 is adjacent to the container side wall 53 to define the outer side wall of the container unit 50. Specifically, the storage container 51 includes two higher relative container side walls 53 and two shorter relative container side walls 53b, which are arranged in a rectangular shape to define two relative container side openings 53a. The size of the insert base 58 and the lower portion 53b of the insert side wall 60 is designed and configured to be nested in the storage container 51. However, the upper portion 60a of each insert side wall 60 extends horizontally outward relative to the lower portion 60b, so that when the insert 57 is nested in the storage container 51, each upper portion 60a occupies the corresponding side opening 53a. In this way, when the insert 57 is nested in the storage container 51, the insert side wall 60 and the container side walls 53, 53b form an adjacent structure (i.e., the outer side wall of the container unit 50).

[0046] like Figure 4B As shown, a portion of the outer surface of the insert side wall 60 may be recessed inwardly to form a handle 61 (ie, a horizontal projection) that may be engaged to move the insert 57 vertically into and out of the storage container 51 .

[0047] One of the advantages of this variant is that, in combination with the above Figure 1Compared to the container unit 50 described above, the entire container unit 50 can be made lighter and cheaper because the storage container 51 includes less material. In this variation, the bottom of the insert 57 is still nested within the storage container 51, which helps prevent the insert 57 from sliding out or away from the storage container 51 in the horizontal direction. To help further prevent unwanted relative movement between the insert 57 and the storage container 51 and stabilize the structure of the container unit 50, the insert side wall 60 is configured to interlock the taller container side wall 53 in the vertical direction at the vertical edge of the container unit 50 (between the corners). Figure 4A and Figure 4B In the example shown, each vertical edge of the insert side wall 60 includes a downwardly extending protrusion 60a that is received in a corresponding recess or cutout 53b in the corresponding vertical edge of the taller container side wall 53 so that the insert side wall 60 and the container side wall 53 interlock at the vertical edges of the container unit 50. Item transfer station

[0048] Figure 5 A portion of an item transfer station 68 is shown that works with the container unit 50 to load and / or unload items from the container unit 50 by transferring the items onto and / or off the insert 57 .

[0049] The item transfer station 68 includes a lifting device 74. The lifting device 74 may include a frame or other mounting surface for mounting components, but for clarity, these are not shown in the drawings. The lifting device 74 is configured to receive the container unit 50 at the bottom 75 of the lifting device 74. In this example, the container unit 50 arrives at the lifting device 74 via the inbound container conveyor 70 and leaves the lifting device 74 via the outbound container conveyor 72. The inbound and outbound container conveyors 70, 72 are connected to form a continuous path through the bottom 75 of the lifting device 74. The container units 50 are arranged on the inbound container conveyor 70 so that each container unit 50 arrives at the bottom 75 of the lifting device 74 with the longitudinal axis 65 of the insert channel 63 oriented in the same direction.

[0050] The lifting device 74 is configured to lift the insert 57 from the storage container 51 to the raised position 66 once the container unit 50 comes to rest at the bottom 75 of the lifting device 74 . Figure 6The insert 57 is shown after the insert 57 has been lifted to the raised position 66. The lifting device 74 includes a pair of opposing lifting members 76, which are located on either side of the container unit 50 where the insert handle 61 is located. Each lifting member 76 includes a horizontally extending engagement portion having an upwardly extending protrusion (not shown) that is configured to be received in the recess 62 of the insert handle 61 when the lifting member 76 engages the insert handle 61 from below. Each lifting member 76 is configured to move in a vertical direction relative to the storage container 51. For example, each lifting member 76 can be moved along one or more vertical tracks (not shown) using known means such as belt drive. Each lifting member 76 is also configured to move toward and away from the container unit in a horizontal direction (e.g., using a linear actuator).

[0051] To lift the insert 57 out of the storage container 51, the lifting members 76 move to a vertical position below the insert handle 61. The lifting members 76 then move horizontally toward the container unit 50 until they are directly below the insert handle 61. The lifting members 76 then move upward, which causes them to engage the insert handle 61 from below and causes the lifting member protrusions to be received in the insert handle recesses 62. The lifting members 76 can then move further upward to lift the insert 57 out of the storage container 51 to the raised position 66, in which the insert base 58 is above the top of the storage container 51. To lower the insert 57 back into the storage container 51, the lifting members 76 move downward until the insert 57 nests back inside the storage container 51. The lifting members 76 then move further downward to disengage them from the insert handle 61 and then move horizontally away from the container unit 50. The container unit 50 can then leave the lifting device 74 via the outbound container conveyor 86.

[0052] The item transfer station 68 further includes an item moving device 78 for transferring items onto and / or off the insert 57 via the end openings 64a, 64b when the insert 57 is in the raised position 66. The item moving device 78 is configured to apply a horizontal force to the item in a direction parallel to the longitudinal axis of the insert channel to move the item onto and / or off the insert 57 in a horizontal direction.

[0053] Figure 7A-7BA first item moving device 78X is shown which can push items away from the insert base 58 when the insert 57 is in the raised position 66. The first item moving device 78 can be mounted on a platform or frame or any other suitable mounting surface. The item transfer station includes an outbound item conveyor 86 which receives items that have been pushed away from the insert base 58 and transports the items away from the lifting device 74. Fig. 7A As shown, the first item moving device 78X includes a pushing member in the form of a vertically oriented push plate 80 having a pushing surface oriented perpendicular to the longitudinal axis 65 of the insert passage 63. The push plate 80 can be linearly moved in a horizontal direction parallel to the longitudinal axis of the insert passage (for example, using a linear actuator). The push plate 80 is located at approximately the same level as the raised position 66 of the insert 57, adjacent to the first end opening 64a of the insert passage 63. Figure 7B and Figure 7C As shown, the push plate 80 moves in a horizontal direction through the insert passage 63 via the first end opening 64a so as to push any item on the insert base 58 out of the insert passage 63 via the opposite second end opening 64b. The outbound item conveyor 86 is located on the same side of the insert 57 as the second end opening 64b so that any item pushed out of the insert 57 via the second end opening 64b is received by the outbound item conveyor 86.

[0054] Figures 8A-8F A second item moving device 78Y is shown that can push items onto and / or away from the insert base 58 when the insert 76 is in the raised position 66. In this example, items are conveyed to the lifting device 74 via an inbound item conveyor 84, and the items are conveyed away from the lifting device via an outbound item conveyor 86 associated with the raised position 66 of the insert 57. The inbound item conveyor 84 is configured to convey items to the first end opening 64a of the insert channel 63, and the outbound item conveyor 86 is configured to receive items from the opposite second end opening 64b of the insert channel 63.

[0055] The second item moving device 78Y includes a pair of vertically oriented push plates 80, which are opposite to each other on both sides of the inbound item conveyor 84 near the first end opening 64a. The second item moving device 78Y can be mounted to a frame or any other suitable mounting surface. Each push plate 80 is pivotally mounted to a support member 82 for, for example, rotating movement around a vertical pivot axis using a rotary actuator. The push plate 80 can rotate between an open position and a closed position around its corresponding pivot axis, in which the push plate 80 is oriented parallel to the longitudinal axis 65 of the insert passage 63, and in the closed position, the push plate 80 is oriented perpendicular to the longitudinal axis 65 of the insert passage 63. In the open position, the push plates 80 are spaced far enough laterally to allow the items on the inbound item conveyor 84 to pass between them. In order to move to the closed position, the push plates 80 rotate inwardly toward each other (toward the longitudinal axis of the insert passage). In the closed position, the push plates 80 block the path of the items transported by the inbound item conveyor 84. The push plates 80 can also be linearly moved (e.g., using a linear actuator) in a direction parallel to the longitudinal axis 65 of the insert passage 63 so that the push plates 80 can be moved through the insert passage 63 via the first end opening 64a. The push plates 80 can also be moved toward and away from each other in a direction perpendicular to the longitudinal axis 65 of the insert passage 63, which may be necessary if the distance between the push plates 80 needs to be reduced so that the push plates 80 can be accommodated in the insert passage 63. For example, the second item moving device 78Y may include a linear actuator for selectively moving the push plates toward and away from each other, or the push plates 80 may be mounted on guide rails for movement in a direction parallel to the longitudinal axis of the insert passage, wherein the guide rails are configured to get closer and closer to each other toward the insert 57.

[0056] The item transfer station 68 optionally further includes a pair of alignment members 73 that are opposite to each other on either side of the inbound item conveyor 84 near the first end opening 64a. The alignment members 73 can be moved toward each other in a horizontal direction perpendicular to the longitudinal axis 65 of the insert passage 63 (e.g., using a linear actuator) so that any item located between the alignment members 73 is centered about the longitudinal axis 65 of the insert passage 63. This helps ensure that the item is in the correct position relative to the insert passage 63 to allow the item to be pushed onto the insert base 58 via the first end opening 64a by the push plate 80.

[0057] In use, when the insert 57 is in the raised position 66, the push plate 80 can be rotated to the closed position ( Figure 8B) and moves the push plate 80 through the insert passage 63 via the first end opening 64a to transfer the first item 96a away from the insert base 58, so that the first item 96a is pushed away from the insert base 58 via the second end opening 64b onto the outbound item conveyor 86 ( Figure 8C ).

[0058] While the insert 57 remains in the raised position 66, the second item 96b can then be transferred from the inbound item conveyor 84 to the insert base 58 by conveying the second item 96b to a position adjacent the first end opening 64a, rotating the push plate 80 back to the open position, moving the push plate 80 back to a position behind the second item 96b, and moving the alignment members toward each other to center the second item 96b about the longitudinal axis. Fig.8D The push plate 80 can then be rotated to the closed position and moved through the insert passage 63 via the first end opening 64a to push the second item 96b onto the insert base 58 ( Fig. 8E ).

[0059] After the item transfer operation is completed, the insert 57 is lowered back into the storage container 51 and the container unit 50 is transported away from the lifting device 74 via the outbound container conveyor 86 ( Figure 8F ). A new container unit 50 can then reach the lifting device 74 to repeat the process.

[0060] If the container unit 50 is to remain empty when leaving the lifting device 74, the second item moving device 78Y is not required to transfer new items to the insert 57 after the items have been transferred from the insert 57. Similarly, if the container unit 50 is empty when arriving at the lifting device 74, the second item moving device 78Y can be used to transfer items only to the insert 57.

[0061] Figures 9A-9DA third item moving device 78Z is shown, which can push items onto and / or away from the insert base 58 when the insert 57 is in the raised position 66. The third item moving device 78Z is mounted above the inbound item conveyor 84, for example, on a frame (not shown) or any other suitable mounting surface. The third item moving device 78Z includes a support member 82, which has a first push plate 80 and a second push plate 81, the first push plate 80 being pivotally mounted at one end of the support member 82 to rotate about a first horizontal pivot axis, and the second push plate 81 being pivotally mounted at the opposite end of the support member 82 to rotate about a second horizontal pivot axis. The first push plate 80 and the second push plate 81 can rotate downward from a horizontal orientation to a vertical orientation and back again around their respective pivot axes. The first and second push plates 80 , 81 may be mechanically connected to a single rotary actuator so that they rotate simultaneously, or each push plate 80 , 81 may be provided with its own rotary actuator so that the first and second push plates 80 , 81 may rotate independently.

[0062] The third item moving device 78Z is configured so that the pivot axes of the first push plate 80 and the second push plate 81 are aligned parallel to each other and perpendicular to the longitudinal axis 65 of the insert passage 63. The first push plate 80 and the second push plate 81 are arranged along the longitudinal axis of the insert passage, wherein the first push plate 80 is located closer to the first end opening 64a of the insert passage 63 than the second push plate 81.

[0063] In the horizontal orientation, the first push plate 80 and the second push plate 81 are oriented parallel to the conveying surface 85 of the inbound item conveyor 84 and are located high enough above the conveying surface 85 so that they do not block items conveyed by the inbound item conveyor 84. In the vertical orientation, the first push plate 80 and the second push plate 81 are oriented perpendicular to the conveying surface 85 of the inbound item conveyor 84 so that they block the path of items conveyed by the inbound item conveyor 84. However, the space between the first push plate 80 and the second push plate 81 in a direction parallel to the longitudinal axis 65 of the insert channel 63 is large enough so that items conveyed by the inbound item conveyor can be accommodated between the first push plate 80 and the second push plate 81.

[0064] The support member 82 can be moved in a horizontal direction (e.g., using a linear actuator) in a direction parallel to the longitudinal axis 65 of the insert channel 63 to the extent that the first push plate 80 moves through the insert channel 63 via the first end opening 64a to push any item on the insert base 58 out of the insert channel 63 via the second end opening 64b.

[0065] In use, the first push plate 80 and the second push plate 81 are initially oriented horizontally, and the insert 57 of the container unit 50 at the lifting device 74 is lifted to the raised position 66 ( Fig. 9A ). The insert 57 may already hold the first item 96a. The inbound item conveyor 84 conveys the second item 96b toward the insert 57 until the second item 96b is located between the pivot axes of the first push plate 80 and the second push plate 81. The first and second push plates 80, 81 are then rotated downward to a vertical orientation ( Fig. 9B Then, the first push plate 80 and the second push plate 81 move horizontally through the insert passage 63 in a direction parallel to the longitudinal axis 65 of the insert passage 63, so that the first push plate 80 pushes the first item 96a from the insert base 63 to the outbound item conveyor 86 via the second end opening 64b, and at the same time, the second push plate 81 pushes the second item 96b from the inbound item conveyor 84 to the insert base 58 via the first end opening 64a ( Figures 9C-9D ). The insert 57 is then lowered back into the storage container 51, the container unit 50 is transported away from the lifting device 74 by the outbound container conveyor 72, and the first and second push plates 80, 81 are rotated back to the horizontal orientation. The process can then be repeated with a new container unit 50 and a new item arriving at the lifting device 74 via the inbound item conveyor 84.

[0066] Similar to Figures 8A-8F The item transfer station 68 shown in the example may further include a pair of alignment members 73 for centering the items on the inbound item conveyor 84 around the longitudinal axis 65 of the insert channel 63. The alignment members 73 may be activated before or while the second push plate 81 pushes the items from the inbound item conveyor 84 onto the insert base 58.

[0067] It can be seen that the third item moving device 78Z allows the first item to be transferred out of the insert 57 and the second item to be transferred onto the insert 57 substantially simultaneously. However, the third item moving device 78Z can also be used to perform only one of these operations on a specific container unit 50. For example, if the insert 57 is already empty when the container unit 50 of the insert 57 reaches the lifting device 74, the third item moving device 78Z can be used to transfer items only onto the insert 57, or if the insert 57 already contains items but does not need to be loaded with new items, the third item moving device 78Z can be used to transfer items only away from the insert 57. In these cases, it is sufficient to appropriately rotate one of the first and second push plates 80, 81 to a vertical orientation.

[0068] The item moving device 78 of the present invention is not limited to the precise form of the above-described embodiment. Modifications of the above-described exemplary item moving device or other item moving devices for horizontally moving items onto and off the insert via the end opening will be apparent to those skilled in the art. Some exemplary modifications are described below.

[0069] The pushing members 80 of the item moving device 78 need not be in the form of plates as long as they comprise a suitable pushing surface for pushing items in a horizontal direction.

[0070] Instead of having a pair of push plates 80, the second item moving device 78Y may alternatively have only one push plate 80 located on one side of the longitudinal axis 65 of the insert passage 63. In this variation, the single push plate is wide enough so that when the push plate 80 is rotated to the closed position, it can fully engage the item to push the item when the push plate 80 moves toward the insert 57.

[0071] The second item moving device 78Y can be modified to allow it to simultaneously transfer the first item away from the insert base 57 and the second item to the insert base 58 in a manner similar to the third item moving device 78Z. For example, the second item moving device 78Y may include a second pair of push plates spaced apart from the first pair of push plates in a direction parallel to the longitudinal axis of the insert channel. This modified arrangement is effectively equivalent to copying the third item moving device and rotating the copy 90 degrees in the opposite direction around the longitudinal axis 65 of the insert channel 63. The two pairs of push plates are spaced far enough apart in a direction parallel to the longitudinal axis 65 of the insert channel 63 so that the items conveyed by the inbound item conveyor 84 can be accommodated between the pivot axes of the two pairs of push plates. Thus, when the first pair of push plates and the second pair of push plates are rotated to the closed position and move toward the insert passage 63, the first pair of push plates enter the insert passage 63 to push the first item from the insert base 58 onto the outbound item conveyor via the second end opening 64b, and the second pair of push plates push the second item from the inbound item conveyor 86 onto the insert base 58 via the first end opening 64a. This variation of the second item moving device 78Y can also be modified to remove one push plate from each of the first pair and the second pair of push plates, so that only one push plate is used to push the item away from the insert base 58, and only one push plate is used to push the item away from the inbound item conveyor 84. These push plates can be arranged on the same side of the longitudinal axis 65 of the insert passage 63, or on opposite sides.

[0072] The third item moving device 78Z may be modified to remove the first push plate 80 or the second push plate 81 so that it works similarly to the second item moving device 78Y, ie, transferring items off and onto the insert 57 as a continuous operation.

[0073] The third item moving device 78Z does not necessarily require a support member 82 connecting the two push plates 80, 81. Alternatively, each push plate 80, 81 may be independently mounted to a linear actuator so that the linear movement of each push plate 80, 81 can be individually controlled.

[0074] Rather than having the item mover 78 be located on the same side of the insert 57 as the inbound item conveyor 84, the item mover 78 may be located on the same side of the insert 57 as the outbound item conveyor 86. The item mover 78 may also be part of the lifting device 74. For example, the item mover 78 may be mounted on the lifting device 74 above the lifting member, and the lifting device 74 may be configured to vertically lift the item mover 78 with or independently of the insert 57 so that when the insert 57 is lifted to the raised position 66, the item mover 78 is at an appropriate height to perform the item moving operation.

[0075] In order to allow items to be transferred onto or away from the insert base 57 simply by applying a horizontal force to the items, when the insert 57 is in the raised position 66, the inbound item conveyor 84 (more specifically, the conveying surface 85 of the inbound item conveyor 84) should be substantially flush with or above the level of the insert base 58, and when the insert 57 is in the raised position 66, the outbound item conveyor 86 (more specifically, the conveying surface 85 of the outbound item conveyor 86) should be substantially flush with or below the level of the insert base 58.

[0076] Fig.10 and Figures 11A-11F An example of an item transfer station 68 is shown that allows multiple items to be transferred from an inbound item conveyor to the same insert 57 in multiple layers, i.e., it allows items to be stacked vertically in the insert 57. In this example, in addition to the raised position 66, the lifting device 74 is also configured to vertically move the insert 57 to a stacking position 67 that is lower than the raised position 66. The item transfer station 68 further includes a stacking mechanism that includes a stacking plate 89 that is located at the end of the inbound item conveyor 84 adjacent to one of the end openings 64a. The stacking plate 89 is oriented parallel to the insert base 58. The stacking plate 89 is horizontally movable (e.g., using a linear actuator) in a direction parallel to the longitudinal axis 65 of the insert channel 63 between a retracted position and an extended position, in which the insert 57 extends into the insert channel via the first end opening 64a (when the insert 57 is in the stacking position 67). For clarity, in Fig.10 and Figures 11A-11FThe item moving device 78 is not shown in FIG. 1 , but any item moving device 78 suitable for moving items horizontally, such as those described above, may be used in this example.

[0077] In use, the insert 57 from the container unit 50 at the lifting device 74 is lifted to the raised position 66 ( Fig.11A The item moving device 78 (not shown) pushes the first item 96a horizontally from the inbound item conveyor 84 onto the insert base 58 ( Fig. 11B ). Then, the lifting device 74 lowers the insert 57 to the stacking position 67, and the second item 96b is transferred to the stacking plate 89 ( Fig. 11C ). The stacking plate 89 is then moved to the extended position so that the stacking plate 89 extends above the top of the first item 96a ( Fig.11D ). The stacking plate 89 is then retracted so that the second item 96b is located on top of the first item 96a ( Fig.11E ). To prevent the second item 96b from moving horizontally with the stacking plate 89 when the stacking plate 89 is retracted, the item moving device 78 may be held in place after the second item 96b is pushed onto the stacking plate 89 to prevent the second item 96b from moving backwards. The insert 57 is then lowered back into the storage container 51, and the container unit 50 leaves the lifting device 74 via the outbound container conveyor 72 ( Fig.11F ).

[0078] To stack items more than two levels, the above process may be repeated by moving the insert 57 using a plurality of stacking positions 67, provided that there is sufficient vertical space in the insert 57 to continue stacking items.

[0079] The item transfer station 68 of the present invention is also not limited to transferring items to and from the insert only at a single elevated position 66. The lifting device 68 can be configured to lift the insert 57 to any one of a plurality of elevated positions 66. At each elevated position 66, items can be appropriately transferred to and / or removed from the insert 57. For example, each elevated position 66 can have an associated inbound item conveyor 84 and / or an associated outbound item conveyor 86. The inbound item conveyors 84 can all be arranged on the same side of the insert 57, or on different sides of the insert 57, depending on the item flow in the entire wider system. Similarly, the outbound item conveyors 86 can all be arranged on the same side of the insert 57, or on different sides of the insert 57, depending on the item flow in the entire wider system. Each raised position 66 may also have an associated item moving device 78, or the item transfer station 68 may include a single item moving device 78 that moves up and down with the insert 57 (e.g., it may be mounted above the lifting member 76 so that the lifting member 76 and the item moving device 78 move vertically together, or the item moving device 78 may be configured for vertical movement independent of the lifting member 76). One or more raised positions 66 may also have an associated stacking mechanism as described above for stacking items vertically in multiple layers on the insert 57. Items transferred to the insert 57 at one raised position may be stacked with items transferred to the insert 57 at another raised position. Depending on what items need to be transferred to or removed from the insert 57, the insert 57 may be lifted to one or more raised positions 66 for one or more item transfer operations before being lowered back into the storage container 51.

[0080] Although the above-mentioned exemplary item transfer station uses a conveyor to transport items and container units to and from the item transfer station, alternative conveying devices may also be used. For example, a vehicle (e.g., an automated vehicle) may transport items and / or container units to and from the item transfer station. The item moving device 78 may move items directly from the vehicle to the insert base 58, or vice versa, or the vehicle may place items on a holder, from which the items are moved to the insert base 58, or vice versa. Storage and retrieval systems

[0081] The container unit 50 and the item transfer station 68 can be used within a storage and retrieval system, wherein the container unit 50 is used to store products to be sold to customers. The products 96 can be stored directly in the container unit 50 (on the insert 57), or the products 96 can be contained in a product sub-container 97 stored in the container unit 50 (on the insert 57). The product sub-containers 97 are similar to the storage containers 51 in that they include a base and side walls defining a top opening, but the product sub-containers 97 are smaller than the storage containers 51 to allow the product sub-containers 97 to fit inside the storage container 51 (on the insert 57). The container unit 50 can be stored in a storage area (e.g., a grid storage structure), an example of which will be described later.

[0082] In order to fulfill a customer order, a container unit 50 containing products 96 from an order can be retrieved from a storage area and transported to a picking station. At the picking station, the ordered products 96 are picked from the container unit 50 and placed in a delivery sub-container 98 (e.g., by a person or a robotic arm). Once all products 96 in an order have been picked into a delivery sub-container 98, the delivery sub-container 98 can leave the storage and retrieval system to be delivered to a customer (e.g., by a delivery vehicle). For reasons of operational efficiency, the delivery sub-container 98 containing a completed order may not be sent directly to a customer. Alternatively, the delivery sub-container 98 can be stored in a container unit 50 within a storage area. The delivery sub-container 98 is similar to the storage container 51 in that they include a base and side walls defining a top opening, but the delivery sub-container 97 is smaller than the storage container 51 to allow the delivery sub-container 98 to be accommodated inside the storage container 51 (on the insert 57).

[0083] Thus, a container unit 50 within a storage and retrieval system may be empty (i.e., a storage container 51 with an insert 57 but no other items), or may contain a plurality of types of items, including, but not limited to: products 96, product sub-containers 97, and delivery sub-containers 98. A product sub-container 97 may contain a product 96, or may be empty if all of the products 96 within the product sub-container 97 have been picked to fulfill a customer order. A delivery sub-container 98 may be "empty" (defined as not containing an ordered product 96, but may contain a shipping package (e.g., a tote bag) for an order placed therein), or may contain an ordered product 96. A container unit 50 may also contain items that are considered "trash," such as product packaging or other debris left in a container unit after all of the products 96 within the container unit 50 have been picked. It is undesirable for trash items to remain in a container unit 50 because they may interfere with storage capacity and product picking, and therefore trash items are typically removed before a container unit 50 is refilled with new items.

[0084] One or more item transfer stations 68 may be used to transfer the items into and / or out of container units 50 within the storage and retrieval system. The storage and retrieval system may include transport means, such as conveyors, for transporting items and container units 50 between one or more item transfer stations 68, storage areas, and other areas of the system.

[0085] Figures 12 to 17 Several ways in which the item transfer station 68 may be used in the context of the above-described storage and retrieval system are shown. In the following examples, to improve clarity, none of the figures shows the item moving device 78. However, any suitable item moving device 78 for horizontally moving items, such as those described above, may be used.

[0086] Fig.12 A first exemplary item transfer station 68 is shown that is configured to operate as a filling station for loading products 96 and / or product sub-containers 97 containing products 96 into container units 50 .

[0087] The first item transfer station 68 includes an inbound item conveyor 84 associated with the raised position 66 of the insert 57. The inbound item conveyor 84 is configured to transport products 96 and product sub-containers 97 to one of the end openings 64a of the insert channel 63. When the insert 57 is lifted to the raised position 66, the item moving device 78 (not shown) pushes the product 96 or product sub-container 97 from the inbound item conveyor 78 horizontally through the end opening 64a to the insert base 58. Then, the insert 57 is lowered back into the storage container 51, and the container unit 50 is transported to the storage area via the outbound container conveyor 72.

[0088] Fig.13 A second example item transfer station 68 is shown for removing trash (e.g., unwanted packaging and other unwanted debris) from the container unit 50. The second transfer station can be used to clean the container unit 50 before it is reused within the system (e.g., refilled with items).

[0089] The second item transfer station 68 includes an outbound item conveyor 86 associated with the raised position 66 of the insert 57. The outbound item conveyor 86 is configured to receive trash from one of the end openings 64b of the insert 57 and transport the trash away from the lifting device 74. When the insert 57 is lifted to the raised position 66, the item moving device 78 moves horizontally through the insert channel so that any trash items on the insert base 58 are pushed horizontally off the insert base 58 via the end opening 64b onto the outbound item conveyor 86. The insert 57 is then lowered back into the storage container 51, and the now cleaned container unit 50 can be transported to another area of ​​the storage and retrieval system via the outbound container conveyor 72.

[0090] The outbound item conveyor 86 can feed into the central outbound item conveyor 88. The central outbound item conveyor 88 can be configured to receive trash from the plurality of outbound item conveyors 86 from the plurality of item transfer stations 68. This configuration of the central outbound item conveyor 88 receiving trash items from the plurality of outbound item conveyors 86 from the plurality of item transfer stations 68 can be used for any type of item (e.g., product sub-containers 97 and delivery sub-containers 98), not just trash. Similarly, the central inbound item conveyor can also be used to feed the inbound item conveyor 84 of the plurality of item transfer stations 68.

[0091] Fig.14 A third example item transfer station 68 is shown for removing two types of items from a container unit—trash and empty product sub-containers 97. The third transfer station 68 may be used to empty a container unit 50 before the container unit 50 is reused within the system (e.g., refilled with items).

[0092] The lifting device 74 is configured to lift the insert 57 of the container unit 50 to the first raised position 66a or the second raised position 66b higher than the first raised position 66a according to the item transfer operation.

[0093] The third item transfer station 68 includes a first outbound item conveyor 86a and a first item moving device 78a (not shown) associated with the first elevated position 66a. The first outbound item conveyor 86a is configured to receive trash from one of the end openings 64b of the insert 57 and transport the trash away from the lifting device 74.

[0094] The third item transfer station 68 further includes a second outbound item conveyor 86b and a second item moving device 78b (not shown) associated with the second elevated position 66b. The second outbound item conveyor 86b is configured to receive an empty product sub-container 97 from one of the end openings 64b of the insert 57 and transport the empty product sub-container 97 away from the lifting device 74.

[0095] To remove trash from the container unit 50, the insert 57 is lifted to the first raised position 66a and the first item mover 78a pushes any trash items from the insert base 58 via one of the end openings 64b onto the first outbound item conveyor 86a.

[0096] In order to remove the empty product sub-container 97 from the container unit 50, the insert 57 is lifted to the second raised position 66b, at which the second item moving device 78b pushes the empty product sub-container 97 away from the insert base 58 via one of the end openings 64b to the second outbound item conveyor 86b.

[0097] If the container unit 50 does not contain an empty product sub-container, the insert 57 of the container unit 50 may be lifted to the first raised position 66a by default to perform a trash removal operation.

[0098] After the insert 57 is emptied, the insert 57 is lowered back into the storage container 51 and the now empty container unit 50 can be transported via the outbound container conveyor 72 to another area of ​​the storage and retrieval system.

[0099] Fig.15 A fourth example item transfer station 68 is shown for loading products 96 and product sub-containers 97 into container units 50 and / or removing empty product sub-containers 97 from container units 50. The fourth item transfer station 68 allows container units 50 to be emptied and then loaded with new products 96 or product sub-containers 97 at the same item transfer station 68, rather than using separate item transfer stations 68 to empty container units 50 and load new products 96.

[0100] The fourth item transfer station 68 includes an inbound item conveyor 84 , an outbound item conveyor 86 , and an item moving device 78 associated with the raised position 66 of the insert 57 .

[0101] Inbound item conveyor 84 is configured to transport products 96 and product sub-containers 97 to first end opening 64a of insert channel 63. Outbound item conveyor 86 is configured to receive empty product sub-containers 97 from second end opening 64b of insert channel 63 and transport the empty product sub-containers 97 away from lifting device 74.

[0102] Once the container unit 50 has been received at the lifting device 74, the insert 57 is lifted to the raised position 66. If the insert 57 contains an empty product sub-container 97, the item moving device 78 pushes the empty product sub-container 97 from the insert base 58 via the second end opening 64b onto the outbound item conveyor 86. Then, the item moving device 78 pushes the new product 96 or product sub-container 97 from the inbound item conveyor 78 via the first end opening 64a onto the insert base 58. Depending on the design of the item moving device 78, these two item transfer operations can be performed substantially simultaneously.

[0103] After the insert 57 has been loaded with the new product 96 or product sub-container 97 , the insert 57 is lowered back into the storage container 51 and the now loaded container unit 50 can be transported to a storage area using the outbound container conveyor 72 .

[0104] Fig.16 A fifth exemplary item transfer station 68 is shown at which products 96 and / or product sub-containers 97 can be loaded into container units 50, and at which trash and / or empty product sub-containers 97 can be removed from container units 50. The fifth item transfer station 68 allows container units 50 to be emptied and then loaded with new products 96 at the same item transfer station 68, rather than using separate item transfer stations 68 for emptying container units 50 and loading new products 96.

[0105] The fifth item transfer station 68 substantially corresponds to the third item transfer station 68, with the addition of an inbound item conveyor 84 associated with the second raised position 66b of the insert 57. The inbound item conveyor 84 is configured to transport products 96 and product sub-containers 97 to the first end opening 64a of the insert channel 63. The second item moving device 78b (not shown) is further configured to push the product 96 or product sub-container 97 from the inbound item conveyor 84 onto the insert base 58. The first outbound item conveyor 86a and the second outbound item conveyor 86b are configured to receive trash and empty product sub-containers 97 from the second end opening 64b of the insert channel 63, respectively.

[0106] The container unit 50 that arrives at the lifting device 74 via the inbound container conveyor 70 may be empty, may contain trash, or may contain empty product sub-containers 97. Once the container unit 50 has been received at the lifting device 74, the insert 57 is lifted to the first raised position 66a or the second raised position 66b based on the item transfer operation to be performed.

[0107] If the empty container unit 50 reaches the lifting device 74 , the insert 57 may be lifted to the second raised position 66 b , in which the second item moving device 78 pushes the product 96 or product sub-container 97 from the inbound item conveyor 84 onto the insert base 58 .

[0108] If the container unit 50 containing garbage reaches the lifting device, the insert 57 can be lifted to the first raised position 66a, in which the first item moving device 78a pushes the garbage from the insert base 58 to the first outbound item conveyor 84a. Then, the insert 57 can be lifted to the second raised position 66b, at which the second item moving device 78b pushes the product 96 or product sub-container 97 from the inbound item conveyor 84 to the insert base 58.

[0109] If the container unit 50 containing the empty product sub-container 97 reaches the lifting device 74, the insert 57 can be lifted to the second raised position 66b, in which the second item moving device 78b pushes the empty product sub-container 97 from the insert base 58 onto the second outbound item conveyor 86b. The second item moving device 78b can then push the new product 96 or product sub-container 97 from the inbound item conveyor 84 onto the insert base 58 (at the same time or after the empty product sub-container 97 is pushed away from the insert base 58, depending on the design of the second item moving device 86b).

[0110] If the container unit 50 does not contain an empty product sub-container, the insert 57 of the container unit 50 may be lifted to the first raised position 66a by default to perform a trash removal operation.

[0111] After the item transfer operation is completed, the insert 57 is lowered back into the storage container 51 and the container unit 50 is transported from the lifting device 74 to the storage area by the outbound container conveyor 72.

[0112] Fig.17 A sixth item transfer station 68 is shown at which delivery sub-containers 98 may be loaded into and / or removed from the container unit 50 .

[0113] As described above, the delivery sub-containers 98 containing the picked customer orders can be stored in the container units 50 in the storage area until the time when the delivery sub-containers 98 will be delivered to the customers. In the storage and retrieval system, the delivery sub-containers 98 are separated from the storage containers 51 before they are loaded onto the delivery vehicles, and therefore the sixth item transfer station 68 works to separate the delivery sub-containers 98 from the storage containers 51. The sixth item transfer station 68 also allows the empty container units 50 to be filled / refilled with empty delivery sub-containers 98 for receiving the picked customer orders.

[0114] The sixth item transfer station 68 is configured substantially the same as the fourth item transfer station 68, except that the inbound item conveyor 84 is now configured to transport empty delivery sub-containers 98 to the first end opening 64a of the insert channel 63, and the outbound item conveyor 84 is now configured to receive loaded delivery sub-containers from the second end opening 64b and transport them away from the lifting device 74.

[0115] If an empty container unit 50 reaches the lifting device 74, the insert 57 is lifted to the raised position 66 and the item moving device 78 (not shown) pushes the empty delivery sub-container 98 from the inbound item conveyor 84 onto the insert base 58 via the first end opening 64a.

[0116] If the container unit 50 reaches the lifting device 74 and contains a loaded delivery sub-container 98, the insert 57 is lifted to the raised position 66, and the item moving device 78 pushes the delivery sub-container 98 from the insert base 58 via the second end opening 64b onto the outbound item conveyor 86. The separated delivery sub-container 98 can then be transported to a loading area, for example. If the container unit 50 is to be reused to hold new delivery containers 98, the item moving device 78 pushes the empty delivery sub-container 98 away from the inbound item conveyor 84 and onto the insert base 58 (as described above, this can be done while pushing the delivery sub-container 98 away from the insert base 58, depending on the design of the item moving device).

[0117] After the item transfer operation is completed, the insert 57 is lowered back into the storage container 51 and the container unit 50 is transported away from the lifting device 74 by the outbound container conveyor 72 .

[0118] Fig.18A seventh item transfer station 68 is shown at which multiple types of items can be loaded into and / or removed from the container unit 50. The seventh item transfer station 68 is configured to load products 96, loaded product sub-containers 97, and empty delivery sub-containers 98 into the container unit 50 and unload trash, empty product sub-containers 97, and loaded delivery sub-containers 98 from the container unit 50 using a single item transfer station 68.

[0119] The seventh item transfer station is basically a combination of the first to sixth item transfer stations mentioned above.

[0120] The lifting device 74 is configured to lift the inserter 57 to any one of a first raised position 66a, a second raised position 66b higher than the first raised position 66a, and a third raised position 66c higher than the second raised position 66b according to a desired item transfer operation.

[0121] The first elevated position 66a is used to remove trash. The seventh item transfer station 68 includes a first outbound item conveyor 86a associated with the first elevated position 66a for transporting trash away from the lifting device 74 and a first item moving device 78a associated with the first elevated position 66a, the first item moving device 78a being configured to push trash from the insert 57 onto the first outbound item conveyor 86a.

[0122] The second elevated position 66b is used to load products 96 and loaded product sub-containers 97 and / or unload empty product sub-containers. The seventh item transfer station 68 further includes a second inbound item conveyor 84b (in this example there is no "first" inbound item conveyor), a second outbound item conveyor 86b and a second item moving device 78b (not shown) associated with the second elevated position 66b. The second inbound item conveyor 84b is configured to transport products 96 and loaded product sub-containers 97 to the first end opening 64a of the insert channel 63; the second outbound item conveyor 74b is configured to receive empty product sub-containers 97 from the second end opening 64b of the insert channel 63 and transport them away from the lifting device 74; and the second item moving device 78b is configured to push products 96 and product sub-containers 97 from the second inbound item conveyor 84b via the first end opening 64a to the insert base 58, and push empty product sub-containers 97 from the insert base 58 via the second end opening 64b to the second outbound item conveyor 86b.

[0123] The third raised position 66c is used to load and / or remove the delivery sub-container 98. The seventh item transfer station 68 further includes a third inbound item conveyor 84c, a third outbound item conveyor 86c, and a third item moving device 78c (not shown) associated with the third raised position 66c. The third inbound item conveyor 84c is used to convey the empty delivery sub-container 98 to the first end opening 64 of the insert base 58; the third outbound item conveyor 86c is used to receive the loaded delivery sub-container 98 from the second end opening 64b of the insert base 58 and transport them away from the lifting device 74; and the third item moving device 78c is used to push the empty delivery sub-container 97 from the third inbound item conveyor 84c to the insert base 58 via the first end opening 64a, and push the loaded delivery sub-container 97 from the insert base 58 via the second end opening 64b to the third outbound item conveyor 86c.

[0124] The container unit 50 that arrives at the lifting device 74 via the inbound container conveyor 70 may be empty or may contain: trash, an empty product sub-container 97, or a loaded delivery sub-container 98. Once the container unit 50 has arrived at the lifting device 74, the insert 57 is lifted to one or more of the first to third raised positions 66a-66c, depending on what type of items need to be transferred to or removed from the insert 57. Once all item transfer operations are completed, the insert 57 is lowered back into the storage container 51, and the container unit 50 is transported away from the lifting device 74 by the outbound container conveyor 72.

[0125] The seventh item transfer station 68 thus provides a multifunctional item transfer station 68 that may be used in storage and retrieval systems having limited warehouse space.

[0126] Although all of the inbound item conveyors 84b, 84c of the seventh item transfer station 68 are shown on one side of the insert channel 63, and all of the outbound item conveyors 86a-86c are shown on the other side of the insert channel 63, this arrangement is not required, and each inbound item conveyor and outbound item conveyor can be on either side, depending on the processes or items within the storage and retrieval system.

[0127] Fig.19 An eighth item transfer station 68 is shown where products packed in cartons can be automatically unpacked and loaded into container units. This eliminates the need for a separate area in the storage and retrieval system to unpack boxed products 99 before loading them onto the inbound item conveyor 84 for transport to the item transfer station 68.

[0128] The eighth item transfer station 68 includes a decartoning platform 90, an inbound item conveyor 84, and an outbound item conveyor 86 associated with the raised position 66 of the insert 57. The inbound item conveyor 84 is configured to transport boxed products 99 to the decartoning platform 90, and the outbound item conveyor is configured to transport trash (removed boxes) away from the decartoning platform.

[0129] The eighth item transfer station 68 further includes an item moving device 78 in the form of a Cartesian robot 92 having a suction end effector 93 (although other types of robots, such as articulated arms and other end effectors for holding boxed products 99, may also be used). The end effector 93 is mounted for movement on a gantry frame 91 extending above the de-boxing platform 90 so that the end effector 93 can move along three orthogonal axes (two horizontal and one vertical). The end effector 93 is also preferably rotatable about a vertical axis to provide a fourth degree of freedom.

[0130] The deboxing platform 90 further includes a cutting area 94 and a suction area 95, wherein the cutting area 94 includes one or more cutting blades protruding upward from the upper surface of the deboxing platform 90, and the suction area 95 includes one or more holes extending through the deboxing platform 90 and a suction pump or other suction tool for drawing air downward through the holes to generate suction.

[0131] Figures 20A-20E 8 is a series of drawings showing the eighth item transfer station 68 in use. The boxed product 99 arrives at the deboxing platform 90 via the inbound item conveyor 84. The insert 57 of the container unit 50 at the lifting device 74 is lifted to the raised position 66. The Cartesian robot 92 picks up the boxed product 99 ( Fig. 20A ) and moving the boxed product 99 relative to the cutting blade (translationally and / or rotationally) in the cutting area 94 so that the bottom 99a of the box of the boxed product 99 is cut around the edge ( Fig. 20B ). The Cartesian robot 92 then slides the boxed product 99 horizontally across the suction area 95 and into the insert channel 63 via one of the end openings 64a. As the boxed product 99 slides over the suction area 95, the suction force holds the cut bottom 99a of the shell product 99, so that the product 96, now only enclosed on the sides and top, slides directly onto the insert base 58 ( Fig. 20C ). The Cartesian robot 92 then raises the end effector 93 so that the remaining portion 99b of the box (top and sides) is lifted away from the product 96, leaving the product 96 on the insert base 58 ( Fig.20DThe Cartesian robot 92 can then drop the removed box 99b onto the outbound item conveyor 86 and pick up the bottom 99a of the box remaining on the suction area 95 and drop it onto the outbound item conveyor 86 as well ( Fig.20E ). Alternatively, to improve efficiency, a second end effector or another robot can be used to remove the bottom 99a of the shell remaining on the suction area 95. The insert 57 is then lowered back into the storage container 51 and the container unit 50 is transported away from the lifting device 74 via the outbound container conveyor 72.

[0132] As an alternative to using the inbound item conveyor 84 to deliver the boxed products 99 to the de-boxing platform 90, the Cartesian robot 92 may pick up the boxed products 99 directly from a pallet positioned next to the de-boxing platform 90. For example, the pallet may have been delivered to the de-boxing platform 90 by a forklift.

[0133] Therefore, it can be seen from the above examples that the container unit 50 and item transfer station 68 of the present invention allow for an automated, flexible, and multifunctional item transfer system in which one or more than one type of items can be transferred into and / or out of the container unit 50. Because the items can be moved into or out of the insert 57 by lifting the insert 57 and moving the items only in the horizontal direction, there is no need to transfer the items by picking up the items, and therefore there is no need to consider how different types of items (which may have different shapes, sizes, weights, flexibility, fragility, etc.) need to be clamped and lifted in the automated system. Therefore, there is no need to provide specialized equipment for picking up each different type of item. Therefore, the present invention provides a system for transferring different types of items into and / or out of storage containers, which is essentially independent of the type of item being transferred. Storage structures and load handling devices

[0134] Fig.21 An exemplary storage structure 1 is shown that can be used to store container units 50 in a storage area of ​​a storage and retrieval system. The storage structure 1 includes a frame including upright members 3 and horizontal members 5, 7 supported by the upright members 3. The horizontal members 5 extend parallel to each other and to the x-axis shown. The horizontal members 7 extend parallel to each other and to the y-axis shown, and extend transversely to the horizontal members 5. The upright members 3 extend parallel to each other and to the z-axis shown, and extend transversely to the horizontal members 5, 7. The horizontal members 5, 7 form a grid pattern defining a plurality of grid cells 14. In the example shown, the container units 50 are arranged in stacks 11 below the grid cells 14 defined by the grid pattern, with each grid cell 14 having a stack 11 of container units 50.

[0135] Fig. 22A large-scale plan view of a section of a track structure 13 is shown, the track structure 13 forming Fig.21 A portion of the storage structure 1 shown in FIG. Fig.21 The storage structure 1 shown in FIG. 1 is on top of the horizontal members 5, 7 of the storage structure 1. The track structure 13 can be provided by the horizontal members 5, 7 themselves (e.g., formed in or on the surface of the horizontal members 5, 7) or by one or more additional components mounted on top of the horizontal members 5, 7. The track structure 13 shown includes x-direction tracks 17 and y-direction tracks 19, i.e., a first set of tracks 17 extending in the x-direction and a second set of tracks 19 extending in the y-direction transverse to the tracks 17 in the first set of tracks 17. The tracks 17, 19 define a hole 15 in the center of the grid unit 14. The size of the hole 15 is designed to allow the container unit 50 located below the grid unit 14 to be lifted and lowered through the hole 15. The x-direction tracks 17 are arranged in pairs separated by channels 21, and the y-direction tracks 19 are arranged in pairs separated by channels 23. Other arrangements of the track structure are also possible.

[0136] Fig.23 Shown in Fig.21 A plurality of load handling devices 25 are shown moving on top of the storage structure 1. The load handling devices 25 (hereinafter referred to as "robots") are provided with sets of wheels to engage with corresponding x- or y-directional tracks 17, 19 to enable the robots 25 to travel across the track structure 13 and reach specific grid cells 14. The pairs of tracks 17, 19 shown separated by channels 21, 23 allow the robots 25 to occupy (or pass each other) adjacent grid cells 14 without colliding with each other.

[0137] like Fig.24 As shown, the robot 25 includes a body 27 in or on which one or more components are mounted that enable the robot 25 to perform its intended functions. These functions may include moving across the storage structure 1 on the track structure 13 and raising or lowering the container unit 50 (e.g., from or to the stack 11) so that the robot 25 can retrieve or deposit the container unit 50 at a specific location defined by the grid pattern.

[0138] The robot 25 shown includes a drive assembly including first and second sets of wheels 29, 31 mounted on the body 27 of the robot 25 and enabling the robot 25 to move in the x and y directions along the tracks 17 and 19, respectively. Fig.24The wheels 29 are mounted on the shorter side of the robot 25, and two further wheels 29 are arranged on the relatively shorter side of the robot 25. The wheels 29 engage with the track 17 and are rotatably mounted on the body 27 of the robot 25 to allow the robot 25 to move along the track 17. Similarly, two wheels 31 are arranged on the body 27 of the robot 25. Fig.24 On the longer side of the robot 25 visible in the figure, and another two wheels 31 are provided on the relatively longer sides of the robot 25. The wheels 31 engage with the track 19 and are rotatably mounted on the body 27 of the robot 25 to allow the robot 25 to move along the track 19.

[0139] To enable the robot 25 to move in the first direction and the second direction on the different wheels 29, 31, the drive assembly further includes a wheel positioning mechanism (not shown) for selectively engaging the first set of wheels 29 with the first set of tracks 17 or engaging the second set of wheels 31 with the second set of tracks 19. The wheel positioning mechanism is configured to raise and lower the first set of wheels 29 and / or the second set of wheels 31 relative to the body 27, thereby enabling the load handling device 25 to be selectively moved across the tracks 17, 19 of the storage structure 1 in the first direction or the second direction.

[0140] The wheel positioning mechanism may include one or more linear actuators, rotating components or other means for raising and lowering at least one set of wheels 29, 31 relative to the body 27 of the robot 25 to remove at least one set of wheels 29, 31 from and contact the tracks 17, 19. In some examples, only one set of wheels is configured to be raised and lowered, and the action of lowering one set of wheels may effectively lift the other set of wheels off the corresponding tracks, while the action of raising one set of wheels may effectively lower the other set of wheels into contact with the corresponding tracks. In other examples, both sets of wheels may be raised and lowered, which advantageously means that the body 27 of the robot 25 remains substantially at the same height, and therefore the weight of the body 27 and components mounted thereon does not need to be raised and lowered by the wheel positioning mechanism.

[0141] The robot 25 also includes a lifting mechanism 33 and a container holding device 37 configured to raise and lower the container unit 50. The lifting mechanism 33 shown includes four tethers 35 connected to the container holding device 37 at their lower ends. The tethers 35 can be in the form of cables, ropes, belts, or any other form of tethers having the physical properties required to lift the container 9. The container holding device 37 includes a clamping mechanism 39 that is configured to engage with features of the storage container 51 of the container unit 50 to releasably hold the container unit 50 from above. In the example shown, the clamping mechanism 39 includes legs that can be received in corresponding holes 10 in the rim of the storage container 51 of the container unit 50 and then moved outward to engage with the bottom surface of the rim of the storage container 51. The tethers 35 can be wound up or down to raise or lower the container holding device 37 as needed. One or more motors and winches or other tools can be provided to achieve or control the upward or downward winding of the tethers 35.

[0142] exist Fig.25 , the side panels of the robot 25 have been omitted from view to allow the interior of the robot 25 to be seen. The body 27 of the illustrated robot 25 has an upper portion 41 and a lower portion 43. The upper portion 41 is configured to accommodate or support one or more operating components (not shown), such as components of the lifting mechanism 33 (e.g., a motor), a wireless communication component, one or more processors for controlling the operation of the robot 25, etc. The lower portion 43 is arranged below the upper portion 41. The lower portion 43 is open to the outside at the bottom and defines a container receiving space 45 for accommodating at least a portion of a container unit 50 that has been lifted into the container receiving space 45 by the lifting mechanism 33. The size of the container receiving space 45 is designed so that the container unit 50 is sufficiently accommodated within the space 45 so that the robot 25 can move across the track structure 13 on the top of the storage structure 1 without the bottom surface of the container unit 50 being stuck on the track structure 13 or another part of the storage structure 1. When the robot 25 has reached its intended destination, the lifting mechanism 33 controls the tether 35 to lower the container holding device 37 and the corresponding container unit 50 from the space 45 to the intended location. The intended location may be a stack 11 of container units 50 or an exit point of the storage structure 1 (or an entry point of the storage structure 1 if the robot 25 has moved to collect container units for storage in the storage structure 1). Although in the illustrated example, the upper portion 41 and the lower portion 43 are separated by a physical divider, in other examples, the upper portion 41 and the lower portion 43 may not be physically separated by a particular component or portion of the body 27 of the robot 25. The up-and-down configuration of the robot 25 allows the robot 25 to occupy only a single grid cell 14 on the track structure 13 of the storage system 1.

[0143] In an alternative example, the container receiving space 45 of the robot 25 may not be within the body 27 of the robot 25. For example, the container receiving space 45 may instead be adjacent to the body 27 of the robot 25, such as in a cantilever arrangement, with the weight of the body 27 of the robot 25 balancing the weight of the container unit 50 to be lifted. In such an embodiment, the frame or arm of the lifting mechanism 33 may protrude horizontally from the body 27 of the robot 25, and the tether 35 may be arranged at corresponding locations on the protruding frame / arm and configured to be raised and lowered from those locations to raise and lower the container into the container receiving space 45 adjacent to the body 27.

[0144] The storage structure 1 may be connected via inbound and outbound container conveyors 70 , 72 to one or more of the item transfer stations 68 of the present invention. Fig.26 An example is shown in which the storage structure 1 includes an entrance column 9 and an exit column 1, each of which is located below a corresponding grid unit. The inbound container conveyor 70 of the item transfer station 68 is arranged between the bottom of the exit column 10 and the lifting device 74, so that the container unit 50 dropped by the robot 31 at the exit column 10 can be transported to the lifting device 74 via the inbound container conveyor 70. Similarly, the outbound container conveyor 72 of the item transfer station 68 is arranged between the bottom of the entrance column 9 and the lifting device 74, so that the container unit 50 leaving the lifting device 74 can be directly transported to the entrance column. Once the container unit 50 is located at the bottom of the entrance column, it can be picked up by the robot 25 to enter the storage structure 1. As an alternative to using the robot 25 to pick up and put down the container unit 20 through the entire entrance column 9 and through the exit column 10, the entrance column 9 and the exit column 10 can each include a container elevator for raising and lowering the container unit 50 within the entrance column 9 and the exit column 10. The container elevator may lower the container unit 50 at least partially down the exit column 10 to the inbound container conveyor 70 , and lift the container unit 50 at least partially up the entry column 9 from the outbound container conveyor 72 .

[0145] The storage and retrieval system may further include a central control system configured to direct the movement of the robot 31 and the container unit 50 within the storage and retrieval system and to track the contents of each container unit 50. Each container unit 50, product sub-container 97, and delivery sub-container 98 may have a unique identifier (e.g., a barcode or RFID tag), and the product 96 may be classified into a stock keeping unit (SKU) having a unique identifier (e.g., a barcode or RFID tag). By scanning the identifiers of the items and container units 50 as they enter and leave the storage and retrieval system, and by tracking (e.g., in a database) where the container units 50 and items are transported, the control system may guide a specific container unit 50 to a specific item transfer station 68 to perform a specific item transfer operation. In addition, for a multifunctional item transfer station 68 that uses a plurality of lift positions 66 to transfer multiple types of items, the control system may guide the lifting device 74 to lift the insert to a specific lift position 66 and activate a specific item moving device 78 based on the existing contents or expected contents of the container unit 50.

[0146] The present invention is not limited to the precise forms described above and various modifications and variations will be apparent to those skilled in the art without departing from the scope of the invention as defined in the appended claims.

Claims

1. An item transfer system, comprising: Container unit, comprising: a storage container having an open top; and an insert configured to be nested within the storage container, the insert comprising an insert base and a pair of opposing insert side walls extending upwardly from the insert base to define an insert channel, the insert channel having a pair of end openings opposite to each other in a horizontal direction for allowing items to enter and exit the insert channel in a horizontal direction; and An item transfer station, the item transfer station comprising: a lifting device configured to vertically move the insert from the storage container to a raised position in which the insert base is above the storage container, and to vertically move the insert from the raised position back into the storage container; and An item moving device is configured to move items horizontally onto and / or out of the insert base via the end opening when the insert is in the raised position.

2. The item transfer system according to claim 1, wherein: The item transfer station is configured to engage the insert sidewalls to vertically move the insert into and out of the storage container.

3. The item transfer system according to claim 2, wherein: Each of the insert side walls includes a horizontally extending handle, and the lifting device is configured to engage the handle to move the insert vertically into and out of the storage container.

4. An item transfer system according to claim 3, wherein the handle of the insert extends outward, and the storage container includes a pair of opposing container side walls, each container side wall includes a cutout extending downward from the top surface of the container side wall, and the cutout is configured so that when the insert is nested in the storage container, each handle protrudes into the space defined by each cutout.

5. The item transfer system according to any one of claims 1 to 3, wherein: The storage container includes a container sidewall arranged to define two opposing side openings, and at least a portion of each insert sidewall is configured to occupy a corresponding side opening such that the insert sidewall and the container sidewall form a substantially contiguous structure.

6. The item transfer station according to claim 5, wherein: The insert sidewalls are configured to vertically interlock with the container sidewalls when the insert is nested within the storage container.

7. An item transfer system according to any one of the preceding claims, wherein: The item moving device includes one or more pushing members, which are configured to move in a direction parallel to a longitudinal axis extending through the end openings of the insert channel to push the item horizontally onto and / or away from the insert base via one of the end openings.

8. An item transfer system according to any one of the preceding claims, wherein: The item moving device includes a first pushing member and a second pushing member, the first pushing member and the second pushing member are spaced apart from the first pushing member in a direction parallel to the longitudinal axis of the insert channel, and the first pushing member and the second pushing member are configured to move in a direction parallel to the longitudinal axis of the insert channel to substantially simultaneously push the first item horizontally onto the insert base and push the second item horizontally away from the insert base.

9. An item transfer system according to any one of the preceding claims, wherein: The item transfer station further includes an inbound item conveyor associated with the raised position of the insert, the inbound item conveyor being configured to transport items to the lifting device, and wherein the item moving device is configured to move items horizontally away from the inbound item conveyor so that when the insert is in the raised position, the item is received onto the insert base via one of the end openings.

10. The item transfer system according to claim 9 further comprises a central inbound item conveyor and a plurality of item transfer stations, each item transfer station comprising an inbound item conveyor, wherein the inbound item conveyors in the plurality of item transfer stations are configured to transfer items from the central inbound item conveyor to the lifting device of its corresponding item transfer station.

11. An item transfer system according to any one of the preceding claims, wherein: The item transfer station further includes an outbound item conveyor associated with the raised position of the insert, the outbound item conveyor being configured to transfer items away from the lifting device, and wherein the item moving device is configured to move items horizontally away from the insert base so that when the insert is in the raised position, the item is received on the outbound item conveyor via one of the end openings.

12. The item transfer system according to claim 11 further comprises a central outbound item conveyor and a plurality of item transfer stations, each item transfer station comprising an outbound item conveyor, wherein the outbound item conveyors of the plurality of item transfer stations are configured to transfer items from the lifting devices of their corresponding item transfer stations to the central outbound item conveyor.

13. An item transfer system according to any one of the preceding claims, wherein: The item transfer station further includes an alignment mechanism configured to centrally align items about a longitudinal axis extending centrally through the end opening of the insert passageway.

14. An item transfer system according to any one of the preceding claims, wherein: The lifting device is configured to vertically move the insert between the storage container and a plurality of elevated positions, and the item transfer station includes one or more item moving devices, which are configured to move items horizontally onto and / or away from the insert base via the end opening at each elevated position.

15. An item transfer system according to claim 14, wherein each elevated position has an associated inbound item conveyor configured to transport items to the lifting device and / or an associated outbound item conveyor configured to transport items away from the lifting device, and for each elevated position, the one or more item moving devices are configured to move items horizontally away from the associated inbound item conveyor so that the items are received on the insert base via one of the end openings, and / or the one or more item moving devices are configured to move items horizontally away from the insert base so that the items are received on the associated outbound item conveyor via one of the end openings.

16. An item transfer system according to any one of the preceding claims, wherein: The item transfer station further comprises: an inbound container conveyor configured to transport container units to the lifting device; and An outbound container conveyor is configured to transport container units away from the lifting device.

17. A storage and retrieval system, comprising an item transfer system according to any one of the preceding claims, further comprising a storage area, in which a plurality of the container units are arranged in a plurality of vertical stacks, and the storage and retrieval system comprises a transport tool, which is configured to transport container units from the storage area to the item transfer station and / or from the item transfer station to the storage area.

18. The storage and retrieval system of claim 17, wherein the storage area comprises a storage structure, the storage structure comprising a track structure mounted on a frame top, the track structure comprising a first set of tracks and a second set of tracks, the first set of tracks extending in a first direction, the second set of tracks extending in a second direction, the second direction being substantially perpendicular to the first direction to form a grid pattern defining a plurality of grid cells, wherein each stack of container units is arranged below a grid cell; and the storage and retrieval system further comprises one or more load handling devices, each load handling device comprising: a drive assembly configured to move the load handling device horizontally on the track structure; a container holding device configured to releasably hold a container unit from above; and A lifting mechanism is configured to lift and lower the container holding device.

19. The storage and retrieval system of claim 18, wherein: The container holding device includes a gripper, and each storage container includes a feature configured to engage with the gripper to allow the container unit to be lifted by the container holding device.

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