Inventory processing station assembly

Abstract

A connector (116) for connecting to at least three support elements of a three-dimensional modular structure, comprising a single body comprises i) a first connector portion (118) for connecting support elements extending in a first direction, ii) a second connector portion (120) for connecting support elements extending in a second direction, iii) a third connector portion (122) for connecting support elements extending in a third direction, the first, second and third directions being substantially perpendicular to each other, iv) one or more mounting protrusions (150a, b), each of the one or more mounting protrusions (150a, b) having a substantially flat mating surface for mating with a corresponding mounting protrusion of an adjacent connector; wherein each of the first, second and third connection portions (118, 120, 122) comprises a key portion (124) that is contoured for controlling the orientation of the support element in a respective first, second and third direction of the support element.

Description

Technical Field

[0001] The present invention relates to the field of storage and retrieval systems for handling storage containers or storage boxes stacked in a grid frame structure, and more particularly to an inventory handling station component for picking one or more goods or items from a storage and retrieval system including a grid frame structure or supplying one or more goods or items to a storage and retrieval system including a grid frame structure. Background Art

[0002] As is known, storage systems include a three-dimensional storage grid structure in which storage containers / boxes are stacked on top of each other. PCT Publication No. WO2021 / 175872A (Ocado) describes a known storage and fulfillment system in which stacks of boxes or containers are arranged within a grid frame structure. The boxes or containers are accessed by loading handling equipment that operates remotely on tracks located on top of the grid frame structure. Figures 1 to 3 of the accompanying drawings schematically illustrate this type of system.

[0003] As shown in Figures 1 and 2, stackable containers (referred to as boxes or containers 10) are stacked on top of each other to form a stack 12. The stack 12 is arranged in a grid frame structure 14 in a warehousing or manufacturing environment. The grid frame is composed of a plurality of storage columns or grid columns 15. Each grid in the grid frame structure has at least one grid column for storing container stacks. Figure 1 is a schematic perspective view of the grid frame structure 14, and Figure 2 is a top view of the stack 12 of boxes 10 arranged in the frame structure 14. Each box 10 typically holds a plurality of product goods (not shown), and the product goods in the box 10 can be the same or different product types, depending on its application.

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

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

[0006] PCT Patent Publication No. WO2015 / 019055 (Ocado), incorporated herein by reference, describes a known load handling device 30 shown in FIGS. 4 and 5 and including a carrier body 32, wherein each load handling device 30 covers only one grid space of the grid frame structure 14. Here, the load handling device 30 includes a wheel assembly, the wheel assembly including a first set of wheels 34 and a pair of wheels 34 located at the front of the carrier body 32 and a pair of wheels 34 located at the rear of the carrier body 32, for engaging with a first set of rails or tracks to guide the movement of the device in a first direction, and a second set of wheels 36, each set of wheels 36, located on each side of the carrier 32, for engaging with a second set of rails or tracks to guide the movement of the device in a second direction. Each set of wheels is driven to enable the carrier to move along the rails in the X and Y directions, respectively. One or both sets of wheels may be moved vertically to lift each set of wheels off its respective tracks, thereby allowing the vehicle to move in the desired direction.

[0007] The load handling device 30 is equipped with a lifting device or crane mechanism to lift the storage container from above. The crane mechanism includes a winch, a tether or cable 38 wound on a reel or spool (not shown), and a grab device 39. The lifting device or crane mechanism includes a set of lifting tethers 38 (one tether near each of the four corners of the grab device) extending in a vertical direction and connected near or at the four corners of a lifting frame 39 (also called a grab device) for releasable connection to the storage container 10. The grab device 39 is configured to releasably clamp the top of the storage container 10 to lift it from a stack of containers in a storage system of the type shown in Figures 1 and 2.

[0008] The wheels 34, 36 are arranged around the periphery of an inner cavity or recess (referred to as a container receiving recess 40) in the lower portion of the load handling device. The recess is sized to accommodate the container 10 when the container 10 is lifted by the crane mechanism, as shown in Figures 5 (a and b). While in the recess, the container is lifted off the underlying track so that the carrier or load handling device can be moved laterally to a different location. Upon reaching the target location (e.g., another stack, an access point in a storage system, or a conveyor belt), the box or container can be lowered from the container receiving portion and released from the gripping device.

[0009] Therefore, after receiving a customer order, a running loading handling device moving on a track is instructed to pick up a storage box containing the ordered goods from a stack in a grid frame structure and transport the storage box to an inventory handling station, where the goods can then be retrieved from the storage box. When an inventory handling station is used to pick one or more goods, such an inventory handling station is also referred to as a picking station. Typically, the loading handling device transports the storage box or container to a box lifting device integrated into the grid frame structure. The mechanism of the box lifting device lowers the storage box or container to the picking station. At the picking station, the goods are retrieved from the storage box. As taught by GB2524383 (Ocado Innovation Limited), picking can be performed manually or by a robot. After being retrieved from the storage box, the storage box is transported to a second box lifting device and then lifted to the grid level to be retrieved by the loading handling device and transported back to its position in the grid frame structure. The control system and communication system track the position of the storage box and its contents in the grid frame structure. Because the individual containers are stacked in vertical hierarchies, their positions in the grid frame structure or "honeycomb" can be represented using three-dimensional coordinates to represent the location of the load handling equipment or container and the container depth (e.g., the container is at (X, Y, Z), depth W). Similarly, the position in the grid frame structure can be represented in two dimensions to represent the location of the load handling equipment or container and the container depth (e.g., the container is at (X, Y), depth Z). For example, Z=1 represents the topmost layer of the grid, which is the layer immediately below the rail system, Z=2 is the second layer below the rail system, and so on, to the lowest layer of the grid, the bottom layer.

[0010] Likewise, when stocking a storage system with goods or replenishing the inventory of a storage system, goods delivered from suppliers are transported to the stock handling station. Since the supply or dumping of goods is to replenish the inventory in the storage system, the stock handling station is also called the dumping station or supply station. Here, the goods are taken out of their packaging, registered with a unique stock keeping unit of measure or SKU according to the type of goods, and then placed in the storage box at the dumping station. At the dumping station, the storage box is transported to the box lifting equipment and then lifted to the grid level to be retrieved by the load handling equipment and transported to the location within the grid frame structure.

[0011] WO2017 / 211640 (Autostore Technology AS) describes a storage system for storing product goods, the storage system comprising a grid structure, a number of storage boxes configured to be stored in vertical compartments in the grid structure, wherein each storage box is configured to contain at least one product good, wherein the storage system comprises a picking station and / or a supply station; and wherein the storage system comprises a conveyor system, the conveyor system being configured to convey the storage box from a first position to a second position and further to a third position. The conveyor system comprises a first tiltable conveyor configured to convey the storage box from the first position via the second position to the third position. The picking station and / or the supply station are arranged adjacent to the grid structure. The first and third positions are arranged below two different vertical compartments in the grid structure. The tiltable conveyor comprises a hydraulic piston and cylinder mechanism for lowering and raising the conveyor. The tiltable conveyor supports the storage box in an inclined position in the second position, thereby allowing manual picking of goods from the storage box. Once picked, the incline conveyor tilts downward and the storage box is transported to a third location, allowing the storage box to be retrieved by load handling equipment operating on the grid structure.

[0012] WO2018 / 069282 (Autostore Technology AS) describes a picking / supply station assembly for a storage system including a grid structure. The picking / supply station assembly includes a first box lifting device, a second box lifting device, and a picking / supply station, wherein the first box lifting device can be arranged to receive a storage box from at least one carrier at the top level of the grid structure and deliver the storage box to the picking / supply station. The picking / supply station includes a box transport assembly arranged to move the storage box from the first box lifting device to the second box lifting device, and the second box lifting device is arranged to receive the storage box from the box transport assembly and can be arranged to transport the storage box to the top level of the grid structure. The box lifting device is arranged in the storage system to receive the storage box from the carrier or the loading handling device at the top level of the grid structure and transport the box downwardly to the supply / picking station in a vertical direction, wherein the supply / picking station is arranged on the ground floor of the building where the storage system is installed. In use, the first storage box is initially placed on the lifting arm at the top level of the grid and descends toward the first conveyor unit. The space between the lifting arms is wide enough to allow the first conveyor unit to pass between them. During the passage, the first storage box will remain on the first conveyor unit while the lifting arms are brought into their lowest position. The first storage box is then transported out of the first lifting device by the first conveyor unit. After the storage box has left the first box lifting device, the lifting arms can return to the top floor to retrieve the second storage box. Since the first and second box lifting devices are integrated into the grid frame structure, the picking station forms an integral part of the grid frame structure.

[0013] A similar box lifting mechanism integrated into a grid frame structure to supply a picking station is described in WO2020 / 074717 (Autostore Technology AS). WO2020 / 074717 (Autostore Technology AS) describes an access station for picking storage containers, comprising: a picking area, at least one conveyor arranged to transport the storage container from an entry position through the picking area to an exit position, wherein the access station includes: at least one tilting device arranged to tilt the storage container at least in the picking area. As taught in WO2017 / 211640 (Autostore Technology AS), when the access station is to be operated by a picker, the tilting device tilts the storage container in the picking area, thereby creating the ergonomic benefit of the tilt. The storage container is received at the rear side of the access station, and the access station is located at an entry position on the entry conveyor. The entry position is configured to be connected to another conveyor, such as a storage system conveyor that transports the storage container to and from the entry position. Once in the access station, the entry conveyor transports the storage container in the transport direction via the tiltable access conveyor in the picking area at the front of the access station to the exit conveyor. The storage container enters and leaves the grid frame structure through the rear of the access station. The entry position and the exit position can each be connected to a storage system conveyor.

[0014] In a storage grid, most of the grid columns are storage columns, i.e., grid columns where storage containers are stacked and stored. However, the grid usually has at least one grid column that is not used to store storage containers, but at least one grid column includes a position where a container handling carrier can lower and / or pick up a storage container so that the storage container can be transported to a second position (not shown in the prior art figure), where the storage container can be accessed from outside the grid or moved out of or into the grid at the second position. In the art, such a position is usually referred to as a "port", and the grid column where the port is located can be referred to as a "delivery column". The storage grid includes two delivery columns. For example, a first delivery column may include a dedicated lowering port, where a container handling carrier or a loading handling carrier can lower a storage container to be transported through a delivery column and further lower it to an access station or a transfer station, while a second delivery column may include a dedicated lifting port, where a container handling carrier can pick up a storage container that has been transported from an access station or a transfer station through a second delivery column. The storage container is delivered to the access station via the first delivery column and leaves the access station via the second delivery column.

[0015] Since the storage and retrieval system must operate under the environment of system operation, such as the storage capacity of the grid frame structure, the size and layout of the footprint of the storage and retrieval system, no storage and retrieval system is the same. Therefore, any peripheral unit used to dump goods into or retrieve goods from the storage container is often a custom structure. This includes the shape and arrangement of the components of the inventory handling station, such as the conveyor system, frame structure, etc. of the inventory handling station. Since the main function of the inventory handling station is to transport the storage container dropped from the drop port of the grid frame structure to the access station or transfer station (where the goods can be picked from the storage container), one of the main components in the inventory handling station that needs to be configured according to the layout of the storage container is the conveyor system. According to the transportation direction of the storage container (generally at the same level), the conveyor system usually includes multiple adjacent conveyor units to provide a continuous conveying surface from the drop / pickup port to the access station, where the goods can be picked or dumped from the storage container. One or more of the multiple conveyor units can be placed in a directional manner to provide different transportation directions for the storage container. Examples of different orientations of the conveyor unit include different transport directions of the storage containers, and different orientations in which the storage containers are conveyed by the leading edge of the conveyor unit along their longest edge or narrow edge, also referred to as WEL (wide edge leading) or NEL (narrow edge leading) orientations.

[0016] In addition to the different orientations or directions of transport of the conveyor system, there are several different configurations of conveyor units, including belt conveyor units, pulley conveyor units, and roller conveyor units. In all of these different conveyor units, side walls are provided on both sides of the conveyor system, which define what is referred to in this application as a "conveyance channel". The side walls reduce the possibility of cargo falling off the sides of the conveyor system. The side walls achieve this by acting as a barrier - by acting as a barrier, preventing the cargo from moving laterally to the outside of the conveyance channel relative to the longitudinal axis of the conveyor system (along which the cargo is intended to be transported). The side walls of the conveyor unit are typically composed of several side guards positioned adjacent to each other. Typically, the side guards are made of metal sheets, and there is usually a small gap between adjacent conveyor units where the side guards meet each other.

[0017] Since the distance between the drop-off or pick-up port and the access or dump station can extend across multiple grid cells, the goods or storage containers transported across the conveyor system must not be damaged or deflected by any obstructions, especially from the side walls of adjacent conveyor units. In other words, there is a continuous conveying path between the multiple adjacent conveyor units from the drop-off / pick-up port to the access station, and the storage containers are transported on the conveyor system with little obstruction, turning or deflection. In order to ensure a continuous conveying path, the adjacent conveyor units must be aligned to prevent the storage containers from deviating from their intended path along the conveyor system. Therefore, the multiple adjacent conveyor units are mounted on a customized frame structure or support platform that spans the multiple conveyor units to minimize any misalignment and provide a continuous conveying path. In some cases, one or more of the conveyor units need to be adjusted to ensure alignment between adjacent conveyor units. Even if attempts have been made to ensure alignment of the conveyor units, there may still be problems with storage containers being caught by the side walls of one or more of the conveyor units. To alleviate this problem, conveyor units of varying lengths are sometimes used, with the longest conveyor unit being used to transport storage containers along the longest side of the inventory handling station (usually from the pick-up port / drop-off port to the access station). As a result, the inventory handling stations are not identical and are often custom structures with conveyor units of varying lengths, which adds significant cost and complexity to the design and assembly of the inventory handling station. Summary of the invention

[0018] The present invention has alleviated the above-mentioned problems by modularizing the inventory handling station so that different layouts and shapes of inventory handling stations can be constructed from a single type of module without having to have custom structures to match the available footprint of the storage and retrieval system. In order to construct a single type of module, it is critical that adjacent modules can be assembled together with little or no adjustment to the alignment of the modules so that the conveyor units mounted to the modules are aligned to provide a continuous conveyor channel. In order to provide a single type of module that can be assembled together, the present invention provides a connector for connecting to at least three support elements of a three-dimensional modular structure, the connector comprising a single body comprising: i) a first connector part for connecting to a support element extending in a first direction, ii) a second connector portion for connecting to a support element extending in a second direction, iii) a third connector portion for connecting the support element extending along a third direction, the first, second and third directions being substantially perpendicular to each other, iv) one or more mounting protrusions, each of the one or more mounting protrusions having a substantially planar mating surface for mating with a corresponding mounting protrusion of an adjacent connector; Each of the first, second and third connecting portions comprises a key portion, the key portion being milled with a contour for controlling the orientation of the support element in the respective first, second and third directions of the support element.

[0019] In order to ensure that adjacent modules can be assembled together, the shape of the modular structures in the assembly must be substantially regular, that is to say substantially equal in shape and / or size of the modular structures. Typically, the modular structure is in the shape of a cube, so that a plurality of cube-shaped modules can be assembled together in any form, creating inventory handling stations of different arrangements. The cube shape of the modular structure is mainly controlled by the orientation of the support elements (also known as "struts") extending from the corners of the modular structure, and by the ability to replicate a given cube-shaped modular structure in a plurality of modular structures in the assembly. If any of the modular structures is irregular, this will be reflected in the connections between adjacent modular structures in the assembly. As for the regular cube shape, at the corners of the structure, the angles between the support elements must be substantially 90°, i.e. the support elements extend in three dimensions along Cartesian coordinates. In order to control the orientation of support elements in a modular structure, the present invention provides a connector, which includes a first, a second and a third connector part for connecting support elements along a first, a second and a third direction, respectively, the first, the second and the third directions being perpendicular to each other, that is, along the x, y and z axes in a three-dimensional Cartesian system; wherein each of the first, the second and the third connecting parts includes a key portion, the key portion is milled with a profile for controlling the orientation of the support element in the first, the second and the third directions of the support element. The profile of the key portion provides an indication of whether the support element is correctly oriented. If any of the support elements is not correctly oriented, this will be reflected at the connection between the key portion and the support element, because the profile of the key portion will hinder the connection with the support element. Since the connector constitutes the corner of the cubic structure, the connector acts as a corner piece of the modular structure.

[0020] In one embodiment of controlling the orientation of the support element, the profile of the key portion includes at least two opposing straight edges to prevent the support element from rotating about an axis, wherein the axis extends through the key portion, and each of the at least two opposing straight edges defines a load-bearing surface. Optionally, the profile of the key portion is substantially quadrilateral. In order to ensure that the support elements are substantially perpendicular to each other, preferably, the keys of the first and second connector parts are located in the same plane and are oriented so that lines extending along the midpoints of the keys of the first and second connector parts intersect at substantially 90°, and wherein the key portion of the third connector part is located in a plane perpendicular to the plane of the keys of the first and second connector parts, so that the connector has a symmetry line extending through the key portion of the third connector part. More specifically, the key portion of the first connector part is a mirror image of the key portion of the second connector part relative to the symmetry line of the key portion extending through the third connector part.

[0021] In order to enable the key to provide a load bearing surface, preferably the key comprises a raised projection. In order to accommodate the support element, the raised projection comprises a substantially flat mating surface. Preferably, the raised projection comprises a hole, such as a threaded hole, to enable connection with the support element. In order to enable connectors from adjacent modular structures to abut each other when assembled together, preferably the connector further comprises one or more mounting projections, the one or more mounting projections having a substantially flat mating surface for mating with corresponding one or more mounting projections in one or more adjacent connectors. Preferably, the one or more mounting projections comprise a first mounting projection located in a first mounting projection plane, and a second mounting projection located in a second mounting projection plane, the first mounting projection plane being substantially perpendicular to the second mounting projection plane, such that a line extending through the first mounting projection is substantially perpendicular to a line extending through the second mounting projection. In the connector, the first mounting projection and the second mounting projection are located in substantially perpendicular planes, and having such a connector increases the flexibility of connecting multiple modular structures from different sides of the modular structure. In order to couple adjacent modular structures together in the assembly, one or more mounting protrusions include a first hole and a second hole, the first hole is a threaded hole, and the second hole is a non-threaded hole. In order to space adjacent modular structures in the assembly, especially when a plurality of modular structures are stacked, the connector further includes a spacer for spacing adjacent connectors. Alternatively, the key portion includes a groove.

[0022] The present invention provides a modular structure comprising a plurality of vertically spaced modular sections, each of the plurality of modular sections comprising four connectors according to the present invention, each of the four connectors in a single modular section being connected to two other connectors by horizontal support elements to form a substantially rectangular frame, and wherein each of the four connectors of vertically adjacent modular sections are connected together by substantially vertical support elements to form a frame structure, and wherein the distal end of each of the horizontal and vertical support elements comprises an opening having a profile, and the profile is complementary to the profile of a key portion of the connector, so that the orientation of the horizontal and vertical support elements is controlled by the profile of the key portion. Alternatively, if the key portion comprises a groove, the distal end of each of the horizontal and vertical support elements comprises a raised protrusion having a profile, and the profile is complementary to the profile of the key portion of the connector.

[0023] One or more of the plurality of vertically spaced modular sections provide a support platform for mounting various components. Where the modular structure forms part of an inventory handling station, one or more of the plurality of vertically spaced modular sections provide a platform for mounting a conveyor unit. To improve the structural integrity of the modular structure, particularly under torsional forces, preferably the connection between the horizontal support elements and the vertical support elements further comprises angle brackets.

[0024] The present invention provides an assembly comprising a plurality of modular structures according to the present invention, wherein adjacent modular structures in the assembly are connected together by one or more mounting protrusions of the respective mounting protrusions of the modular structures. Since the connector of the present invention is capable of controlling the orientation of the supporting elements in a substantially vertical direction, the modular structure finally formed has a substantially cubic shape, which allows the assembly to be composed of a regular cubic structure, i.e., the modular structure represents a building block or cell of the assembly. One or more mounting protrusions of the connector enable the modular structure to be connected to any side of the cubic structure. Since the connectors can be connected to each other, modular structures of different arrangements can be assembled together. Optionally, a plurality of modular structures can be arranged in a stacked arrangement. Alternatively or in addition to arranging a plurality of modular structures in a stacked arrangement, a plurality of modular structures can be arranged side by side.

[0025] One embodiment using a connector according to the present invention provides an inventory handling station for use with a storage and retrieval system, the storage and retrieval system including a grid frame structure including: a plurality of upright posts, the plurality of upright posts being located in one or more vertical planes and arranged to form a plurality of grid posts for stacking one or more containers between the plurality of upright posts in a vertical direction and guided by the plurality of upright posts, the plurality of upright posts being interconnected at their top ends by a first set of grid members extending in a first direction and a second set of grid members extending in a second direction, the second set of grid members running transversely to the first set of grid members in a substantially horizontal plane to form a grid comprising a plurality of grid cells or grid spaces; The first and second groups of grid members support first and second groups of tracks, respectively, at an upper level of the grid frame structure so that the load handling equipment can move one or more storage containers on the grid frame structure. In which, the inventory processing station component includes a component of a modular structure according to the present invention, and the component of the modular structure is arranged to support a conveying system including a plurality of conveying units, each of the plurality of conveying units being mounted on respective modular parts of adjacent modular structures to form a continuous conveyor.

[0026] A benefit of ensuring that adjacent modular structures are aligned is that multiple conveyor units supported by the components are aligned, thereby providing a continuous conveying system. Optionally, the components of the modular structure are arranged to support: a port station for receiving storage containers that are lowered through the grid cells and picked up; an access station to enable access to one or more storage containers lowered from the port station, and Therein, the conveying system is arranged for conveying storage containers between a port station and an access station.

[0027] The ability to stack a plurality of modular structures allows the plurality of modular structures to be assembled and form a vertical chute that can be configured to cooperate with at least one upright column, the at least one vertical chute having a first opening for receiving a storage container lowered through a grid unit by at least one loading handling device, and a second opening for allowing the container to leave the port station.

[0028] Optionally, the vertical chute includes a box lifting device, which is configured to lift the storage container upward toward the grid structure so that when in use, the storage container can be retrieved by at least one loading and handling device. Optionally, the port station includes a supply area for receiving storage containers lowered through the grid unit, and a picking area for picking up storage containers through the grid unit. Optionally, the plurality of conveyor units include an entrance conveyor unit configured in the supply area, an access conveyor unit arranged in the access station, and an exit conveyor unit arranged in the picking area. Optionally, the entrance conveyor unit, the exit conveyor unit and the access conveyor unit are arranged to transport the storage container along the first, second and third transport directions respectively, and wherein the first transport direction of the entrance conveyor unit is opposite and parallel to the second transport direction of the exit conveyor unit, and the third transport direction of the access conveyor unit is orthogonal to the first transport direction of the entrance conveyor unit and the second transport direction of the exit conveyor unit. Optionally, the inlet conveyor unit, the outlet conveyor unit and the access conveyor unit are arranged to transport the storage container along a first, a second and a third transport direction, respectively, and wherein the conveyor system is arranged so that the first transport direction of the inlet conveyor unit is orthogonal to the second transport direction of the outlet conveyor unit and the third transport direction of at least one access conveyor unit. Optionally, the port station and / or the access station comprises a load sensor.

[0029] The present invention further provides a fulfillment / dumping system comprising: i) Storage and retrieval system. The storage and retrieval system includes a grid frame structure. The grid frame structure includes: a plurality of upright posts, the plurality of upright posts being located in one or more vertical planes and arranged to form a plurality of grid posts for stacking one or more containers between the plurality of upright posts in a vertical direction and guided by the plurality of upright posts, the plurality of upright posts being interconnected at their top ends by a first set of grid members extending in a first direction and a second set of grid members extending in a second direction, the second set of grid members running transversely to the first set of grid members in a substantially horizontal plane to form a grid comprising a plurality of grid cells or grid spaces; First and second sets of grid members support first and second sets of tracks, respectively, at an upper level of the grid frame structure for use by a robotic load handling device to move one or more storage containers on the grid frame structure, ii) one or more load handling devices, the one or more load handling devices being remotely operated to move one or more containers stored in the grid frame structure, each of the one or more load handling devices comprising: i) a wheel assembly, the wheel assembly being used to guide the load handling equipment on the grid structure; ii) a container receiving space, the container receiving space being located above the grid structure; and iii) a lifting device, the lifting device being arranged to lift a single container from the stack into the container receiving space, iii) A stock handling station according to the present invention, configured to receive one or more storage containers from a storage and retrieval system. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Further features and aspects of the present invention will become apparent from the following detailed description of illustrative embodiments with reference to the accompanying drawings, in which: FIG1 is a schematic diagram of a grid framework structure according to a known system; FIG2 is a schematic diagram showing a top view of a stack of boxes arranged within the frame structure of FIG1 ; FIG3 is a schematic diagram of a system of known load handling equipment operating on a grid frame structure; FIG4 is a schematic perspective view of a loading and handling device showing a lifting device for gripping a container from above; 5( a ) and 5 ( b ) are schematic perspective cross-sectional views of the load handling apparatus of FIG. 4 , showing (a) a container accommodated in a container receiving space of the load handling apparatus and (b) the container receiving space of the load handling apparatus; Figure 6 is a top plan view of a fulfillment center including a mezzanine to accommodate inventory handling station components according to an embodiment of the present invention; Figure 7 is a perspective front view of an inventory handling station assembly according to a specific embodiment of the present invention; Figure 8 is a top plan view of a conveyor system according to a specific embodiment of the present invention; Fig. 9 is a top plan view of a conveyor system according to another specific embodiment of the present invention; Fig.10 is an exploded view of a modular structure according to the present invention; Fig.11 yes Fig.10 an exploded view of a corner section of the modular structure shown; Fig.12 is a perspective view of a corner piece according to the present invention; Fig.13 is a top plan view of a corner piece showing the orientation of a raised projection for controlling the orientation of a support element; Fig.14 yes Fig.10 A perspective view of components of the modular structure of the support conveyor system shown, wherein the components are arranged in an L-shape; Fig.15 is a top plan view of a corner piece showing the orientation of mounting projections for coupling with an adjacent corner piece; Fig.16 is a perspective view of juxtaposed corner pieces showing the mating of corresponding mounting projections; Fig.17 yes Fig.14 a side view of the assembly shown; Fig.18 yes Fig.14 a top plan view of the components of the illustrated modular structure; Fig.19 are perspective views of different arrangements of modular structures according to the present invention, wherein stacking of the modular structures is shown; Fig. 20 is a perspective view of the cooperation of stacked corner pieces according to the present invention; Fig.21 is a perspective view of the components of the modular structure with cladding; Fig. 22 yes Fig.21 A perspective view of an embodiment of a panel for cladding a modular structure is shown. DETAILED DESCRIPTION

[0031] The present invention is designed with respect to known features of storage systems, such as the grid frame structure and load handling equipment described above with reference to Figures 1 to 5. In a typical fulfillment center, various goods (such as grocery goods) are stored in storage boxes or containers, and the storage boxes or containers are stored in one or more stacks in the grid frame structure, more specifically, in one or more stacks within a grid column. The grid column is composed of a plurality of upright columns or vertical columns arranged as vertical storage positions. Individual containers can be stacked in vertical levels, and their positions in the grid frame structure or "honeycomb" can be represented using three-dimensional coordinates to represent the position of the load handling equipment or container and the depth of the container (e.g., the container is at (X, Y, Z), depth W). Likewise, locations in a grid frame structure may be represented in two dimensions to represent the location of loading handling equipment or containers and the depth of the containers (e.g., the container is at (X, Y), depth Z). For example, Z=1 represents the topmost level of the grid frame structure, i.e., the level immediately below the track or rail system, Z=2 is the second level below the rail system, and so on, to the lowest level, bottom level, of the grid frame structure. Most grid columns in a grid frame structure are storage columns.

[0032] A typical order fulfillment system includes a box or container filling station, a storage and retrieval system, a plurality of order picking stations, an order container handling and sorting system, and a shipping facility. PCT / IB2014 / 062165 (Ocado Innovation Limited) describes the details of the order fulfillment system, the specific contents of which are incorporated by reference into this application. In an order fulfillment system such as that described in PCT / IB2014 / 062165 (Ocado Innovation Limited), individual containers are stored in a storage and retrieval system and may contain one or more goods, and one or more goods may be the same. The storage and retrieval system includes a grid frame structure in which storage boxes or containers are stored in grid columns.

[0033] In order to pick orders including different goods, it is usually necessary to retrieve goods from multiple storage containers. Such containers can be retrieved from the storage and retrieval system and brought to the desired order picking system. The specific container required to fulfill the order is accessed by a robotic loading handling device operating on a grid frame structure. The robotic loading handling device preferably includes a control unit that receives control signals from a radio communication unit of a control system or a central control system, and the control signals are related to information about the location of picking and delivering storage boxes or containers in the grid frame structure. The control system controls the operation of one or more loading handling devices running on the grid frame structure and includes one or more processors, memory (read-only memory and random access memory) and a communication bus. The memory can be any storage device known in the art, including but not limited to RAM, computer-readable media, magnetic storage media, optical storage media, or other electronic storage media that can be used to store data and accessed by one or more processors.

[0034] At least one grid column of the grid frame structure is not used for storage containers and typically includes a location where load handling equipment can drop storage containers or boxes to a picking station outside the grid frame structure and / or pick up storage containers or boxes from a supply station outside the grid frame structure. In the art, such locations are generally referred to as "ports" and correspond to the grid cells where storage boxes or containers are dropped or picked up. Depending on whether the port location is used to drop off or pick up storage containers, the grid column where the port is located may be referred to as a "delivery column" located at the drop port and a "retrieval column" located at the pick port. Separate areas are set up adjacent to the grid frame structures to accommodate various stations, including picking / dumping stations, such as service stations, charging stations, etc. Typically, the separate areas are set up by incorporating mezzanines supported by vertical beams between adjacent grid frame structures, such as Figure 6 The mezzanine 104 provides a tunnel to accommodate, for example, a picking station and / or any of the above-mentioned stations. Figure 6A grid frame structure 14 is shown on either side of a tunnel 102 formed by a mezzanine 104, which is suitable for accommodating an inventory handling station assembly of the present invention. A grid or grid structure 22 from an adjacent grid frame structure extends through the top of the mezzanine 104 to connect to the grid 22 on either side of the mezzanine 104. For purposes of the present invention, a picking / replenishment station may be referred to as an inventory handling station assembly, and the inventory handling station assembly has an access station that can be used as a picking station and / or a replenishment station. One or more storage boxes or containers 10 are stacked in a grid column 15a (first grid column) on either side of the tunnel 102 formed by the mezzanine 104. The height of the grid column will vary depending on the number of storage boxes or containers stacked in the grid column. The inventory handling station assembly is located below the grid columns 15b, 15c (second grid columns) extending through the top of the mezzanine so that one or more of the grid columns 15b, 15c on the mezzanine 104 represents a drop port column and a pick port column (see Figure 7 ).

[0035] The inventory handling station components cooperate with the storage and retrieval system to provide a fulfillment system 100 for fulfilling one or more orders. Figure 7 The exemplary inventory handling station 60 shown includes one or more chutes 62 forming a supply area 64, an access station 66, and one or more bin lift devices 68 forming a buffer area 70. As the name implies, the one or more chutes 62 allow a robotic load handling device operating on the grid frame structure 14b to lower a storage bin or container without any assistance from the one or more chutes 62. This may be by gravity allowing the storage bin or container to descend along the chutes 62 under the weight of the storage bin or container and / or by a lifting or winching mechanism of the load handling device.

[0036] Depending on whether the access station 66 is used as a picking station or a replenishment station, one or more goods are picked from one or more storage boxes or containers in the access station 66, or one or more goods are loaded into one or more storage boxes or containers in the access station 66. One or more chutes 62 and one or more box lifting devices 68 are arranged to cooperate with the grid frame structure 14b above. The grid frame structure 14b includes a plurality of upright columns, which are located in one or more vertical planes and are arranged to form a plurality of vertical positions or vertical grid columns 15 so that the container is guided in a vertical direction by the plurality of upright columns. The plurality of vertical grid columns extend through the one or more chutes 62 and one or more box lifting devices 68 of the inventory handling station assembly 60 (see Figure 7). A plurality of upright columns are interconnected at their top ends by a first group of grid members extending in a first direction and a second group of grid members extending in a second direction, the second group of grid members running transversely to the first group of grid members in a substantially horizontal plane to form a grid comprising a plurality of grid cells or grid spaces. The size of the plurality of grid cells is designed to allow storage boxes to enter or leave the grid cells. The plurality of grid cells include a drop port and a pick-up port arranged to cooperate with one or more chutes 62 and one or more box lifting devices 68, respectively. More specifically, the grid columns where the drop port (delivery column 15b) and the pick-up port (retrieval column 15c) are located are arranged to cooperate with one or more chutes 62 and one or more box lifting devices 68 of the inventory processing station assembly 60, respectively.

[0037] The inventory handling station assembly of the present invention may be arranged as a freestanding frame that divides the inventory handling station assembly into a supply area 64, a buffer area 70, and an access station 66. One or more chutes 62 of the supply area 64 include at least two vertical guides that can be received in a grid column 15b of the grid frame structure and are arranged to guide storage boxes or containers down the grid column 15b through a drop port into the supply area 64. By definition, the grid column in the grid where the drop port is located is referred to as a delivery column 15b. Similarly, the grid column in the grid where the pick-up port is located is referred to as a retrieval column 15c.

[0038] The conveyor system 76 transports storage boxes or containers from the supply area 64 to the access station 66 and then to the buffer 70 where they are accumulated vertically for retrieval by a load handling device operating on the grid frame structure 14b and returned to their original destination in the grid frame structure or to a new destination in the grid frame structure. In a particular embodiment of the present invention, the conveyor system 76 includes a plurality of conveyor units, namely an inlet conveyor unit 78, at least one access conveyor unit 80, and an outlet conveyor unit 82, and is arranged to transport storage boxes or containers from the supply area 64 to the buffer 70 via the access station 66. The storage boxes or containers are paused at the access station 66, which serves as a picking station or replenishment station. The plurality of conveyor units are arranged adjacent to or connected to each other so as to transport the storage boxes from one conveyor unit to an adjacent conveyor unit as the storage boxes travel along the conveyor system 76.

[0039] The inlet conveyor unit 78 is arranged in the supply area 64, more specifically, in front of each chute of one or more chute 62. Figure 7As shown, the inlet conveyor unit 78, at least one access conveyor unit 80, and the outlet conveyor unit 82 are on the same level. Similarly, the outlet conveyor unit 82 is arranged in the buffer zone 70. Each conveyor unit may include any suitable belt, chain (one or more) and / or roller arrangement well known in the art of conveyor systems. Figure 7 In the particular embodiment of the invention shown, the inlet conveyor unit 78, the at least one access conveyor unit 80, and the outlet conveyor unit 82 include a plurality of roller conveyors for transporting storage boxes or containers along a path on the conveyor system 76. Figure 7 As shown, the conveyor system 76 is mounted on a roller frame. The inlet conveyor unit 78 and the outlet conveyor unit 82 are arranged to accommodate a single storage container on top. Figure 7 As shown, the access station 66 includes a work surface 86 above the at least one access conveyor unit 80 and having an opening 88 that enables an operator to access storage boxes or containers on the at least one access conveyor unit 80 below. The path or transport direction of the inlet conveyor unit 78 can be parallel or opposite to the path or transport direction of the outlet conveyor unit 82, so that the path or transport direction of the at least one access conveyor unit 80 is perpendicular or orthogonal to the path or transport direction of both the inlet conveyor unit 78 and the outlet conveyor unit 82 (e.g., Figure 8 In other words, Figure 8 As shown, the storage boxes or containers travel along the conveyor system 76 in a U-shaped path, i.e., the storage boxes change direction twice along the conveyor system. At least one access conveyor unit 80 extends between the entrance conveyor unit 78 and the exit conveyor unit 82, and may include a plurality of conveyor units, which are arranged adjacent to each other in a horizontal plane so as to transport the storage boxes or containers from one conveyor unit to an adjacent conveyor unit along the access conveyor unit 80. Typically, one or more of the rollers of at least one access conveyor unit 80 and optionally also the entrance conveyor unit 78 and / or the exit conveyor unit 82 include an integrated drive motor (not shown), while the remaining rollers may be connected to the drive rollers by belts (not shown), or the remaining rollers may be passive. The shaded area 90 of the at least one access conveyor unit 80 is arranged as shown. Figure 7 The working surface 86 is shown below the opening 88. Optionally and as Fig. 9As shown, the path or transport direction of the exit conveyor unit 82 extends longitudinally in the same transport direction as the at least one access conveyor unit 80, i.e., the exit conveyor unit 82 is an extension of the at least one access conveyor unit 80. Here, the path or transport direction of the entry conveyor unit 78 is perpendicular or orthogonal to the paths or transport directions of both the at least one access conveyor unit 80 and the exit conveyor unit 82, so that the storage boxes or containers travel along the conveyor system 76 in an L-shaped path, i.e., the storage boxes or containers change direction once when they travel from the supply area to the buffer area.

[0040] Figure 8 is an embodiment in which the leading edge of the storage container is the narrow end (NEL) of the storage container when the storage container is transported from the entrance conveyor unit to at least one access conveyor unit 80. Optionally, the conveyor system can be arranged so that the path or transportation direction of the storage box can be a U-shaped path and an L-shaped path along the conveyor system 76. The combination of the U-shaped path and the L-shaped path allows multiple storage boxes or containers to be queued in the buffer 70 and then lifted toward the grid for subsequent retrieval by loading handling equipment operating on tracks or rails on the grid. Compared to the solutions of the prior art, this allows multiple storage boxes or containers to be processed through the access station 66. Compared to the solutions of the prior art, the combination of the U-shaped path and the L-shaped path enables an inventory handling station component for processing multiple storage boxes or containers at the access station 66 and having a relatively narrow width.

[0041] The additional conveyor unit 84 is positioned adjacent to the inlet conveyor unit 78 and / or the outlet conveyor unit 82 (see Figure 8 and 9 ) is integrated into at least one access conveyor unit 80. In a particular embodiment of the invention, the additional conveyor unit or reversing conveyor unit 84 comprises one or more rollers or belts or chains, which are arranged transversely between the rollers of the at least one access conveyor unit or are staggered between the rollers of the at least one access conveyor unit and are arranged to be driven transversely to the transport direction of the at least one access conveyor unit (see Figure 8 and 9 The additional conveyor unit or reversing conveyor unit 84 is lowered or raised relative to the rollers of the at least one access conveyor unit 80 by a lifting mechanism (not shown) so that in the raised position, the reversing conveyor unit 84 is in contact with the storage box so that the reversing conveyor unit 84 drags or pulls the storage box from the entry conveyor unit 78 to the at least one access conveyor unit 80. This is done by Figure 8 and Fig. 9 The arrow in shows.

[0042] The operator can pick the desired goods (one or more) from the storage bin in the access station 66 or supply the desired goods (one or more) to the storage bin in the access station 66, depending on whether the access station 66 is used as a picking station or a replenishment station. The access station can optionally include a load cell for measuring the weight of the goods in the access station. In the case where the at least one access conveyor unit 80 includes a plurality of conveyor units, the access conveyor unit 90 (received by the access conveyor unit 90) arranged below the opening 88 in the working surface 86 Figure 8 and 9 The access station 66 (shown as light shading in FIG. 1 ) may be mounted on a weighing cell, or alternatively, the weighing cell may be positioned anywhere along at least one access conveyor unit 80. The weighing cell is arranged below at least one access conveyor unit 80 to weigh the storage boxes in the access station 66. The weighing cell may be a load cell, or any other weighing cell known in the art. A control panel (not shown) in front of the access station 66 displays the weight of the storage box when goods are picked from or loaded into the storage box. For example, when operating as a picking station, the weighing cell measures the weight of the storage box or container when one or more items are picked from the storage box. The storage control and communication system is used to monitor the inventory or stock of specific goods by recording the weight of the storage box when the goods are picked in the storage box. This enables the storage control and communication system to track the contents of each storage box or container stored within the grid frame structure. When the contents of a particular storage bin or container having a particular attribute or SKU are low, as measured by the load cell and recorded by the storage control and communication system, a notification is sent to an operator (eg, via a control panel) to restock the storage bin.

[0043] In order to prevent one or more storage boxes or containers from being blocked at the access station 66, the buffer zone 70 includes one or more box lifting devices 68 to allow one or more storage boxes to be vertically accumulated in the buffer zone 70. The box lifting device 68 includes a lifting arm and a lifting mechanism. In a specific embodiment of the present invention, the box lifting device 68 includes a pair of or two lifting arms 92. When the lifting arm 92 descends through the outlet conveyor unit 82, the space between the lifting arms 92 is wide enough to allow the outlet conveyor unit 82 to pass between the lifting arms 92. In use, the lifting arm 92 descends to the lowest level below the outlet conveyor unit 82 so that the lifting arm 92 can engage with the bottom wall of the storage box on the outlet conveyor unit. The storage box or container is lifted from the lowest position on the outlet conveyor unit 82 toward the grid frame structure 14b to the highest position so that the storage box is vertically spaced apart from the outlet conveyor unit 82. This enables a second storage box or container to enter the outlet conveyor unit 82 and vertically accumulate below the storage box or container above it. The storage box at the uppermost position remains waiting until the loading handling equipment operating on the grid at the upper level is able to retrieve the storage box or container through the pick-up port via the retrieval column 15c. More specifically, the gripping equipment of the loading handling equipment is able to grab the storage box or container at the uppermost level and lift the storage box or container into the container receiving space of the loading handling equipment. The sensor detects the retrieval of the storage box at the uppermost level and sends a signal to the control system or controller to lower the lifting arm 92 to below the second storage box or container resting on the exit conveyor unit 82, and then be lifted to the uppermost level, thereby allowing the third storage box or container queued in the buffer area to enter the buffer area 70 via the exit conveyor unit 82. The whole process is repeated as the storage boxes or containers enter the buffer area 70.

[0044] The box lift 68 may include multiple pairs of lifting arms 92 spaced vertically apart to allow multiple storage boxes to be accumulated vertically at different heights of the buffer zone 70. For example, a first pair of lifting arms may be arranged to lift a first storage box to a first height, a second pair of lifting arms may be arranged to lift a second storage box to a second height, and so on. This enables multiple storage boxes to be accumulated vertically at different heights of the buffer zone 70. In addition, one or more box lifts 68 may be arranged adjacent to each other. In order to save space and reduce the footprint of the inventory handling station assembly 60, a first box lift may be arranged at the end of at least one access conveyor unit 80 so that the storage box or container can be transported to the first box lift along the same path of the access conveyor unit 80. If the first box lift is fully occupied, the storage box may be instructed to change direction to enter the adjacent second box lift, for example, in a direction perpendicular to the transport direction of the at least one access conveyor unit. This can be achieved by controlling a reversing conveyor unit 84 adjacent to the buffer zone 70 to transport the storage box to the second box lift. Here, the control system or a separate controller monitors the occupancy of the first box lift and the second box lift, and decides whether to transport the storage box to the first box lift or the second box lift based on their occupancy. The occupancy of the box lift 68 is determined by one or more sensors to detect the presence of the storage box or container in the box lift. Examples of sensors include, but are not limited to, proximity sensors, such as light sensors.

[0045] One of the primary criteria for a conveyor system 76 is to ensure that storage containers or cargo being transported along its conveyor lanes reach their intended destination and that the storage containers or cargo do not fall off the sides of the conveyor system 76. While attempts have been made to reduce the likelihood of cargo or storage containers falling off the sides of the conveyor system by installing side walls or barriers on either side of the conveyor system, the problem remains of jamming the conveyor system due to one or more conveyor units being misaligned, causing one or more cargo or storage containers to become stuck. This is particularly true when adjacent conveyor units in the conveyor system are not perfectly aligned, causing one or more cargo or storage containers to deviate from their intended path on the conveyor system. Therefore, it is critical to have adjacent conveyor units perfectly aligned to reduce the likelihood of cargo or storage containers in transit deviating from their intended path on the conveyor system. To reduce the likelihood of misalignment, multiple conveyor units are typically mounted on a custom conveyor frame or base structure that extends across multiple grid units. The custom conveyor frame is typically a one-piece structure to minimize the likelihood of conveyor unit misalignment. Likewise, the lengths of conveyor units in a conveyor system vary to accommodate different transport lengths of the conveyor system. For example, Figure 8 and Fig. 9At least one of the access conveyor units 80 may be a single conveyor unit that is elongated and extends across multiple grid units between the delivery column 15b and the retrieval column 15c, rather than being a single, connected short conveyor unit. Thus, each inventory handling station is different because they often have a customized conveyor system that relies on the available space in the storage and retrieval system to access storage containers that are lowered from the grid structure.

[0046] The present invention alleviates the above-mentioned problems by modularizing the inventory handling station so that the inventory handling station can be built from regularly arranged modules or modular structures 110 (wherein each modular structure 110 constitutes a cell of the inventory handling station). The pattern of the inventory handling station is determined by the arrangement of the modular structures. In order to construct the inventory handling station with components of the modular structures 110, each modular structure in the modular structure is substantially identical in shape and size. Subsequently, the modular structures of the repeating pattern can be assembled into a frame or support structure for supporting different components of the above-mentioned inventory handling station, such as a conveyor system. When assembled together, the components will provide a substantially aligned frame for supporting a plurality of aligned conveyor units. Fig.10 In a specific embodiment of the present invention shown in an exploded view of a single modular structure 110, the single modular structure 110 has a cubic frame structure composed of a plurality of horizontal 112a, 112b and vertical 114 support elements or braces, which are connected at the corners by connectors 116. In order to ensure that the modular structure 110 has a regular cubic structure, the horizontal support elements 112a, 112b and the vertical support elements 114 at the corners of the modular structure must be substantially perpendicular to each other. The basic building block of the cubic structure has eight external corners and twelve support elements, four of the twelve support elements are vertical and eight of the twelve support elements are horizontal. Fig.10 In the particular embodiment of the invention shown, the geometry of the modular structure is a cuboid structure in which all angles are substantially right angles and the opposite sides of the cuboid structure are equal. The angles of the support elements at the corners of the modular structure are controlled by connectors 116. For purposes of definition, and because the connectors form the corners of the modular structure, the connectors may be broadly defined as corner pieces 116.

[0047] Fig.10The particular embodiment of the modular structure according to the present invention shown can be broken down into a plurality of vertically spaced modular sections 117, each of the plurality of modular sections 117 providing mountings for supporting component units of the inventory handling station, such as conveyor units. Each of the plurality of modular sections 117 is assembled from four corner pieces 116, wherein in a single modular section 117, each of the four corner pieces 116 is connected to two other corner pieces 116 by horizontal support elements or braces 112a, 112b to form a substantially rectangular frame that lies in a substantially horizontal plane (see Fig.11 Each of the plurality of modular sections 117 is vertically spaced apart by connecting each of the four corner pieces 116 of vertically adjacent modular sections 117 together with vertical support elements or struts 114, thereby forming a cubic structure.

[0048] In order to ensure that the support elements 112a, 112b, 114 are substantially perpendicular to each other at the corners of the modular structure, the connector or corner piece 116 has a keying feature 124 that controls the orientation of the support elements. In this application, the terms "key" and "key portion" are used interchangeably. For a cubic structure, the keying feature controls the orientation of the support elements at right angles to each other in the horizontal plane and the vertical plane, that is, in the x, y and z directions of the Cartesian coordinate system. Figures 11 to 13 An embodiment of a corner piece 116 according to the invention is shown, comprising a first 118, a second 120 and a third 122 connection portion for connecting to support elements 112a, 112b, 114 so that they extend in a first, second and third direction. The first, second and third directions are perpendicular to each other, i.e. in the x, y and z directions of a Cartesian coordinate system. In order to control the orientation of the support elements in the first, second and third directions, a keying feature 124 at each of the first, second and third connection portions 118, 120, 122 is milled out of profile for controlling the orientation of the support elements 118, 120, 122 in the respective first, second and third directions. The keying feature 124 should not only be able to control the orientation of the support elements 112a, 112b, 114, but must also be able to provide a load-bearing surface 126 to prevent the cubic shape of the modular structure 110 from being deformed. In a particular embodiment of the invention, this is accomplished by raised projections or protruding projections 124 which are contoured to provide a load bearing surface 126 to prevent movement of the support elements 112a, 112b, 114 in their respective horizontal or vertical planes.

[0049] In order to limit the movement of the support elements 112a, 112b, 114 when mounted to the raised protrusions 124, the connecting ends 128 of the support elements 112a, 112b, 114 include openings 130 that are contoured so as to be secured in a particular orientation on the raised protrusions 124. Specifically, the contours of the openings 128 in the connecting ends 128 of the support elements 112a, 112b, 114 are formed under tight tolerances such that the size of the openings 130 is slightly larger than the size of the raised protrusions 124 so that the raised protrusions can be received within the openings at the connecting ends of the support elements in a close-fitting manner. Fig.11 An embodiment is shown in which an opening in the connecting end of the support element is provided to the raised protrusions of the first, second and third connecting parts of the connector. The shape of the profile of the opening 130 corresponds to the shape of the profile of the raised protrusion 124, so that there is only one orientation in which the support element can be connected to the corner piece 116. This allows the profile of the raised protrusion 124 to determine the orientation of the support elements 112a, 112b, 114, and prevents connection to the raised protrusion 124 when the orientation is different from the orientation determined by the raised protrusion. In many cases, the connecting ends 128 of the support elements 112a, 112b, 114 cannot engage with the raised protrusion 124 of the corner piece 116. For example, the lengths of the opposing support elements are not substantially equal, resulting in a distortion of the cubic shape of the modular structure, and / or support elements are incorrectly provided to the corner piece. In Fig.11 In the particular embodiment shown, the raised projection 124 has a generally rectangular profile and provides at least two opposing straight sides and is configured to be received in a close-fitting manner within a correspondingly shaped opening 130 in the connecting end of the support member.

[0050] In order to manufacture the profile of the opening 130 of the support elements 112a, 112b, 114 to a tight tolerance, the opening 130 is preferably machined in the support element. In the embodiment where the opening in the connecting end of the support element is machined to a tight tolerance, laser cutting is used, but other forms of precision cutting of the opening in the support element are also suitable for the present invention. Although the support elements 112a, 112b, 114 are shown as diagonal beams to provide the necessary bending stiffness when the component unit is mounted to the modular part 117, other cross-sectional shapes (e.g., I-shaped, U-shaped) and support elements with the necessary bending stiffness to support the component (e.g., conveyor unit) are also suitable for the present invention. The support element may include one or more mounting points 132 for fastening different types of component units. In a specific embodiment of the present invention, one or more mounting points 132 include one or more mounting holes for receiving bolts or screws or other types of fasteners.

[0051] The geometry and / or profile of the raised projections are strictly controlled so that the support elements connected to the raised projections are substantially perpendicular to each other. Therefore, lines 134, 136 extending along the midpoints of the raised projections 124 of the first 118 and second 120 connecting portions located in the horizontal plane intersect at substantially 90°. In order to enable the corner piece 116 to be rotated 90° so that the support elements 112a, 112b, 114 at different corners of the modular structure 110 can be connected using the same type of corner piece, the corner piece 116 has a symmetry line 138, wherein the symmetry line 138 extends through the raised projection 124 of the third connecting portion 122 located in the vertical plane. The intersection lines 134, 136 and the symmetry line 138 are arranged in a substantially perpendicular manner. Fig.13 124 so that the raised protrusions precisely engage the openings in the support element, one way is to machine the profile from a single body so that the corner piece is formed as a single piece of material. For example, the corner piece 116 can be machined from a single piece of metal, such as aluminum. However, other forming methods and / or materials for manufacturing corner pieces so that the profile tolerances of the raised protrusions are strictly controlled are also suitable for the present invention. For example, the use of additive manufacturing and / or the use of plastic materials can be used as alternative manufacturing methods or materials to form a corner piece with a raised protrusion, and the profile of the raised protrusion is strictly controlled.

[0052] Each of the raised protrusions 124 has a substantially flat mating surface that provides a contact surface for contacting the support element. In order to secure or tighten the support elements 112a, 112b, 114 when the support elements are mounted to the corner pieces 116, the raised protrusions 124 may include threaded holes 140 to receive threads such as Fig.11 To assemble the modular structure, the horizontal support elements 112a, 112b and the vertical support elements 114 are provided as shown. Fig.11 The corner piece 116 shown is configured so that the raised protrusions are received in the openings in the connecting ends 128 of the support elements 112a, 112b, 114. The tight tolerances on the profile of the raised protrusions ensure that the support elements are oriented in the correct direction. For a cubic structure, any difference in the length or shape of the relative support elements will be apparent when the raised protrusions cannot be received in the openings of the support elements. More specifically, for the relative support elements, the spacing between the openings 130 at the far end of a given support element is substantially equal. The closer the angle between the support elements at the corner is to 90°, the greater the ability of the corner piece at each corner to be keyed to the support element.

[0053] All else being equal, the support elements can be connected to the corner pieces so that the support elements are oriented in a substantially vertical orientation at each corner of the modular structure and the resulting modular structure takes a substantially cubic shape. To prevent deformation of the modular structure and to increase the structural rigidity of the modular structure, reinforcements or corner brackets 144 may be used to support the horizontal support elements to the vertical support elements (see Fig.10 ). One or more of the modular sections 117 may support the platform 146 to provide a support surface and / or increase the torsional stiffness of the modular structure (see Fig.10 146, a platform 146 is shown connected to the horizontal and vertical support elements in a single modular section 117 to reinforce the modular structure in the X and Y directions.

[0054] Because the angles at the corners of the modular structure are substantially right angles and the opposite sides are substantially equal, the resulting modular structure can be assembled together with other similar or similar modular structures repeatedly or in a regular pattern with little risk of misalignment between adjacent modular structures. This is particularly important when the components form a stock handling station supporting a conveyor system from a drop port or pick-up port to an access station as described above. Fig.14 An embodiment of an assembly of modular structures 148 according to the present invention for use in an inventory processing station is shown. Each modular structure in the modular structures 110 acts as a cell in the assembly 148 and is regularly repeated to form various patterns. Different arrangements of modular structures 110 can be assembled together to form various patterns occupying different footprints. Fig.14 In the embodiment, the modular structures 110 are arranged side by side in an L-shaped pattern or configuration. In addition to arranging the modular structures side by side, the modular structures can also be stacked on top of each other. In the case where the assembly is used as an inventory handling station, the stacked modular structures can provide chutes that cooperate with ports in the grid structure to form a drop chute (delivery column) or a pick chute (retrieval column) in the supply area or buffer area, respectively, as described above. In the case where the chute is used as a pick chute to form a retrieval column as described above, one or more of the modular structures can optionally include one or more box lifting devices as described above.

[0055] To facilitate coupling adjacent modular structures 110 together, the corner pieces 116 at the corners of the modular structures 110 include one or more mounting protrusions 150a, 150b, each of the one or more mounting protrusions 150a, 150b including a flat mating surface for abutting against a corresponding mounting protrusion of a corner piece in an adjacent modular structure. Fig.15In the particular embodiment of the present invention shown, the corner piece 116 includes a first mounting protrusion 150a and a second mounting protrusion 150b located in respective vertical planes, wherein the vertical planes are substantially perpendicular to each other. Each of the first 150a and second 150b mounting protrusions includes a mating surface located in a respective vertical plane so as to be able to abut against a corresponding mating surface of an adjacent corner piece. Fig.16 A top plan view of the mating of corner pieces from adjacent modular structures is shown in FIG. Fig.17 As shown in the side view of the assembly of the modular structure shown, when adjacent modular structures are placed side by side, the mating surfaces of the first or second mounting protrusions 150a, 150b of the corner pieces 116 from the adjacent modular structures 110 are placed together so that they are as shown in FIG. Fig.16 The first and second mounting projections are shown to abut against each other so that their respective mating surfaces ultimately lie in the same or common vertical plane. In order to fasten or secure adjacent corner pieces together, each of the first and second mounting projections includes at least one hole for receiving a bolt or a pin. The at least one hole may be a blind hole or a through hole. Fig.12 In a particular embodiment of the present invention as best shown in FIG. 1 , each of the first 150a and second 150b mounting protrusions includes a first hole 152 and a second hole 154, and at least one of the first hole 152 and the second hole 154 has a threaded inner wall for threaded engagement with a bolt or a screw. The advantage of having one of the first hole 152 or the second hole 154 having a threaded inner wall and the other having a non-threaded inner wall is that it helps to assemble adjacent modular structures together. Because the corner piece of the present invention has symmetry, it can be rotated 90 degrees, so when the corner pieces from adjacent modular structures in the assembly are put together (see FIG. 1 ), the corner pieces from adjacent modular structures in the assembly can be rotated 90 degrees. Fig.17 ), so that when their corresponding mating surfaces are in contact, the non-threaded hole is always adjacent to the threaded hole. When the hole is a through hole, the non-threaded hole adjacent to the threaded hole allows the threaded bolt to be initially fed into the non-threaded hole so that the threads of the bolt eventually engage with the threads of the hole in the adjacent corner piece.

[0056] Assembling multiple modular structures involves putting the individual modular structures together so that adjacent modular structures in the assembly are placed side by side (see Fig.17). When each of the modular structures is substantially cubic, the holes in the corresponding first or second mounting protrusions of adjacent corner pieces at the corners of the modular structures are aligned for receiving bolts. Adjacent modular structures in the assembly are fastened together by threading the bolts through the holes of the mounting protrusions of the adjacent corner pieces. The shape or footprint of the assembly can be changed by simply bolting additional modular structures to the existing assembly. Ultimately, the assembly includes modular structures arranged in a regular or repeating arrangement, wherein each modular structure forms a cell in the assembly. Due to the modular nature of the inventory handling station, multiple modular structures can be assembled together in a variety of patterns.

[0057] The corner pieces of the present invention are capable of connecting support elements in a substantially vertical direction, so that each modular structure in the modular structure maintains a uniform shape and size, thereby improving the ability to align adjacent modular structures in the assembly. This is particularly important when the assembly is to support a conveying system including a plurality of adjacent conveyor units, as it is necessary to ensure that goods or storage containers transported by the conveying system will not become stuck on the side walls of the conveying system due to misalignment of adjacent conveyor units. Fig.18 In the particular embodiment shown in the top view of the components shown, the conveyor system 76 includes a plurality of conveyor units arranged in an L-shaped pattern, including an entry conveyor unit 78, an exit conveyor unit 82, and at least one access conveyor unit 80 between the entry 78 conveyor unit and the exit 82 conveyor unit. The present invention also allows for conveyor systems of various other patterns, depending primarily on the arrangement of the modular structure.

[0058] As described above, in order to form a vertical chute for cooperating with the port column to lower one or more storage containers onto the conveyor system for transportation to the access station, or to pick up one or more storage containers leaving the access station to enter the buffer zone, a plurality of modular structures 110 can be stacked on top of another modular structure to form a vertical column. In addition to assembling the modular structures of the present invention side by side (see Fig.17 and 18 ), the corner piece 116 of the present invention can also enable the modular structure to be stacked into three layers, such as Fig.19 As shown. In contrast to the mounting protrusions for connecting modular structures side by side, the corner pieces optionally include spacers 156 to space adjacent modular structures in the stack. Fig. 20 In the particular embodiment of the invention shown, the spacers 156 are frusto-conical in shape, but other shapes that separate adjacent corner members in a stack are also suitable for use with the invention. Fig. 20 As shown, the frustoconical shape has a mating surface of a platform for abutting the spacer of an adjacent corner piece in the stack. The spacer 156 includes a hole 158 so that adjacent modular structures can be fastened together via their respective corner pieces. Fig.14and 17 As shown, the spacer 156 also provides a mount for securing the foot 160 to the assembly.

[0059] The components of the modular structure provide a support structure or mounting frame for mounting various functional components of the above-mentioned inventory handling station, such as a conveyor system, a box lifting device, a drive motor for the conveyor system and the box lifting device, electronic and electrical components for operating the drive motor, and / or a load sensor. In addition to the functional components mounted to the support structure or mounting frame, the exterior of the support structure can also be covered with one or more panels 170 to accommodate the functional components within the surrounding member. The panel 170 can be fastened to the horizontal support elements and / or vertical support elements of the components of the modular structure by one or more fasteners (e.g., bolts). Alternatively, the panel 170 may include a locking piece 172, which is configured to interlock with one or more openings (not shown) in the horizontal support elements and / or vertical support elements 112a, 112b, 114 of the components of the modular structure 110. Access can be achieved through the opening 88 in the surrounding member to pick and / or dump one or more goods into a storage container transported on the conveyor unit 80.

[0060] By controlling the orientation of the support elements in a substantially vertical direction, the connector 116 of the present invention has a variety of uses in storage and retrieval systems that require alignment of adjacent structures. For example, in a grid frame structure, a grid opening in the grid structure is to be aligned with a grid column, wherein the grid column is composed of a plurality of upright columns for guiding storage containers through the grid opening. The connector of the present invention can be used to control the orientation of grid components and / or tracks in a grid frame structure so that the grid components are arranged in a grid pattern, wherein the grid pattern has a first group of grid components extending in a first direction and a second group of grid components extending in a second direction, the second direction being substantially perpendicular to the first direction. For example, in addition to being used as a corner piece having two connecting portions extending in two perpendicular directions in a horizontal plane, the connector can also have four connecting portions, the four connecting portions being perpendicular to each other and located in a horizontal plane, so that the connector is in a cross shape, for connecting respective grid components in the grid pattern. As with the connecting portion of the corner piece, the contour of the key portion (e.g., the raised protrusion) of the connector controls the orientation of the grid components so that they are arranged in a grid pattern. Track elements may be mounted to the grid members for guiding movement of one or more robotic load handling devices in first and second directions on the grid structure. It is also possible that a plurality of modular structures 110 may be arranged in a grid pattern and at different heights to form a grid frame structure.

Claims

1. A connector for connecting to at least three supporting elements of a three-dimensional modular structure, the connector comprising a single body comprising: i) a first connector part for connecting to a support element extending in a first direction, ii) a second connector portion for connecting to a support element extending in a second direction, iii) a third connector portion for connecting the support element extending along a third direction, wherein the first, second and third directions are substantially perpendicular to each other, iv) one or more mounting protrusions, each of the one or more mounting protrusions having a substantially planar mating surface for mating with a corresponding mounting protrusion of an adjacent connector; Each of the first, second and third connecting portions comprises a key portion, the key portion being milled with a contour for controlling the orientation of the support element in the respective first, second and third directions of the support element.

2. The connector according to claim 1, wherein: The profile of the key portion includes at least two opposing straight edges to prevent the support element from rotating about an axis extending through the key portion, each of the at least two opposing straight edges defining a load-bearing surface.

3. The connector according to claim 2, wherein: The outline of the key portion is substantially quadrilateral.

4. A connector according to any preceding claim, wherein: The key portions of the first and second connector parts lie in the same plane and are oriented so that lines extending along the midpoints of the key portions of the first and second connector parts intersect at substantially 90°.

5. The connector according to claim 4, wherein: The key portion of the third connector part lies in a plane perpendicular to the plane of the key portions of the first and second connector parts such that the connector has a line of symmetry extending through the key portion of the third connector part.

6. A connector according to any preceding claim, wherein: The key portion includes a raised protrusion.

7. The connector according to claim 6, wherein: The raised projection includes a substantially planar mating surface.

8. The connector according to claim 7, wherein: The raised projection includes a hole.

9. A connector according to any preceding claim, wherein: Each of the one or more mounting protrusions includes a first protrusion located in a first mounting protrusion plane, and a second mounting protrusion located in a second mounting protrusion plane, wherein the second mounting protrusion plane is substantially perpendicular to the first mounting protrusion plane, so that a line extending through the first mounting protrusion is substantially perpendicular to a line extending through the second mounting protrusion.

10. A connector according to any preceding claim, wherein: Each of the one or more mounting protrusions includes a first hole and a second hole, the first hole being a threaded hole and the second hole being a non-threaded hole.

11. A connector according to any preceding claim, further comprising a spacer for spacing away from an adjacent connector.

12. A modular structure comprising a plurality of vertically spaced modular sections, each of the plurality of modular sections comprising at least four connectors as defined in any one of claims 9 to 12, each of the at least four connectors in a single modular section being connected to two other connectors by horizontal support elements to form a substantially rectangular frame, and wherein, Each of the at least four connectors of vertically adjacent modular parts is connected together by a basically vertical support element to form a frame structure, and wherein the distal end of each of the horizontal support elements and the vertical support elements includes an opening with a contour, and the contour is complementary to the contour of the key portion of the connector so that the orientation of the horizontal support element and the vertical support element can be controlled by the contour of the key portion.

13. The modular structure according to claim 12, wherein: The connection between the vertical support elements and the horizontal support elements includes brackets.

14. A modular structure according to claim 12 or 13, wherein: The modular structure has a substantially cubic structure.

15. An assembly comprising a plurality of modular structures according to any one of claims 12 to 14, wherein: Adjacent modular structures in the assembly are coupled together by one or more of the respective mounting protrusions.

16. The assembly of claim 15, wherein: The plurality of modular structures are stacked and arranged.

17. An assembly according to claim 15 or 16, wherein The plurality of modular structures are arranged side by side.

18. An inventory handling station for use with a storage and retrieval system, the storage and retrieval system comprising a grid frame structure, the grid frame structure comprising: a plurality of upright posts located in one or more vertical planes and arranged to form a plurality of grid posts for stacking one or more containers between and guided by the plurality of upright posts in a vertical direction, the plurality of upright posts being interconnected at their top ends by a first set of grid members extending in a first direction and a second set of grid members extending in a second direction, the second set of grid members running transversely to the first set of grid members in a substantially horizontal plane to form a grid comprising a plurality of grid cells or grid spaces; The first and second groups of grid members support first and second groups of tracks, respectively, at an upper level of the grid frame structure for load handling equipment to move one or more storage containers on the grid frame structure, Wherein, the inventory processing station component includes a component of a modular structure according to any one of claims 15 to 17, and the component of the modular structure is arranged to support a conveying system including a plurality of conveying units, each of the plurality of conveying units being mounted on respective modular parts of adjacent modular structures to form a continuous conveyor.

19. The inventory processing station of claim 18, wherein: The components of the modular structure are arranged to support: i) a port station for receiving storage containers dropped and picked up through the grid unit; ii) an access station to enable access to one or more storage containers lowered from said port station, and Therein, the conveying system is arranged for conveying storage containers between the port station and the access station.

20. The inventory processing station of claim 19, wherein: The port station includes a vertical chute configurable to cooperate with at least one upright column, the at least one vertical chute having a first opening for receiving a container lowered through a grid unit by at least one load handling device, and a second opening for allowing the container to exit from the port station.

21. The inventory processing station of claim 20, wherein: The components of the modular structure are stacked and arranged to define the vertical slideway.

22. The inventory processing station of claim 21, wherein: The vertical chute includes a box lift apparatus which may be configured to lift a storage container upwardly towards the grid so that, in use, the storage container can be retrieved by the at least one load handling apparatus.

23. A stock handling station according to any one of claims 18 to 22, wherein: The port station includes a supply area for receiving storage containers lowered through the grid unit, and a pick-up area for picking up storage containers through the grid unit.

24. The inventory processing station of claim 23, wherein: The plurality of conveyor units include an entrance conveyor unit configured in the supply area, an access conveyor unit arranged in the access station, and an exit conveyor unit arranged in the pick-up area.

25. The inventory processing station of claim 24, wherein: The entrance conveyor unit, the exit conveyor unit and the access conveyor unit are arranged to transport storage containers along a first, a second and a third transport direction, respectively, and wherein the first transport direction of the entrance conveyor unit is opposite to and parallel to the second transport direction of the exit conveyor unit, and the third transport direction of the access conveyor unit is orthogonal to both the first transport direction of the entrance conveyor unit and the second transport direction of the exit conveyor unit.

26. The inventory processing station of claim 24, wherein: The entrance conveyor unit, the exit conveyor unit and the access conveyor unit are arranged to transport storage containers along a first, second and third transport direction, respectively, and wherein the conveyor system is arranged so that the first transport direction of the entrance conveyor unit is orthogonal to the second transport direction of the exit conveyor unit and the third transport direction of the at least one access conveyor unit.

27. A stock handling station according to any one of claims 18 to 26, wherein: The port station and / or the access station comprises a load sensor.

28. A fulfillment / dumping system, the fulfillment / dumping system comprising: i) a storage and retrieval system, the storage and retrieval system comprising a grid frame structure, the grid frame structure comprising: a plurality of upright posts located in one or more vertical planes and arranged to form a plurality of grid posts for stacking one or more containers between and guided by the plurality of upright posts in a vertical direction, the plurality of upright posts being interconnected at their top ends by a first set of grid members extending in a first direction and a second set of grid members extending in a second direction, the second set of grid members running transversely to the first set of grid members in a substantially horizontal plane to form a grid or grid structure comprising a plurality of grid cells or grid spaces; The first and second sets of grid members support first and second sets of tracks, respectively, at an upper level of the grid frame structure for robotic load handling equipment to move one or more storage containers on the grid frame structure, ii) one or more load handling devices, said one or more load handling devices being remotely operated to move said one or more containers stored in said grid frame structure, each of said one or more load handling devices comprising: i) a wheel assembly for guiding the load handling equipment on the grid structure; ii) a container receiving space, the container receiving space being located above the grid structure; and iii) a lifting device arranged to lift a single container from a stack into the container receiving space, iii) An inventory handling station as defined in any one of claims 18 to 27, configured to receive one or more storage containers from the storage and retrieval system.

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