Warehousing system for storing and retrieving goods in container

Abstract

A product order fulfillment system for mixed product units, the product order fulfillment system comprising: a storage array having at least one elevated storage level in which mixed product units are entered and distributed in the storage array in bins having common types of product units per bin; an automated transport system having at least one asynchronous transport system for level transport and an elevator for level transport, communicatively connected to the storage array, and a controller configured to automatically retrieve and output product units distributed in the bin in the at least one elevated storage level of the storage array from the storage array, the output product unit being one or more of: a hybrid singulated product unit, in a hybrid packaging group, and in a hybrid bin; wherein the at least one asynchronous transport system and the elevator are configured so as to form more than one transport lane.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application is a non-provisional application of and claims the benefit of U.S. Provisional Patent Application No. 63 / 365,368, filed on May 26, 2022, the disclosure of which is incorporated herein by reference in its entirety. Technical Field

[0002] The disclosed embodiments relate generally to material handling systems and, more particularly, to the transportation and storage of items within a material handling system. Background Art

[0003] It is recognized that integrating automated storage and retrieval systems into a logistics chain (particularly, a goods-to-person system) is highly advantageous in terms of efficiency and cost throughout the logistics chain. Even conventional systems with advanced automated storage and retrieval system integration in logistics facilities generally operate by storing product (e.g., supply) containers, where the supply containers include: boxes, packages, etc., which contain common types of goods (also referred to as products) in the supply containers. The product containers may arrive on pallets (e.g., pallets of common supply containers) or as truck loads, and be depalletized or unloaded from trucks and stored in the logistics facility, distributed by the automated storage and retrieval system throughout the storage capacity of the logistics facility (e.g., in a three-dimensional array of storage racks).

[0004] With the growth of e-commerce and just-in-time inventory systems, logistics facility customers may purchase small quantities of specific items rather than entire cases of those specific items resulting in mixed product containers. Order fulfillment from the logistics facility is generally accomplished by an automated storage and retrieval system that manually or automatically outputs product / supply containers (each containing one or more cargo items of a common cargo type, i.e., each cargo item in the product container is the same or substantially similar) from storage locations throughout a three-dimensional array of storage racks to a workstation using an automated storage and retrieval system goods-to-person configuration, particularly in situations where mixed product containers are traditionally desired (e.g., where any given order set The packing may have mixed / different products or product types held by a common container, such as in the case of direct fulfillment to the consumer, or if indirect to the consumer, such as via a retail order pick-up location, then at least partially generating an ordered mix of products in the order container at the logistics facility before output from the logistics facility), enabling the generation of mixed product containers to pick and remove goods from different product / supply containers fed to a given workstation by the automated storage and retrieval system in accordance with a given fulfillment (or completion) order, and place different picked goods (mixed or common if the given order contained is so fulfilled) into the order container. Such a workstation may be referred to as a split pack station, where the product container is "split" and its contents may be placed in whole or in part in an order container or into what may be referred to as a split pack storage container (e.g., a tote), such as where the product container is not suitable for continued holding of remaining product items after the split pack operation, and such remaining product (i.e., the remaining portion of the product in the "split" product container) should be returned to storage by the automated storage and retrieval system in a three-dimensional array of storage racks. To increase efficiency, the order containers may also be brought into the three-dimensional array of storage racks, and potentially to a storage location on the storage racks storing the product containers, until such time as order output is desired, otherwise both entry and output from the three-dimensional array of storage racks is accomplished by an automated storage and retrieval system. An improved system for processing decomposed products into at least mixed product bins is desired. BRIEF DESCRIPTION OF THE DRAWINGS

[0005] The above aspects and other features of the disclosed embodiments are explained in the following description taken in conjunction with the accompanying drawings, in which: Figure 1A is a schematic illustration of an automated storage and retrieval system according to aspects of the disclosed embodiments; Figure 1B According to aspects of the disclosed embodiments Figure 1A A schematic illustration of a portion of an automated storage and retrieval system; Figure 1C According to aspects of the disclosed embodiments, Figure 1A Schematic illustration of mixed pallet loads formed by an automated storage and retrieval system; Figure 2 According to aspects of the disclosed embodiments Figure 1A A schematic illustration of a portion of an automated storage and retrieval system; Figure 3A According to aspects of the disclosed embodiments Figure 1A A schematic illustration of a portion of an automated storage and retrieval system; Figure 3B According to aspects of the disclosed embodiments Figure 1A A schematic illustration of a portion of an automated storage and retrieval system; Figures 4A-4C is the use of aspects according to the disclosed embodiments Figure 1A An exemplary flow chart of product group collection formation performed by an automated storage and retrieval system; Figures 5A-5F According to aspects of the disclosed embodiments Figures 4A-4C A schematic illustration of the method; Figure 6 is an exemplary illustration of product assignments to merchant categories and merchant departments in accordance with aspects of the disclosed embodiments; Figure 7 is an exemplary schematic illustration of a merchant pallet load packaging distribution according to aspects of the present disclosure; Figure 8 is an exemplary schematic illustration of a merchant pallet load packaging distribution according to aspects of the present disclosure; Fig. 9 is an exemplary schematic illustration of a merchant pallet load packaging distribution according to aspects of the present disclosure; Fig.10 According to the disclosed embodiments, Figure 1A Schematic illustration of containerized flow of automated storage and retrieval systems; Figures 11A-11D is the use of aspects according to the disclosed embodiments Figure 1A An exemplary flow chart of product containerization by an automated storage and retrieval system; Fig.12 According to aspects of the disclosed embodiments Figures 11A-11D A schematic illustration of containerization of the method; Fig.13 According to aspects of the disclosed embodiments Figure 1A Schematic illustration of product sequencing in an automated storage and retrieval system; Fig.14A and14B According to aspects of the disclosed embodiments Figure 1A Schematic illustration of sequencing / order flow in an automated storage and retrieval system; Figures 15A-15E is the use of aspects according to the disclosed embodiments Figure 1A An exemplary flow chart of product sequencing performed by an automated storage and retrieval system; Fig.16 According to aspects of the disclosed embodiments, Figure 1A An exemplary flow chart of a method implemented by an automated storage and retrieval system; and Fig.17 According to aspects of the disclosed embodiments, Figure 1A An exemplary flow chart of a method implemented by an automated storage and retrieval system. DETAILED DESCRIPTION

[0006] Figure 1A 1 is a schematic illustration of an automated storage and retrieval system (also referred to herein as a warehousing system or product order fulfillment system) 100 according to aspects of the disclosed embodiments. The automated storage and retrieval system can be disposed in a warehouse 199 or in any other suitable location. Although aspects of the disclosed embodiments will be described with reference to the accompanying drawings, it should be understood that aspects of the disclosed embodiments may be embodied in many forms. In addition, any suitable size, shape, or type of element or material may be used.

[0007] As described herein, aspects of the disclosed embodiments provide a split packaging system with containerization and sequencing optimized for end-user (e.g., customer / consumer) requests or order fulfillment. Aspects of the disclosed embodiments implement a split packaging system based on a customer order 299 (see Figure 2 ) associated product group characteristics and one or more of the predetermined rules and the product unit BPG (also known as the supplier package, each or the split package goods, each of which has a corresponding three-dimensional shape) in a bounded area (such as, any suitable transport container). As an example, using the store / customer rules SR (e.g., the commodity characteristics framework - see Figure 2 ) is used to program the controller 120 of the storage and retrieval system 100, the store / customer rules SR defining the product (goods) groups PGA-PGn and the complementarity, affinity and / or combinability of the product groups PGA-PGn with each other.

[0008] According to aspects of the disclosed embodiment, warehouse packages or case units CU holding product units BPG are input into an automated storage and retrieval system 100 (e.g., as described herein) and grouped into product groups PGA, PGB, PGC (see Figure 2, where three product groups are illustrated for exemplary purposes only - it should be noted that there may be any number of product groups), each product group having a unique predetermined product group characteristic that provides (e.g., biases towards) merging of product units BPG (e.g., for containerization) of one product group PGA, PGB, PGC with product units BPG of the same product group PGA, PGB, PGC or product units BPG of different product groups PGA, PGB, PGC. These product groups PGA, PGB, PGC are assigned to corresponding storage or picking levels 130L (also referred to herein as elevated storage levels or elevated storage and transportation levels) of the storage structure 130 based at least on the mergability of the product units BPG and distributed on the corresponding storage or picking levels 130L to achieve orthogonal processing of product groups PGA, PGB, PGC on the corresponding storage levels 130L (where "orthogonal" as used herein means unrelated or lacking mutual relationship or connection, independent). Here, the combinability of product units BPG in product groups PGA, PGB, PGC enables the merchandise categories (e.g., personal hygiene, household goods, detergents, clothing, small appliances, groceries, etc.) to be combined with customer orders 299 (see Figure 2 ) are not linked or normalized to achieve orthogonal processing of product groups PGA, PGB, PGC. It should be noted that each of the at least one elevated storage and transportation level 130L is (or can be) separate and distinct from each other elevated storage and transportation level 130L, wherein each elevated storage and transportation level 130L achieves orthogonal transportation output of product units distributed in the storage array 130SA relative to each other elevated storage and transportation level 130L. As will be described herein, product groups PGA, PGB, PGC can be dynamically reassigned between product levels (e.g., based on the mergibility of different product groups (as described herein)). For example, in the case where there is an excessive or sufficient number of products on one transport level (such as, for example, transport level 130L1), some of the warehouse packages CUA, CUB, CUC, Cui holding the products can be dynamically reassigned to another transport level 130 (such as, for example, one or more of transport levels 130L2, 130L3), where the product group PGA (or at least one of its warehouse packages CU) can be merged with one or more of the product groups PGB, PGC of other storage levels 130L2, 130L3. The reassignment of product groups between transport levels can maintain a substantially equal division of work (e.g., transport transaction rates) between transport levels.

[0009] The product units BPG of the warehouse packages CU from the product groups PGA, PGB, PGC are almost containerized by the controller 120 of the automated storage and retrieval system 100 to realize the filling plan for a given shipping container (also referred to as a container herein). The product units BPG are batched with each other in the container based on the application of the mergibility of the product units BPG with each other, for example. When the filling plan is established, the product units BPG from the product groups PGA, PGB, PGC are picked from the (one or more) corresponding storage levels 130L of the storage array 130SA (for example, the storage structure 130), and the product units BPG from the product groups PGA, PGB, PGC are transported to the splitting and packaging station 140 to realize the filling of one or more given containers. The product units BPG are sequenced in any suitable manner (such as during the transportation of the product units from the storage level 130L to the splitting and packaging station 140 and / or from the splitting and packaging station 140 to the container) for filling the container.

[0010] The grouping of warehouse pack CUs based at least on the combinability of the product units BPGs held in the warehouse pack CUs may appear to increase the number of autonomous transport vehicles 110 trips from the storage space 130S in the storage array 130SA to, for example, the depackaging station 140 for filling containers (e.g., aspects of the disclosed embodiments increase the number of commodity categories on each level where each vehicle 110 transports one case unit CU corresponding to the respective commodity category per trip); however, counterintuitively, arranging warehouse pack CUs on storage levels 130L based on the combinability of product units BPGs optimizes case unit transfers (e.g., reduces the number of trips) because the product unit BPGs of one warehouse pack CU can be used to fill more than one container for any given transport of the warehouse pack CU. It should be noted that the combinability of product unit BPGs is a measure of, and enables, batching of product unit BPGs in any given container.

[0011] Orthogonal processing of warehouse packages CU based at least on the combinability of the product units BPG held in the warehouse packages CU of the product groups PGA, PGB, PGC in which the warehouse packages CU are grouped enables matching combinable product units BPG with one another, wherein for a given warehouse package transport the existence of suitable product units for batch processing is known. For example, also refer to Figure 2, the product group PGA may include: warehouse packages (or box units) CUA, CUB, CUC, CUi, including corresponding product units A, B, C, and i. Customer orders may be placed for product units A+i, B+i, and C+i. Here, the vehicles 110 on the storage level (or levels) 130L corresponding to the product group PGA transport the warehouse packages CUA, CUB, CUC, CUi holding product units A, B, C, i to the split packing station 140, respectively. Knowing that the product units A, B, C, i are mergeable with each other based on the product group PGA to which the warehouse packages are assigned, the product unit i may be batched with each of the product units A, B, C, wherein only a single transport journey from the storage array 130SA to the split packing station 140 is utilized to fulfill three customer orders. In fact, the known mergeability of the product units BPG in a given product group increases the probability (or "hit rate") that any given warehouse package CU of the given product group will be adopted for any given single transport journey in more than one containerized filling.

[0012] Still referring to Figure 1, according to aspects of the disclosed embodiment, the automated storage and retrieval system 100 can be operated in a retail distribution center or warehouse to, for example, fulfill orders received from different customers (such as those described herein) for split packaged goods BPG and / or warehouse packages (also referred to herein as box units) CU. Suitable examples of automated storage and retrieval systems incorporating or capable of incorporating split packaged goods systems are described, for example, in the following: U.S. Patent No. 10,822,168, issued on November 3, 2020; U.S. Provisional Patent Application No. 17 / 657,705, filed on April 1, 2022, and entitled “Warehousing System for Storing and Retrieving Goods in Containers”; and U.S. Provisional Patent Application No. 17 / 358,383, filed on June 25, 2021, and entitled “Warehousing System for Storing and Retrieving Goods in Containers”, the disclosures of which are incorporated herein by reference in their entirety.

[0013] As an example, a warehouse package CU is a box or unit of goods that is not stored (e.g., not contained) in a tray, on a transport bag, or on a pallet. In other examples, a warehouse package CU is a box or unit of goods contained in any suitable manner (such as in a tray, on a transport bag, in a container (such as a container of the remaining goods after the decomposed warehouse packaging structure is not suitable for transporting the remaining goods as a unit) or on a pallet). In still other examples, the warehouse goods CU is a combination of uncontained and contained items. It should be noted that the warehouse package CU, for example, includes boxed units (e.g., boxes of soup cans, boxes of cereals, etc.) or individual goods that are adapted to be taken from or placed on a pallet. According to aspects of the disclosed embodiments, a shipping box (e.g., a carton, a barrel, a box, a wooden box, a can, or any other suitable device for holding a box unit) for a warehouse package CU can have a variable size, and can be used to hold the box unit in shipment, and can be configured so that they can be placed on a pallet for shipment.

[0014] It should be noted that when, for example, a bundle or pallet of a warehouse package CU (eg, a mixed product unit) arrives at the storage and retrieval system 100 (see Figure 2 In the case of a pallet that is not a pallet, the contents of each pallet may be uniform (e.g., each pallet holds a predetermined number of identical items—one pallet holds soup and another pallet holds cereal), and as the pallets leave the storage and retrieval system, the pallets may contain any suitable number and combination of different warehouse packages CU or containerized product units BPG (e.g., mixed pallets, where each mixed pallet holds a different type of warehouse package and / or containerized product unit BPG—a pallet holds a combination of soup and cereal), which are provided to, for example, a palletizer in a sorted arrangement (e.g., implemented by at least a pallet output sorting 185 echelon of the automated storage and retrieval system 100, where at least one or more transport box units in the container robot 110 and the elevator module 150B are used for sorting) for forming mixed pallets. In aspects of the disclosed embodiments, the storage and retrieval system 100 described herein may be applied to any environment in which warehouse packages CU are stored and retrieved.

[0015] refer to Figure 1A and 1B According to aspects of the disclosed embodiment, the automated storage and retrieval system 100 includes: one or more unpacking modules 266 (see Figure 1B), configured to decompose product containers or warehouse packages CU (which may generally be referred to as supply cargo containers or supply containers 265) into split-pack cargo containers 264 (which are used to ship split-pack cargo, such as shipping containers) for order fulfillment in a manner similar to that described in the following: U.S. Provisional Patent Application No. 17 / 657,705, filed on April 1, 2022, and entitled “Warehousing System for Storing and Retrieving Goods in Containers” and U.S. Provisional Patent Application No. 17 / 358,383, filed on June 25, 2021, and entitled “Warehousing System for Storing and Retrieving Goods in Containers”, the disclosures of which were previously incorporated herein by reference in their entirety. One or more split-pack modules 266 may be communicatively coupled to one or more stacking (storage) levels 130L of the automated storage and retrieval system 100, wherein the one or more levels 130L of the automated storage and retrieval system 100 include at least one split-pack module 266. The split pack module(s) 266 can be: a plug-and-play module that can be coupled to any suitable portion of the structure of the automated storage and retrieval system 100. For example, the split pack module(s) can be coupled to the container transfer deck 130DC of the automated storage and retrieval system 100 (see also Figure 1B The container transfer deck 130DC2 in the container transfer deck 130DC2) or (one or more) picking (or picking) aisle 130A. (One or more) split packaging modules 266 can be set on any suitable number of stacking storage levels of the automated storage and retrieval system 100.

[0016] Any suitable controller 120 is configured to implement the operations of the automated storage and retrieval system 100 described herein. For example, the controller 120 is configured to implement the following operations of at least one container robot or autonomous guided vehicle 110 and at least one cargo robot or autonomous guided split-package cargo transport vehicle 262, as well as any elevators 310A, 310B and other components of the automated storage and retrieval system 100 described herein: assembling orders of split-package cargo or product units BPG from supply containers or case units (also referred to herein as warehouse packages) CU into split-package cargo containers 264 (see Figure 1A) in the container storage location 130S; and feed the split package cargo container 264 to the output station 160UT through the container feed-out station TS. For example, the controller 120 is configured to implement the operation of (one or more) container robots 110 between the container storage location 130S, the split package operation station 140, and the split package cargo container 264 located at the seed wall 263W along the split package cargo transfer deck or cargo deck 130DG (for example, the split package cargo container 264 located at the split package cargo interface station / container station 263L of the seed wall 263W). As another example, the controller 120 is configured to implement the operation of (one or more) cargo robots 262, so that the transportation of the split package cargo BPG by the cargo robot 262 traverses on the cargo transfer deck 130DG, and the split package cargo BPG is sorted (for example, in the split package order sorting 188 echelon of the automated storage and retrieval system 100, as described herein) to the corresponding split package cargo container 264. As a further example, the controller 120 is configured to implement operation of (one or more) container robots 110 so that (one or more) container robots 110 access the corresponding split package cargo container 264 at the cargo transfer deck 130DG from the seed wall 263W, and transport the split package cargo container 264 to at least one of the container output / transfer station TS and the corresponding container storage location 130SB of the storage shelf of the corresponding level 130L of the multi-level storage array via traversal along the container transfer deck 130DC (for example, to at least partially implement the split package output sorting 189 echelon as described herein).

[0017] The controller 120 is also configured to implement the operation of the (one or more) container robots 110 and the elevators 150 (for example, to form a container supply system) so as to introduce an empty split-pack cargo container 264 into the automated storage and retrieval system, so that the (one or more) container robots 110 transport the empty split-pack cargo container 264 along the transport / travel loop 233BP of the (one or more) container transfer decks 130DC and into the split-pack module for placement at (one or more) split-pack cargo interface positions 263L of the split-pack cargo interface 263 for transfer of the split-pack cargo BPG into the split-pack cargo container 264 in a manner similar to that described in the following: U.S. Provisional Patent Application No. 63 / 044,721 filed on June 26, 2020 and U.S. Provisional Patent Application No. 17 / 358,383 filed on June 25, 2021, both of which are entitled “Warehousing System for Storing and Retrieving Goods In Containers", the disclosures of which are incorporated herein by reference in their entirety. It should be noted that the split package cargo interface 263 can be substantially similar to one or more of the transfer station TS and buffer station BS described herein, and include: an uncertainty surface (similar to the uncertainty surface of the rack storage space 130S described herein), on which the split package cargo container 264 is placed to form an uncertainty interface between the cargo transfer deck 130DG and the container transfer deck 130DC (for example, or otherwise, forming part of the container transfer deck 130DC or communicatively coupled to the container transfer deck 130DC (one or more) container robot travel surfaces 266RS). In other aspects, the empty split package cargo container 264 can be transferred to the storage space 130SB, 130S ( Figure 1B ) and is stored in the storage space 130SB, 130S, or buffered at the feed-in station, wherein the controller 120 is configured to implement the transfer of the empty split-pack cargo container 264 from the storage space 130SB, 130S or the buffer position to the split-pack cargo interface 263 in a manner similar to that described above.

[0018] In one or more aspects, the controller 120 is configured to implement operation of (one or more) container robots 110 and elevators 150 (e.g., forming a container supply system) to introduce empty supply containers 265 or standardized containers (as described herein) into an automated storage and retrieval system (in a manner similar to that described in the following: U.S. Provisional Patent Application No. 63 / 044,721 filed on June 26, 2020 and U.S. Non-Provisional Patent Application No. 17 / 358,383 filed on June 25, 2021, both of which are entitled "Warehousing System for Storing and Retrieving Goods In Containers," the disclosures of which were previously incorporated herein by reference in their entireties), so that (one or more) container robots 110 transport empty supply containers 265 or standardized containers 265S along the transport / travel loop 233, 233A of (one or more) container transfer decks 130DC and to the split packaging operation station 140 for split packaging.

[0019] As can be realized, the container robot 110, the cargo robot 262, the elevator module 150, the unpacking module 266, and other suitable features of the storage and retrieval system 100 described herein are controlled in any suitable manner, such as by, for example, one or more central system control computers (e.g., control servers) 120 through, for example, any suitable network 180 to achieve the operations described herein. In one aspect, the network 180 is a wired network, a wireless network, or a combination of wireless and wired networks using any suitable type and / or number of communication protocols. In one aspect, the control server 120 includes a collection of substantially simultaneously executed programs (e.g., non-transient computer program code / system management software) for substantially automatically controlling the automated storage and retrieval system 100 as described herein. The collection of programs running substantially simultaneously is configured, for example, to manage the storage and retrieval system 100, including, for exemplary purposes only, controlling, scheduling, and monitoring the activities of all active system components, managing inventory (e.g., which case units are input and removed, the orders in which cases are removed and in which case units are stored) and picking faces (e.g., one or more case units that are movable as a unit and handled as a unit by components of the storage and retrieval system), and interfacing with the warehouse management system 2500. In one aspect, the control server 120 may be configured to control features of the storage and retrieval system in the manner described herein.

[0020] Also refer to Figure 1CIt should be noted that when, for example, incoming bundles or pallets (e.g., from a manufacturer or supplier of case units) arrive at the storage and retrieval system for replenishing the automated storage and retrieval system 100 (again, see, for example, Figure 2 265) and / or split pack cargo containers 264 (collectively referred to as "shipping containers" or "boxes", where, for example, each pallet may hold a predetermined number of the same items - one pallet holds soup and another holds cereal). As may be realized, the warehouse packages or case units CU of such a pallet load may be substantially similar or in other words homogeneous boxes (e.g., similar size) and may have the same SKU (otherwise, as previously mentioned, the pallet may be a "rainbow" pallet with layers formed by homogeneous boxes). As the pallet PAL leaves the storage and retrieval system 100, the pallet PAL may contain any suitable number and combination of different case units CU (including entire (i.e., non-retired) supply containers 265) and / or split pack cargo containers 264 (collectively referred to as "shipping containers" or "boxes", where, for example, each pallet may hold different types of shipping containers with different types of commodity categories - a pallet may hold a combination of canned soup, cereal, beverage packages, cosmetics, and household cleaners). The boxes combined onto each pallet may be of different sizes and / or different SKUs, where the boxes fulfill customer replenishment orders.

[0021] In one aspect of the disclosed embodiment, the storage and retrieval system 100 can be configured to generally include an infeed section, a storage and sorting section (where, in one aspect, storage of items is optional and sorting is achieved using one or more of the different orthogonal sortings as described herein), and an output section (e.g., which can also provide sorting achieved using one or more of the different orthogonal sortings as described herein), as will be described in more detail below. As can be implemented, in one aspect of the disclosed embodiment, the system 100 operating as, for example, a retail distribution center can serve to receive uniform pallet loads of boxes, break up pallet loads or disassociate boxes from uniform pallet loads into independent box units that are individually handled by the system, retrieve and sort the different boxes sought by each order into corresponding groups, and transport and assemble corresponding groups of boxes into what can be referred to as mixed box pallet loads MPL. As may also be implemented in one aspect of the disclosed embodiment, the system 100 operating as, for example, a retail distribution center may serve to receive uniform pallet loads of boxes, break up the pallet loads or disassociate boxes from the uniform pallet loads into independent box units that are individually handled by the system, retrieve and sort the different boxes sought by each order into corresponding groups, and transport and sequence the corresponding groups of boxes in the manner described in U.S. Patent No. 9,856,083, issued on January 2, 2018, and having application serial number 14 / 997,920, the disclosure of which is incorporated herein by reference in its entirety.

[0022] The automated storage and retrieval system 100 is configured to assemble appropriate groups of ordered boxes that may differ in SKU, size, etc. into mixed box pallet loads (which include box units and / or one or more of split pack containers 264) and / or split pack containers 264 as described in the following: U.S. Provisional Patent Application No. 63 / 044,721 filed on June 26, 2020 and U.S. Non-Provisional Patent Application No. 17 / 358,383 filed on June 25, 2021, both entitled "Warehousing System for Storing and Retrieving Goods In Containers", the disclosures of which were previously incorporated herein by reference in their entirety. For example, where a mixed box pallet load is assembled, the output section of the automated storage and retrieval system 100 generates the pallet load in what may be referred to as a structured architecture of a mixed box stack. The structured architecture of the pallet load described herein is representative, and in other aspects, the pallet load may have any other suitable configuration. For example, the structural framework can be any suitable predetermined configuration, such as a truck compartment load or other suitable container or load container envelope that holds a structural load. The structural framework of the pallet load can be characterized as having several flat box layers L121-L125, L12T, as described in U.S. Patent No. 9,856,083, which is previously incorporated herein by reference in its entirety. As a further example, the split pack container 264 can be assembled and output by the output section of the automated storage and retrieval system 100 for individual shipment to customers or with other split pack containers 264 to one or more customers.

[0023] refer to Figure 3A and 3BIn order to enable assembly of one or more of a mixed pallet load, individual split pack containers 264, and grouped split pack containers 264, the controller 120 can operate the container robot 110, the cargo robot 262, the elevator module 150, the split pack module 266, and other suitable features of the storage and retrieval system 100 so that different orthogonal sorting echelons are implemented. For example, the box robot 110 can implement a pallet out sorting 185 echelon, in which box units are retrieved and output from storage for inclusion in a mixed pallet load. One or more of the box robot 110 and the split pack module elevators 310A, 310B can also implement (orthogonal / independent of the pallet out sorting 185) a split pack station input sorting 186 echelon, in which supply containers 265 are provided to the split pack module 266 in a predetermined sequence. Each of the split-pack operation stations 140 of the split-pack module 266 can also implement orthogonal sorting (e.g., split-pack station output sorting 187 echelon) of split-pack goods BPG to the cargo robot 262, wherein the cargo robot 262 is configured to implement another orthogonal sorting (e.g., split-pack order sorting 188 echelon) of the split-pack goods PGB to the split-pack container 264 at the sowing wall 263W. The box robot 110 picks the split-pack container 264 from the sowing wall 263W and provides the split-pack output sorting 189 echelon (which is orthogonal to the sorting 185-188) to the output section of the automated storage and retrieval system 100.

[0024] According to aspects of the disclosed embodiments, again referring to Figure 1A, the automated storage and retrieval system 100 includes an input station 160IN (which includes: a depalletizer 160PA and / or a conveyor belt 160CA for transporting items (e.g., inbound supply containers) to the elevator module 150A for entry into the storage structure or storage level 130L of the multi-level container storage array 130SA) and an output station 160UT, 160EC (which includes: a palletizer 160PB, an operator station 160EP and / or a conveyor belt 160CB for transporting items (e.g., outbound supply containers and filled split-pack cargo (order) containers) from the elevator module 150B for removal from storage (e.g., to a palletizer (for a palletizer load) or to a truck (for a truck load)). Here, the output station 160EC is an individual fulfillment (or e-commerce) output station, where, for example, filled split-pack cargo (order) containers including single cargo items and / or small groups of cargo are transported for fulfilling individual fulfillment orders (such as, orders placed by consumers on the Internet). The output station 160UT is a commercial output station where bulk goods are typically provided on pallets for fulfilling orders from commercial entities such as stores, warehouse clubs, restaurants, distribution centers (e.g., where goods such as split-pack goods, case units, picking faces, etc. are held for shipment to individual customers), etc. As can be realized, the automated storage and retrieval system 100 includes both the commercial output station 160UT and the individual fulfillment output station 160EC; while in other aspects, the automated storage and retrieval system includes one or more of the commercial output station 160UT and the individual fulfillment output station 160EC.

[0025] The automated storage and retrieval system 100 also includes input and output vertical lift modules 150A, 150B (generally referred to as lift modules 150 - it should be noted that although input and output lift modules are shown, a single lift module may be used to both import and remove case units from the storage structure), a storage structure 130 (which may have at least one elevated storage level (also referred to herein as elevated storage and transport levels) and in some aspects form a multi-level storage array 130SA), and at least one autonomous guided container transport vehicle or container robot 110, which may be constrained to a respective storage level of the storage structure 130 and distinct from the transfer deck 130DC (also referred to herein as the transport area) on which they travel (or in which). It should be noted that the depalletizer 160PA may be configured to remove case units from a pallet so that the input station 160IN can transport the items to the lift module 150 for import into the storage structure 130. The palletizer 160PB may be configured to place the items removed from the storage structure 130 on a pallet PAL ( Figure 1C) for shipment. As used herein, the elevator module 150, storage structure 130, unpacking module 266, cargo robot 262, and container robot 110 may be collectively referred to herein as the above-mentioned multi-level automated storage system (e.g., storage and sorting section) to define (e.g., relative to, for example, the container robot 110 reference system or any other suitable storage and retrieval system reference system) transportation / throughput axes (in, for example, three dimensions) serving the three-dimensional multi-level automated storage system, wherein each throughput axis has complete "just-in-time sorting" (e.g., sorting of case units during their transportation), so that case unit sorting and throughput occur substantially simultaneously without a dedicated sorter, as previously described in U.S. Patent No. 9,856,083, which is incorporated herein by reference in its entirety.

[0026] As an example of the throughput of box units or split-pack cargo containers when related to sorting, also refer to Figure 3B, the storage and retrieval system 100 includes several areas or zones of throughput. For example, there are multiple levels of case unit storage throughput 130LTP that implement the placement of case units into storage. The placement / organization of case units in the storage space 130S can be unrelated to (e.g., not prepared for) the sorting of case units and / or split packaged goods BPG in the different sorting echelons described herein. The horizontal case unit transport throughput 110TP implements the transport of (one or more) case units along the picking aisles, the transfer deck from the storage, and to / from the split packaged goods interface. The horizontal case unit transport throughput 110TP at least partially implements one or more of the pallet output sorting 185 echelon and the split package station input sorting 186 echelon. The pallet output sorting 185 sorts case units destined for mixed pallet loads, where such case units are not provided to the split package station 266. The split pack station throughput 266TP (e.g., the decomposition of the supply boxes at the split pack operation station) implements one or more of the split pack station input sorting 186 echelons (e.g., via the split pack module elevators 310A, 310B) and the split pack station output sorting 187 echelons (via the split pack operation station 140). The horizontal cargo transportation throughput 262TP provides for the transfer of split pack cargo from the split pack operation station 140 to the split pack cargo interface and implements the split pack order sorting 188 echelon. The case buffering throughput BTSTP provides a buffer of case units to facilitate the transfer of case units between storage / split packing and vertical transportation, and may at least partially implement one or more of the pallet output sorting 185 and the split pack output sorting 189. The vertical transportation throughput 150TP implements the transfer of case units by the vertical elevator 150, and may further at least partially facilitate one or more of the pallet output sorting 185 and the split pack output sorting 189. The throughput at the output station 160TP is also provided, which includes, for example, transportation by conveyor belt 160CB and placement on a pallet by palletizer 160PB. In one aspect, as described herein, sorting of case units is achieved substantially coincidentally (e.g., "just in time") with the throughput 130LTP, 110TP, 266TP, 262TP, BTSTP, 150TP of the case units along each throughput axis (e.g., relative to, for example, the X, Y, Z axes of the reference system of the container robot 110 and / or the elevator 150), and sorting along each axis is independently selectable so that sorting is achieved along one or more of the X, Y, Z axes.

[0027] Also refer to Figure 1A and 1BThe storage structure 130 may include: (one or more) container autonomous transport travel loops 233, 233A (e.g., formed on and along the container transfer deck 130DC), which are arranged at corresponding levels of the storage structure 130. It should be noted that the elevators 150 are connected to the container transfer deck 130DC via a transfer station TS (also referred to herein as a container feed-in station when the elevator 150 is an inbound elevator 150A, or referred to herein as a container feed-out station when the elevator 150 is an outbound elevator 150B), and each elevator is configured to lift one or both of the supply containers 265 (empty or filled) and the split packaged cargo containers 264 (empty or filled, wherein the filled split packaged cargo containers 264 are containers ready for shipment and are filled so that the split packaged cargo BPG in the container occupies at least about 30% or at least about 50% of the total container volume) into and out of the at least one elevated storage level 130L of the storage structure 130. An array of storage racks 130SA (e.g., forming at least part of the storage area of ​​the storage structure 130 and also referred to herein as a multi-level container storage array) is configured with container storage locations (or spaces) 130S arranged along the periphery of the container transshipment deck 130DC, wherein the transport area of ​​the storage structure 130 is substantially continuous and includes at least the transshipment deck 130DC and the picking aisle 130A, so that the transshipment area communicatively connects each storage rack in the array of storage racks 130SA to each other. For example, a plurality of storage rack modules RM ( Figure 1B ) is accessible from the storage or deck level 130L. As used herein, the term "high density three-dimensional rack array" refers to a three-dimensional rack array RMA having indeterminate open upper shelves distributed along the picking aisle 130A, wherein, in some aspects, multiple stacked shelves are accessible from a common picking aisle travel surface or picking aisle level, as previously described in U.S. Patent No. 9,856,083, which is incorporated herein by reference in its entirety.

[0028] Each storage level 130L includes a picking face storage / switching space 130S (referred to herein as storage space 130S or container storage location 130S) arranged along the periphery of the container transfer deck 130DC. At least one of the storage locations 130S is a supply container / warehouse package WHPK (generally referred to as a box unit CU) storage location 130SS, and another of the container storage locations is a split package cargo (or order) container storage location 130SB. The storage space 130S is formed in one aspect by a rack module RM, wherein the rack module includes shelves arranged along a storage or picking aisle 130A (which is connected to a container transfer deck 130DC), the storage or picking aisle 130A extending, for example, linearly through the rack module array RMA, and providing the container robot 110 with access to the storage space 130S and (one or more) transfer decks 130B (for example, the container robot 110 is configured to traverse the container transfer deck 130DC and the picking aisle 130A at each corresponding level, and transport containers (such as those described herein) accessed to and from container storage locations / spaces (such as those described herein) on each of the storage shelves at each corresponding level of the storage structure 130 to the split packaging operation station 140). In one aspect, the shelves of the rack module RM are arranged as multi-level shelves distributed along the picking aisle 130A. As can be implemented, the container robot 110 travels along the picking aisle 130A and the container transfer deck 130DC on the corresponding storage level 130L to transfer box units between any one of the storage spaces 130S of the storage structure 130 (e.g., on the level where the container robot 110 is located) and any one of the elevator modules 150 (e.g., each of the container robots 110 has access to each storage space 130S on the corresponding level and access to each elevator module 150 on the corresponding storage level 130L).

[0029] The container transfer decks 130DC are arranged at different levels (corresponding to each level 130L of the storage and retrieval system) that can be stacked one above the other or horizontally offset, such as having one container transfer deck 130DC at one end or side RMAE1 of the storage rack array RMA or at several ends or sides RMAE1, RMAE2 of the storage rack array RMA, as described, for example, in U.S. Patent No. 10,822,168 issued on November 3, 2020, the disclosure of which is incorporated herein by reference in its entirety. The container transfer deck 130DC is substantially open and is configured for multiple travel channels (e.g., along a plurality of travel channels relative to the cross-transfer deck 130B and along the transfer deck 130B) . Figure 6D) traverses the container robot 110 with uncertainty. As described in U.S. Patent No. 10,556,743, issued on February 11, 2020, the disclosure of which is incorporated herein by reference in its entirety, multiple travel channels can be configured to provide multiple access paths or routes to each storage location 130S (e.g., a picking face, a case unit, a container, or other items stored on a storage shelf of a rack module RM), so that if the main path to the storage location is blocked, the container robot 110 can use, for example, a secondary path to reach each storage location. As can be implemented, the (one or more) transfer decks 130B at each storage level 130L communicate with each of the picking aisles 130A on the corresponding storage level 130L.

[0030] The container robot 110 bidirectionally traverses between the container transfer deck(s) 130DC and the picking aisle 130A at each corresponding storage level 130L to pick and store containers along the picking aisle (e.g., along the direction relative to the picking aisle). Figure 6 D) and accesses storage spaces 130S provided in rack shelves along the sides of each of the picking aisles 130A (e.g., the container robot 110 can access storage spaces 130S distributed on both sides of each aisle along the Y throughput axis, so that the container robot 110 can have different orientations when traversing each picking aisle 130A, for example, the drive wheels of the container robot 110 lead the travel direction or the drive wheels track the travel direction). As can be realized, the throughput outbound from the storage array 130SA in the horizontal plane corresponding to the predetermined storage or deck level 130L is achieved by and is apparent in the combined or integrated throughput along both the X and Y throughput axes. As mentioned above, the (one or more) container transfer decks 130DC also provide the container robot 110 with access to each of the elevators 150 on the corresponding storage level 130L, wherein the elevators 150 feed box units to each storage level 130L and / or remove box units from each storage level 130L (e.g., along the Z throughput axis), and wherein the container robot 110 implements box unit transfers between the elevators 150 and the storage space 130S.

[0031] The container robot 110 may be any suitable independently operable autonomous transport vehicle that carries and transfers / transports box units and / or picking faces, respectively (which may be individually or collectively referred to as supply containers 265) and split pack cargo containers 264, such as along the X and Y throughput axes throughout the storage and retrieval system 100 (see Figure 1B). In one aspect, the container robot 100 is an automated, independent (e.g., free-riding) autonomous transport vehicle. Suitable examples of robots may be found, for exemplary purposes only, in the following: U.S. Patent No. 10,822,168, issued on November 3, 2020; U.S. Patent No. 8,425,173, issued on April 23, 2013; U.S. Patent No. 9,561,905, issued on February 7, 2017; U.S. Patent No. 8,965,619, issued on February 24, 2015; U.S. Patent No. 8,696,010, issued on April 15, 2014 ; U.S. Patent No. 9,187,244 issued on November 17, 2015; U.S. Patent No. 11,078,017 issued on August 3, 2021; U.S. Patent No. 9,499,338 issued on November 22, 2016; U.S. Patent No. 10,894,663 issued on January 19, 2021; and U.S. Patent No. 9,850,079 issued on December 26, 2017, the disclosures of which are incorporated herein by reference in their entireties. The container robot 110 (described in more detail below) can be configured to place case units (such as, the retail items described above) into the picking inventory in the one or more levels of the storage structure 130, and then selectively retrieve the ordered case units. As can be implemented, in one aspect, the throughput axes X and Y (e.g., the picking face transport axes—see Figure 1BA reference frame REFZ in the storage and retrieval system 100 is defined by the picking aisle 130A, at least one container transfer deck 130DC, the container robot 110, and the extendable end effector of the container robot 110 (and in other aspects, the extendable end effector of the elevator 150 also at least partially defines the Y throughput axis). Picking faces (which in one aspect include supply containers 265) are transported between an inbound section of the storage and retrieval system 100 (such as, for example, the input station 160IN) and a load filling section of the storage and retrieval system 100 (such as, for example, the output station 160UT or the output station 160EC) in which an outbound picking face to the array is generated, in which the outbound picking face from the array is arranged to fill a load according to a predetermined load filling order sequence, or to complete (one or more) individual fulfillment orders according to a predetermined individual fulfillment order sequence. In another aspect, a picking face (e.g., a supply container 265) is transported between a storage space 130S and a load filling section (such as, for example, an output station 160UT or an output station 160EC) of the storage and retrieval system 100 to fill a load according to a predetermined load filling order sequence, or to complete (one or more) individual fulfillment orders according to a predetermined individual fulfillment order sequence. In still other aspects, (one or more) split-pack cargo containers 264 (in one aspect, multiple split-pack cargo containers can be arranged in a picking face and transported as a picking face) are transported by a container robot 110 between the storage space 130S and the load filling section and / or between the split-pack cargo interface 263 of (one or more) split-pack modules 266 and a load filling section (such as, for example, an output station 160UT or an output station 160EC) of the storage and retrieval system 100 to fill a load according to a predetermined load filling order sequence, or to complete (one or more) individual fulfillment orders according to a predetermined individual fulfillment order sequence. The control server 20 can operate the automated storage and retrieval system 100 in different operating modes so that the picking face (e.g., of the supply container 265) and the split-pack cargo container 264 are transferred to the load filling section according to one or more of the above aspects to utilize one or more of the picking face (e.g., of the supply container 265) and the split-pack cargo container 264 to fill the load.

[0032] As described above, reference Figure 1BIn one aspect, the storage structure 130 includes: a plurality of storage rack modules RM configured in a three-dimensional array RMA (e.g., forming an array of storage shelves 130SA), wherein the racks are arranged in an aisle 130A, and the aisle 130A is configured for the travel of the container robot 110 within the aisle 130A. The container transfer deck 130DC has an uncertain transport surface on which the container robot 110 travels, wherein the uncertain transport surface (also referred to as the deck surface herein) 130BS has a plurality of travel channels (e.g., more than one juxtaposed travel channels (e.g., a high-speed robot travel path HSTP)) for the container robot 110 to travel along (one or more) container autonomous transport travel loops 233 formed by the container transfer deck 130DC, wherein the plurality of travel channels connect the aisle 130A. The container autonomous transport travel loop(s) 233 provide the container robot 110 with random access to any and each picking aisle 130A and random access to any and each elevator 150A, 150B on the corresponding level 130L of the storage structure 130. At least one of the plurality of travel lanes has a lane meaning that is opposite to another travel lane meaning of another of the plurality of travel lanes (so as to form the container autonomous transport travel loop 233).

[0033] In one aspect, the storage rack module RM and the container robot 110 are arranged so that the storage rack module RM and the container robot 110 in combination implement just-in-time sorting of mixed box picking faces (e.g., such as, the pallet output sorting 185 echelon) that coincide with transportation on at least one of the throughput axes (or in other aspects, at least one of each of more than one of the throughput axes), so that two or more picking faces are picked from one or more of the storage spaces according to a predetermined load filling order sequence and placed at one or more picking face holding positions (such as, for example, buffer and transfer stations BS, TS) different from the storage space 130S.

[0034] As can be implemented, any suitable controller of the storage and retrieval system 100 (such as, for example, the control server 120) can be configured to create any suitable number of alternative paths or diversions for retrieving one or more case units (and / or split-pack cargo containers) from their respective storage locations 130S when paths providing access to those case units are constrained or otherwise blocked in the manner described in the following: U.S. Provisional Patent Application No. 63 / 044,721, filed on June 26, 2020, and entitled “Warehousing System for Storing and Retrieving Goods In Containers,” the disclosure of which was previously incorporated herein by reference in its entirety.

[0035] It should be noted that the storage and retrieval system shown and described herein has only an exemplary configuration, and in other aspects, the storage and retrieval system can have any suitable configuration and components for storing and retrieving items as described herein. For example, in other aspects, the storage and retrieval system can have any suitable number of storage sections, any suitable number of transshipment decks, any suitable number of split packaging modules 266 and corresponding input / output stations.

[0036] As can be realized, the juxtaposed travel paths are juxtaposed along a common indeterminate transport surface 130BS between opposite sides 130BD1, 130BD2 of the container transfer deck 130DC. Figure 1BAs illustrated in the figure, in one aspect, the aisle 130A is connected to the container transfer deck 130DC on one side 130BD2 of the container transfer deck 130DC, but in other aspects, the aisle is connected to more than one side 130BD1, 130BD2 of the container transfer deck 130DC in a manner substantially similar to that described in U.S. Patent No. 10,822,168, issued on November 3, 2020, the disclosure of which was previously incorporated herein by reference in its entirety. As described in U.S. Provisional Patent Application No. 63 / 044,721, filed on June 26, 2020, and entitled “Warehousing System for Storing and Retrieving Goods In Containers,” and U.S. Patent Application No. 17 / 358,383, filed on June 25, 2021, the disclosures of which were previously incorporated herein by reference in their entirety, the other side 130D1 of the container transshipment deck 130DC may include: deck storage racks (e.g., interface stations (also known as transshipment stations) TS and buffer stations BS) distributed along the other side 130BD1 of the container transshipment deck 130DC, such that at least a portion of the transshipment deck is placed between the deck storage racks (such as, for example, buffer stations BS or transshipment stations TS) and the aisle 130A. The deck storage rack is arranged along the other side 130BD1 of the container transfer deck 130DC, so that the deck storage rack communicates with the container robot 110 from the container transfer deck 130DC and communicates with the elevator module 150 (for example, the deck storage rack is accessed by the container robot 110 from the container transfer deck 130DC, and is accessed by the elevator 150 for picking and placing picking faces, so that the picking faces are transferred between the container robot 110 and the deck storage rack, and between the deck storage rack and the elevator 150, and thus between the container robot 110 and the elevator 150).

[0037] Reference again Figure 1A , each storage level 130L may also include: a charging station 130C (e.g., located at any suitable container transfer location) for charging the onboard power supply of the container robot 110 on that storage level 130L, such as described in, for example, U.S. patent application No. 14 / 209,086 filed on March 13, 2014 and U.S. Patent No. 9,082,112 issued on July 14, 2015, the disclosures of which are incorporated herein by reference in their entirety.

[0038] As described above and with reference to Figure 1A and 2Aspects of the disclosed embodiments provide a break-pack system with containerization and sequencing optimized for end-user (e.g., customer / consumer) requests or order fulfillment of mixed product units or break-pack goods BPG. As described herein, the storage array 130SA has at least one elevated storage level 130L (see Figure 1A and 3A ), where mixed product units are entered and distributed (in the manner described herein) in storage array 130SA in boxes (e.g., warehouse pack CUs) with common types of product units per warehouse pack CU. Customer order 299 (see Figure 2 ) has mixed product units (e.g., a mix of split packaged goods / supplier packages BPG), wherein each unit is stored in a case storage array 130SA with a common kind of product units per case (i.e., unretired warehouse packages or case units CU). Each of the customer orders 299 has (i.e., includes) at least one of the mixed product units (e.g., each customer order 299 includes at least one split packaged goods / supplier packages BPG).

[0039] An automated transport system 277 (such as described herein) having at least one asynchronous transport system 255A-255n (including at least one container robot 110) for level transport and elevators 150A-150n (such as, outbound elevators 150B) for transport between storage structure levels 130L is communicatively connected to the storage array 130SA. The asynchronous transport system 255A-255n may be provided with a corresponding one of the at least one of the elevated storage levels 130L so as to automatically retrieve and output the product units / split packaged goods BPG distributed in the case unit CU from the storage array 130SA. The automated transport system 277 may include any suitable number of asynchronous transport systems 255A-255n and elevators 150A-150n (where "n" is an integer representing the upper limit of the range An). As described herein, the automated transport system 277 automatically retrieves and outputs the product units BPG distributed in the corresponding warehouse packages CU in the at least one elevated storage level 130L of the storage array 130SA from the storage array 130SA. The output product unit BPG is output as one or more of the following: mixed singulated products (e.g., individual split-packaged goods), in mixed packaging groups (e.g., more than one split-packaged goods packaged in a group of split-packaged goods in a common container), and mixed boxes or warehouse packages CU (e.g., unretired warehouse packages, each with a common type of goods).

[0040] The at least one asynchronous transport system 255 and the elevator 150 are configured to at least partially form more than one transport channel 260A-260n. Each of the more than one transport channel 260A-260n includes a picking aisle 130A (of one or more elevated storage levels 130L) that asynchronously traverses the corresponding level of the at least one elevated storage level 130L, a transfer deck 130DC (of one or more elevated storage levels 130L), and an autonomously guided autonomous robot 110. The robot 110 transports the case unit CU and / or the split package cargo container 264 from the storage to the elevator 150 for outputting the case unit CU and / or the split package cargo container 264 from the storage structure 130 and / or transferring between the storage levels 130L. Each autonomous guided autonomous robot 110 is configured to transport a box CU of product units of a common kind, such as from storage to a split packing module 266 and / or from storage to an elevator 150; it should be noted that each robot is also configured to transport a split packing cargo container 264 that may hold one or more split packing cargoes of the same kind or different kinds.

[0041] Each of the more than one transport lanes 260A-260n also includes a split pack module 266 input, where split pack cargo is removed from the case unit CU and transferred to a split pack cargo container 264 by the cargo robot 262. The split pack cargo container 264 is located at the seed wall 263W, where the container robot 110 retrieves the split pack cargo container 264 for output from the storage structure, as described in the following: U.S. Provisional Patent Application No. 17 / 657,705, filed on April 1, 2022, and entitled "Warehousing System for Storing and Retrieving Goods In Containers"; and U.S. Provisional Patent Application No. 17 / 358,383, filed on June 25, 2021, and entitled "Warehousing Systemfor Storing and Retrieving Goods In Containers," the disclosures of which were previously incorporated herein by reference in their entirety. Reference is also made to Figure 3A, at least one transport channel 260A-260n is connected to at least one elevated storage level 130L that is separate and different from each other transport channel. The at least one transport channel 260A-260n is connected to a corresponding one or more of the at least one elevated storage level 130L, the corresponding one or more being different from the elevated storage level 130L of the storage array / structure 130 connected to and corresponding to each other transport channel 260A-260n. For example, each transport channel includes a storage structure 130 (see Figure 3A ) and is associated with at least one product group set PGSA-PGSn, as described herein.

[0042] At least one of the transport channels 260A-260n is separate and distinct from another transport channel 260A-260n. Each transport channel 260A-260n is communicatively connected to the output of the at least one elevated storage level 130L and the storage array (e.g., such as one or more output stations 160UT). The at least one transport channel 260A-260n enables orthogonal transport output of product units BPG in case units / warehouse packages CU distributed in the storage array 130SA relative to each other transport channel 260A-260n. The at least one transport channel 260A-260n is independent of each other transport channel in the more than one transport channel 260A-260n, so that the output of product units (e.g., mixed product units BPG held in case units CU and / or split packaging cargo containers 264) from the at least one transport channel 260A-260n is orthogonal to the output from each other transport channel 260A-260n, as described herein.

[0043] The controller 120 is communicatively connected to at least one elevated storage and transport level 130L. The connection of the controller 120 to the at least one elevated storage and transport level 130L also communicatively connects the controller 120 to more than one transport lane 260A-260n including a corresponding elevated storage and transport level 130L in the at least one elevated storage and transport level 130L. The controller 120 is configured (e.g., using any suitable non-transient computer program code) to register customer orders for product units (whether as supplier packaged / split packaged goods BPG or entire unretired warehouse packages CU) (see Figure 2) and describes each order in one or more product (goods) groups PGA-PGn of the product unit BPG. Each product group PGA-PGn has a unique predetermined product group characteristic that characterizes the product group PGA-PGn and relates the product groups PGA-PGn to each other. In other aspects, the controller 120 is configured to register customer orders 299 for product units BPG represented by one or more product groups PGA-PGn of the product unit BPG, wherein each product group PGA-PGn has a unique predetermined product group characteristic that characterizes the product unit BPG of the product group PGA-PGn and relates the product group PGA-PGn to each other.

[0044] The unique predetermined product group characteristic may be one or more of product type (e.g., toothpaste, deodorant, shaving cream, footwear, bakeware, detergent, etc.), product structural characteristics (e.g., fragility of the product or product packaging, etc.), affinity of one product to another according to store rules (as described herein), and any other suitable characteristics. Here, the relationships between product groups PGA-PGn result from the grouping of product groups PGA-PGn by merchandise category (and its unique predetermined product group characteristic, e.g., corrosive products are to be placed below non-corrosive products, products are to be stacked or otherwise integrated with the most fragile products at the top of the stack and the least fragile products at the bottom of the stack, etc.), and inform or otherwise define the combinability of merchandise categories. The grouping of commodity categories at a given one or more storage levels 130L in a product group set PGSA-PGSn (e.g., based on rules and / or predetermined characteristics) includes many split packaged products BPG into several product group sets PGSA-PGSn, so that there is a bias towards the merging of commodity categories into product group sets PGSA-PGSn for cross-customer orders (e.g., not linked to customer orders). According to aspects of the disclosed embodiments, there are maximized commodity categories that become product group sets PGSA-PGSn, and correspondingly, each product group set PGSA-PGSn includes the maximum or optimal number of commodity categories.

[0045] The controller 120 is also configured to heuristically resolve product groups PGA-PGn of more than one order into product group sets PGSA-PGSn based on product group characteristics. In other aspects, the controller 120 dynamically resolves the product groups PGA-PGn describing each customer order 299 into product group sets PGSA-PGSn via a heuristic solution based on product group characteristics (which are unique and predetermined as mentioned herein). Each product group set PGSA-PGSn has multiple product groups PGA-PGn and is orthogonal to each other product group set PGSA-PGSn and has a maximum number of mergeable product groups PGA-PGn. The controller is configured to dynamically bind the product units BPG of the assigned product group set PGSA-PGSn of the at least one elevated storage and transportation level 130L (or transportation lanes 260A-260n) to predetermined boundaries (e.g., split pack containers 264) in batches of mixed product units BPG for each customer order 299 corresponding to the assigned product group set PGSA-PGSn using another heuristic solution as will be described herein with respect to the containerization process. The another heuristic solution is based on at least one product group characteristic and a customer or default affinity rule as described herein.

[0046] The controller 120 is configured to implement dynamic resolution of the product group set PGSA-PGSn based at least on the number of the assigned product group set PGSA-PGSn relative to a predetermined threshold (e.g., the average supplier packaging requirement of Equation 2A or Equation 2B) of the product units (e.g., supplier packaged / split packaged goods PBG) transported via the at least one transportation channel 260A-260n and the number of other assigned product group sets PGSA-PGSn (e.g., assigned to other transportation channels 260A-260n) relative to the corresponding threshold (e.g., the average supplier packaging requirement of Equation 2A or Equation 2B) of each other transportation channel 260A-260n, respectively. Each resolved product group set PGSA-PGSn is orthogonal to each other product group set PGSA-PGSn and has a maximum number of complementary, affinitive (e.g., affinity characteristics as described herein) and / or mergeable product groups PGA-PGn.

[0047] The product group(s) sets PGSA-PGSn are dynamically allocated for retrieval and output of the product units BPG forming the product group sets PGSA-PGSn into order containers (e.g., split pack containers 264) holding batches of mixed product units BPG via the at least one storage and transportation level 130L, wherein the product group sets are dynamically allocated so as not to exceed a predetermined threshold (e.g., the average supplier packaging requirement of Equation 2A or Equation 2B) of the product units BPG transported via the at least one storage and transportation channel 260A-260n. In the event that the predetermined threshold (for a given transportation channel) is exceeded (it should be noted that, as will be further described herein, the predetermined threshold for balancing transactions between storage levels or transportation channels in order to maximize the throughput of the storage and retrieval system 100 is a dynamic factor that fluctuates depending on the orders completed by each transportation channel and the new orders received (e.g., the demand for the order(s) per transportation channel relative to the transaction output per channel) to achieve dynamic recovery of balanced transactions), the product group(s) of the product group set can be dynamically reassigned to another transportation level (see Figure 2 ) on which product units being transported are below a predetermined threshold. Since the reassignment is based on the mergibility of products, and taking into account the orthogonality of the transport levels, the products reassigned to this other level can be selected for inclusion in the product group set (replacing the packaging of the same product located on the originally assigned level) if such selection results in a more efficient product output for the corresponding transport channel and product group set. Here, the reassignment is based on what can be called the highest fill potential (e.g., determined by the highest average supplier packaging for the current transport channel compared to the average supplier packaging for other levels). In one or more aspects, the controller 120 is configured to implement dynamic allocation of the parsed product group sets PGSA-PGSn to the at least one transport channel 260A-260n (and / or to at least one elevated storage and transport level 130 thereof). The controller can also be configured to balance (e.g., to provide a substantially random distribution of case units / products that is not tied to but in accordance with aligned (if non-overlapping) customer rules) the product group sets PGSA-PGSn assigned to the at least one transport lane 260A-260n with the other assigned product group sets PGSA-PGSn assigned to each other transport lane 260A-260n.

[0048] For example, at the input of a warehouse package CU into the storage and retrieval system 100, the warehouse package CU is assigned / parsed or otherwise formed into one or more product group sets or work groups PGSA-PGSn. Each product set PGSA-PGSn includes one or more product groups PG in a product group PGA-PGn. Each of the one or more product groups PG, PGA-PGn is dynamically assigned / allocated (such as by the controller 120) to a corresponding storage level 130L, 130L1-130L3. At least one of the parsing and allocation of the product group sets PGSA-PGSn minimizes the robot 110 transportation of box CUs (including split-pack cargo containers 264) of product units per customer order 299. For example, the parsing of the product group sets PGSA-PGSn provides for the merging of products with each other at, for example, a split-pack module 266, which provides for including products from one box unit into many split-pack cargo containers 264 of a batched customer order 299C, thereby minimizing the number of journeys for a particular box unit. Dynamic assignment of product groups PGA-PGn to different storage levels 130L (and / or dynamic reassignment of at least part thereof - see Figure 2 ) distributes product transport loads substantially evenly (in a substantially random distribution as described herein) between the storage levels 130L, and reduces the number of trips taken by the container robot 110 to transport box units (as described herein) for any given order. Warehouse packages CU may be assigned to product groups PG of a corresponding set of product groups PGSA-PGSn in any suitable manner (such as by any suitable product characteristics including but not limited to those described herein).

[0049] At least one of the parsing and allocation of the product group sets PGSA-PGSn optimizes the transportation of product units (e.g., box units CU and / or split packaged goods BPG) by the asynchronous transportation system 255A using the corresponding transportation channels 260A-260n per customer order 299. For exemplary purposes, each product group set PGSA-PGSn can correspond to a customer (or a group of similar customers), and the product groups PGA-PGn can correspond to the goods sold / distributed by the customer. The product groups PG, PGA-PGn are generated by the controller 120 in a manner that favors the placement of warehouse packages CU in the storage array 130SA, so that the split packaged goods BPG maintained in the warehouse packages CU are known to be mergeable with each other in a common shipping container (e.g., can be packaged with each other according to predetermined criteria as mentioned herein). For example, the controller 120 can group the warehouse packages CU based on affinity rules and / or any other suitable criteria (as described herein, including but not limited to product type, product structure characteristics, etc.) applied at each storage level 130L. Here, the product groups PG, PGA-PGn are divided into any suitable number of operating zones based on any suitable criteria (such as affinity rules, product types, etc.) so that the products within the warehouse packages CU of the corresponding product groups PG are processed orthogonally in the corresponding operating zones. The generation of product groups PGA-PGN and product group sets PGSA-PGSn utilizes the aggregation or availability of many product groups PGA-PGn (e.g., commodity categories) of one or more customers at the storage level (e.g., the distribution of warehouse packages CU in a substantially random distribution in the storage array 130SA) to optimize the combinability of products in any given order. The formation of product group sets PGSA-PGSn as described herein is biased towards combinability to maximize the number of merchant categories (or product groups PGA-PGn) that can be merged into the product group set PGSA-PGSn, where the controller iterates through the commodity categories to provide customer rules that are aligned (if not overlapping) (see Figures 4A-4C and 5A-5F) are not linked but are distributed essentially randomly according to the customer's rules.

[0050] In the examples described herein, the operation zone corresponds to one or more storage levels 130L; while in other aspects, there may be more than one operation zone operating on a corresponding storage level 130L. As an example, the controller 120 is configured to assign the warehouse package CU to the corresponding storage level 130L based on criteria, including but not limited to the number of split packaged goods for a given customer order and the combinability of the split packaged goods BPG. With respect to the number of split packaged goods for a given customer order, the picking / transportation load is evenly distributed across the storage levels 130L or between the storage levels 130L. With respect to the combinability of split packaged goods (e.g., of one commodity category) with other split packaged goods (e.g., of another commodity category), the commodity category proximity is maximized so that the shipping container filling is maximized and the number of shipping containers is minimized. Product category proximity can be based on: store affinity rules, such as described in U.S. Provisional Patent Application No. 63 / 288,253, filed on December 10, 2021, and entitled “Material Handling System and Method Therefor,” the disclosure of which is incorporated herein by reference in its entirety; and / or any other suitable criteria (as described herein, including but not limited to product type, product structural characteristics, etc.).

[0051] Merchandise category proximity may enable a "store-friendly" pallet PAL output from the automated storage and retrieval system 100, where "store-friendly" refers to the store affinity of a pallet load or pallet load store affinity such that a pallet load configuration (i.e., pallet load build) includes predetermined characteristics (or factors) of store affinity that bias or factor into the interpretation of each pallet load PALO so that each resulting pallet load PALO conforms to and provides each resulting pallet load PALO with retail store characteristics that are in accordance with or commensurate with the retail store predetermined characteristics. For example, when a mixed product order (see Figure 2When (one or more) pallet loads PALO of an "order" (e.g., "order") arrives at the ordering store or customer 200, the (one or more) pallet loads PALO can be quickly unloaded (e.g., such as in accordance with "just in time" inventory practices) and its goods distributed (e.g., replenished / stocked) to the store shelves 233 with minimal disruption to store operations. To facilitate rapid unloading and distribution of goods to store shelves 233, the storage and retrieval system 100 is configured to construct (one or more) pallet loads PALO so that the structure of the goods on the (one or more) pallet loads PALO is grouped in a manner similar to the manner in which goods CU are distributed to store shelves 233 (e.g., singularized products (e.g., individual split-pack goods), in mixed packaging groups (e.g., more than one split-pack goods packaged in a group of split-pack goods in a common container), and mixed boxes or warehouse packages CU (e.g., unretired warehouse packages, each with a common type of goods)).

[0052] It should be noted that each of the one or more pallet load PALOs in the mixed product order 299 is constructed by the automated storage and retrieval system 100 so that each pallet load PALO is a "store-friendly pallet" or "store-friendly pallet load." For example, when the (one or more) pallet load PALOs (see Figure 7-9 ) arrives at the order store 700, the pallet load(s) PALO (e.g., Figure 7 Pallet load PALOC, Figure 8 PALOA, PALOA' and Fig. 9 The PALOC, PALOC') in the pallet loads 730 are quickly unloaded (e.g., such as in accordance with "just in time" inventory practices) and their goods are distributed (e.g., replenished / stocked) to store shelves 733 with minimal disruption to store operations. To facilitate rapid unloading and distribution of goods to store shelves 733, the automated storage and retrieval system 100 is configured to construct (one or more) pallet loads PALO so that the structure of goods CU (also referred to herein as packages, products, case units, mixed cases, boxes, shipping cases, and shipping units) on (one or more) pallet loads PALO are grouped in a manner similar to the way goods CU are distributed to store shelves 733.

[0053] Each warehouse customer (e.g., order store 200) of warehouse 199 may have its own preferences regarding the handling of pallet loads within order store 200. Aspects of the present disclosure provide for the construction of store-friendly pallets corresponding to the different ways in which pallet loads are handled and products are distributed by warehouse customers. These different ways of handling pallet loads and distributing products are referred to as order store affinity characteristics. These order store affinity characteristics (e.g., predetermined customer affinities) are cluster aisle pallet load packaging distribution methods (see, e.g., Figure 7 ), adjacent aisle pallet load packaging distribution method (see e.g. Figure 8 ) and mixed-mode cluster and adjacent aisle pallet load packaging methods (see e.g. Fig. 9 The order-store affinity characteristic(s) may be stored in any suitable memory (such as a memory of the control server 120 and / or the pallet machine of the output station 160UT) and employed by the control server 120 and / or the output pallet machine for generating the pallet load PALO described herein.

[0054] refer to Figure 7 , an exemplary way of handling pallet loads PALO can be referred to as a "cluster aisle pallet load packaging distribution method", and includes: deconstructing / stacking (one or more) pallet loads PALOC in the loading deck area 722 (or other suitable area) of the order store; and placing goods CU belonging to different sections of the order store 200 onto two or more separate auxiliary pallets PAL21-PAL23 (in Figure 7 These auxiliary pallets PAL21-PAL23 include goods CU assigned to predetermined shopping aisles and are moved to the corresponding predetermined shopping aisles for unloading (see Figure 7 ). In the case where the auxiliary pallets PAL21-PAL23 are in the corresponding shopping aisles, the goods CU from the auxiliary pallets PAL21-PAL23 are distributed to the assigned shelves 733.

[0055] refer to Figure 8 Another example of handling a pallet load PALO may be referred to as a "near-aisle pallet load package distribution method" and includes: moving the entire pallet load PALOA, PALOA' (e.g., without stacking the pallet) into a shopping aisle. With the pallet load PALOA, PALOA' in the shopping aisle, distributing the goods CU substantially directly from the (one or more) pallet loads PALOA, PALOA' to the assigned shelf 733 (see Figure 8Here, the goods CU are arranged on the pallet loads PALOA, PALOA' so as to minimize the travel distance of each pallet load PALOA, PALOA' within the store and substantially avoid the pallet PALOA, PALOA' from returning to an aisle previously visited by the corresponding pallet (e.g., the pallet passes through the aisle only once along the predetermined path 801, 802). The goods CU may be arranged on the pallet loads PALO, PALOA' according to the travel path 801, 802 of the corresponding pallet loads PALOA, PALOA' through the shopping aisles.

[0056] refer to Fig. 9 Yet another example of handling pallet PALO may be referred to as a "mixed mode cluster and adjacent aisle pallet load packaging distribution method", and includes a combination of the above handling methods. Fig. 9 , the pallet load PALOC, PALOC' arrives at the order store 200 in a truck (or other suitable transport) from the warehouse / distribution center 199. The pallet load PALOC, PALOC' is moved (without de-stacking the pallet) to a shopping area generally near the shelf to which the goods CU on the pallet load PALOC, PALOC' are assigned. With the pallet load PALOC, PALOC' generally located near the assigned shelf, the pallet load PALOC, PALOC' is de-stacking into the corresponding auxiliary pallet PALO21, PALO22, PALO23, PALO21', PALO22' assigned to the corresponding shopping aisle. Here, the pallet loads PALOC, PALOC' are constructed so that each pallet load PALOC, PALOC' includes goods belonging to / assigned to store aisles that are close to each other (for example, the pallet load PALOC includes goods located in aisle 1, aisle 2 (which is adjacent to aisle 1), and aisle 4, which is only one aisle away from aisle 2; similarly, the pallet load PALOC' includes goods belonging to / assigned to adjacent aisles 12 and 13). The goods CU can also be arranged in the corresponding pallet loads PALOC, PALOC' so that the pallet structure corresponds to the way the goods are stacked down to the corresponding auxiliary pallets (for example, such as sequential stacking, where, for example, the goods assigned to the auxiliary pallet PALO21 are at the top of the pallet structure of the pallet load PALOC, the goods assigned to the auxiliary pallet PALO22 are in the middle of the pallet structure of the pallet load PALOC, and the goods assigned to the auxiliary pallet PALO23 are at the bottom of the pallet structure of the pallet load PALOC). In this aspect, the aisle to which the goods CU are assigned may not be along the corresponding specific path for unloading the goods CU of the corresponding pallet load PALO, PALO' onto the store shelves (see, for example Figure 8 The paths 801, 802) are arranged in this manner.

[0057] The above described examples of pallet handling / destacking methods in the order store 200 are merely exemplary. It should be noted again that the pallet loads PALOC, PALOC', PALOA, PALOA' for each of the pallet handling / destacking methods are generally referred to herein as pallet loads PALO. It should also be noted that (one or more) pallet loads PALO can be constructed by the automated storage and retrieval system 100 in any suitable manner so that the goods on (one or more) pallet loads PALO are arranged according to any suitable at least one order pallet and order store affinity characteristics (which may include goods arrangement based on product type, product structure characteristics, etc.) for the pallet load packaging distribution method described herein. It should be noted that the store affinity pallet load analysis (as described herein) is not linked to the storage array 130SA settings and the material handling system 190 throughput of the box CU to the pallet machine 162. Here, the output of the box CU from the storage array 130SA by the automated transportation system 277 is selected to comply with or otherwise depend on (based on) the store affinity pallet load analysis. In one or more aspects, the throughput of the box CUs output by the material handling system 190 can be achieved in a manner similar to that described in U.S. patent application No. 17 / 091,265, filed on November 6, 2020, and entitled “Pallet Building System with Flexible Sequencing,” the disclosure of which is incorporated herein by reference in its entirety. According to aspects of the present disclosure, the box CU settings within the storage array 130SA can be freely optimized for optimal throughput separated from the parsing and construction of store-affinity pallet loads PALO. Examples of throughput optimization can be found in U.S. Patent No. 9,733,638, filed on August 15, 2017, and entitled “Automated Storage and Retrieval System and Control System Thereof,” the disclosure of which is incorporated herein by reference in its entirety.

[0058] As an example of the formation / generation of the product group set PGSA-PGSn, and reference Figure 3A , 4A -4C, 5A-5F and 6, the controller may dynamically assign the product group set PGSA to the storage level 130L1, 130L2, 130L3 based on any suitable criteria such as customer identity. Figure 6Each item / stock holding unit (e.g., case unit CU or warehouse pack WHPK and the stock holding unit SKU held therein) in the picking stock entered into the storage array 130SA is assigned a merchant category (personal hygiene, household products, detergents, etc.) and a merchant department number that occurs as a characteristic of the picking order. Figure 6 , SKU (Stock Holding Unit) indicates the identity of the case unit CU, WHPK / VNPK is the supplier packaging required for each SKU of the batch of order 299 (e.g., consolidated order 299C), DEPT is the customer department number, and CAT is the commodity category. Based on the characteristics of the picking order (e.g., merchant category and merchant department number), the case unit CU is divided into product groups as described below. As will be described below, the supplier packaging required for each item is determined by the controller 120 in combination with the batch for the order (e.g., customer orders are consolidated into batches - see Figure 2 ) is a metric used to distribute the supplier packages BPG within the box units CU substantially evenly among the storage levels 130L based on the constraint that a product category or a department cannot be distributed to multiple levels.

[0059] At the storage level 130L1, warehouse packages CUs with commodity categories A and B are assigned (e.g., based on the mergibility of commodity categories) to product groups PGA and PGB. At the storage level 130L2, warehouse packages CUs with commodity categories B and C are assigned (e.g., based on the mergibility of commodity categories) to product groups PGB and PGC. At the storage level 130L3, warehouse packages CUs with commodity category D are assigned (e.g., based on the mergibility of commodity categories) to product group PGD. The controller 120 is configured to perform the following operations in any suitable manner (e.g., in a manner that is consistent with the embodiment of the present invention). Figures 4A-4C The exemplary manner illustrated in FIG. 2 is implemented as a working group (for example, forming a product group set PGSA-PGSn).

[0060] As an example, the cargo input includes case units CU A, B, B', C and D, where case unit A belongs to commodity category A, case units B, B' belong to commodity category B, case unit C belongs to commodity category C, and case unit D belongs to commodity category D (see also Figure 5A -5G, where A, B, B', C and D represent not only the commodity category but also the case unit of the commodity). The controller 120 is configured to cycle through / determine which are not assigned to a level or need to be reassigned (see, for example, Figure 2 ) for all case units CU of commodity categories (for example, commodity categories AF here) entered for different levels of goods ( Figure 4A, box 401). The controller 102 also determines, for a given picking level 130L, whether there is already a commodity category assigned to the corresponding picking level 130L ( Figure 4A , block 402). In the event that the picking level 130L does not have any merchandise categories assigned to the picking level, the controller assigns the merchandise categories to the picking level ( Figure 4A , block 403). For example, storage level 130L1 is determined by the controller to have no merchandise category associated with it, and case units for merchandise category A are removed by controller 120 (see Figure 5A and 5B ) is assigned to storage level 130L1, and the controller returns to Figure 4A , frame 401.

[0061] In the case where the commodity category does exist on storage level 130L ( Figure 4A , box 402), the controller 120 determines whether the commodity category of the cargo input can be merged with the commodity category of the picking level ( Figure 4A , block 404). For example, merchandise category A is assigned to picking level 130L1, and the controller 120 is making a level assignment of merchandise category / case unit B for the cargo input. Here, the controller 120 determines (e.g., based on the criteria described herein) that merchandise category / case unit B can be merged with merchandise category A. The controller 120 determines ( Figure 4A , box 405) is the number of required split-pack goods / supplier packages (VNPK RQD) in the case unit of commodity category B for the order batch (i.e., the combined customer order) plus the number of split-pack goods BPG of commodity category B already existing on storage level 130L1 (VNPK CURRENT) is less than or equal to the predetermined average supplier package (AVG VNPK) for each storage level (see Equation 1 below).

[0062] VNPKRQD+VNPK CURRENT<=AVG VNPK*[Equation 1].

[0063] Here, the average supplier packaging can be called the threshold, which is defined as: AVGVNPK = (CO ORD x BPG CASE) / NUM LVLS [Equation 2A] Where CO ORD is the number of case units CU ordered, BPG CASE is the number of split-pack goods per case unit, and NUM LVLS is the number of storage levels; or AVGVNPK = TTL CASES / TTLNUM VNPK [Equation 2B] Where TTL CASES is the total number of case units in storage for a given split packaged good, and TTLNUM VNPK is the total number of a given split packaged good BPG in storage. The split packaged good / vendor package required (VNPK RQD) is equal to the total warehouse package quantity ordered for the item (TWPQO) divided by the warehouse package per vendor package (WPVP) for the item, as shown in Equation 3 below.

[0064] VNPKRQD=TWPQO / WPVP*[Equation 3] In the case where Equation 1 is satisfied, the controller adds a case unit for the commodity category (in this example, it is commodity category / case unit B) to the storage level (in this example, it is storage level 130L1) ( Figure 4A , Box 403 - See Figure 5B and 5C ), and the controller returns to Figure 4A , frame 401.

[0065] *As previously mentioned, and with respect to Equations 1 and 3 above, and as can be implemented, average supplier packaging is a dynamic factor that fluctuates depending on orders completed by each shipping channel and new orders received (e.g., demand for (one or more) orders per shipping channel relative to transaction output per channel) to achieve dynamic recovery of balanced transactions.

[0066] Regarding commodity category B, there may be another case unit B' to be assigned to the storage level. In the event that equation 1 is not satisfied, the controller 120 determines whether the commodity category being assigned is the last commodity category eligible to be merged into the work group ( Figure 4B , box 406) (in this example, it is a group of product groups / merchandise categories made of storage level 130L1). If the merchandise category being assigned is the last merchandise category eligible to be merged into storage level 130L1 ( Figure 4B , box 406), then the commodity category being assigned is assigned to the storage level 130L1 ( Figure 4A , block 403), and the controller returns to Figure 4A , box 401 (see Figure 5C ). In the case where the commodity category being assigned is not the last commodity category eligible to be grouped with the commodity category on the storage level 130L1 ( Figure 4B , box 406), the controller 120 determines whether the commodity category being assigned can be merged with other commodity categories that are not assigned to the picking level ( Figure 4B, block 407 - for example, in the example provided, item category B may also be merged with unassigned item category C). In the event that the item category being assigned may be merged with the unassigned item category, the controller 120 determines (see Figure 4B , block 409) whether: VNPKADDED+VNPK CURRENT<=AVGVNPK+VAR[Equation 4] Where VAR is a predetermined percentage by which the average supplier packaging AVG VNPK may be increased for a given storage level. VAR may be the same for one or more storage levels 130L and / or different for one or more other storage levels 130L. In the case where Equation 4 is satisfied, adding case unit B' to a storage level 130L ( Figure 4A , Box 413 - See Figure 5C ). In the event that Equation 4 is not satisfied, the commodity category being assigned (in this example, commodity category B and case unit B') is assigned to the next available storage level ( Figure 4C , Box 410 - See Figure 5D ).

[0067] In the case where the commodity category being assigned cannot be merged with the unassigned commodity category ( Figure 4B , box 407) (such as, for example, item category C cannot be combined with item category D), the controller 120 determines whether the item category cannot be combined with any other item category and can be added to the picking level based on the average supplier packaging requirements ( Figure 4B , block 408). In the case where the non-combinable commodity category C can be added to a picking level (such as picking level 130L2) according to the average supplier packaging requirements, the non-combinable commodity category is added to the picking level ( Figure 4A , Box 403 - See Figure 5D and 5E ).

[0068] Regarding commodity category / box unit D, for exemplary purposes only, commodity category D cannot be merged with other commodity categories assigned to a storage level ( Figure 4A , box 404), cannot be merged with merchandise categories that are not assigned to a storage level ( Figure 4B , box 407), and cannot be added to the storage level based on average supplier packaging requirements ( Figure 4B , block 408. Here, the controller assigns the commodity category / case unit D to the next storage level (which is storage level 130L3 in this example).

[0069] exist Figure 4C In block 411, the controller 120 determines Figure 4C, whether the storage level to which the commodity category is assigned in block 410 is the last storage level. If it is not the last storage level, the controller 120 returns to Figure 4A , box 401. If it is the last storage level, the controller 120 assigns the remaining commodity categories to the last picking level ( Figure 4C , box 412).

[0070] In the case where the product group set PGSA-PGSn is generated, the automated transport system 277 transports the warehouse package CU to the allocated storage space 130S of the allocated storage level 130L for customer order fulfillment. In the case where the product groups PGA-PGs of the product group set PGSA-PGSn are set in the storage array 130SA, the controller 120 is also configured to assign each parsed product group set PGSA-PGSn to the at least one transport channel 260A-260n for retrieving and outputting the product units BPG forming the product group set PGSA-PGSn into the order container of the mixed product units via the at least one transport channel 260A-260n, wherein the product group set PGSA-PGSn is assigned so as not to exceed a predetermined threshold (e.g., the average supplier packaging requirement of Equation 2A or Equation 2B) of the product units transported via the at least one transport channel 260A-260n. For example, as customer orders 299 are received and fulfilled, the controller 120 implements operation of the asynchronous shipping system 255A associated with the corresponding product group sets PGSA-PGSn so that each shipping channel 260A-260n retrieves and outputs the ordered products orthogonally to each other shipping channel 260A-260n.

[0071] As an example of orthogonal output of transport channels 260A-260n, the products output by each transport channel 260A-260n are orthogonally output as an output product set. The output product set of each transport channel 260A-260n is a closed set of merged commodity categories (e.g., product groups) that are closed within the corresponding transport channel 260A-260n, such that the closed set of merged commodity categories is not linked to, and will not be incorporated with, any commodity category / product of any other output product set from any other transport channel 260A-260n. The output product set of each transport channel can be referred to as an output stream of products, wherein a stream from one transport channel 260A-260n does not depend on, will not be incorporated with, and will not cross any other stream from any other transport channel 260A-260n.

[0072] refer to Fig.10, where the product group sets PGSA-PGSn are parsed and the product groups PG, PGA-PGn are arranged in the storage array 130SA (see e.g. Figure 2 , 3A and 5A-5F), the controller 120 implements containerization of mixed product units based on individual store / customer 200 orders 299. Fig.10 As can be seen in the figure, customer orders 299 (four customer orders are shown as batched as a combined order 299C and corresponding to the customer orders also in Fig.10 299C) is received in / by controller 120. It should be noted that containerization of the product units for order 299C is performed by controller 120 prior to shipping the product units from storage. In the event that containerization of the product units is planned, controller 120 implements sequencing (as described herein) of the product units for shipping and physical containerization according to a predetermined containerization plan.

[0073] To implement the containerization plan, the controller 120 splits the consolidated order 299C into waves or order segments 299CS, each segment corresponding to one or more customers and being operated by a respective shipping lane 260A, 260B. The consolidated order 299C may be split based on any suitable criteria, such as, for example, a comparison between one or more of the product groups included in the order for each customer, the product groups arranged in the storage array 120SA, and a store planogram for the customer's store.

[0074] In the case where the consolidated order 299C is split into order segments 299CS, the controller applies any suitable containerization algorithm to the order segments 299CS. Examples of containerization algorithms include, but are not limited to, a first fit algorithm and a best fit algorithm. With respect to the first fit algorithm, the controller 120 plans the placement of products in a container (e.g., such as a split package cargo container 264) in any suitable scheduled order / fill sequence, which order / fill sequence includes, but is not limited to, sequencing based at least in part on the following rules as described below: the rule arranges products in the container according to product type characteristics (e.g., corrosive is below non-corrosive, etc.) and / or product structure characteristics (e.g., where the least fragile product is at the bottom of the container) until the next item in the scheduled order does not fit in the container. Here, the controller 120 closes the container (even if the container is not full) and places the next item in the next subsequent container. With respect to the best fit algorithm, the controller plans the placement of products in the container in any suitable scheduled order / fill sequence until the container is filled. The containerization algorithm may be specified by the customer 200, in which case the specified containerization algorithm is also considered when splitting the consolidated order 299C into order segments 299CS.

[0075] The controller 120 plans the products in the order segment 299CS to be allocated to the corresponding customer 200 for execution at the split packing station 266. Here, the split packing goods / supplier packages BPG are removed from the case unit / warehouse package CU and transported to the split packing container 264 (set at the seed wall 263W) by the cargo robot 262 according to the containerization rule 264R (see Figure 1A ). The containerization rules 264R include, but are not limited to, placing products into split-pack cargo containers 264 based on one or more of: affinity of one product to another (e.g., as described herein with respect to store planograms); item / product characteristics (e.g., product type—food items should not be mixed with corrosives, corrosives are placed below non-corrosives, least fragile products are at the bottom of the container, etc.); item picking qualifications and picking station rates (e.g., manual versus robotic picking); customer-specified product grouping sequences; and segregation of departments (e.g., products of a department in a store are not mixed with products of another department in the store). As mentioned above, the outputs of the transport lanes 260A-260n are orthogonal, such that different transport lanes 260A-260n and different customer containerizations of different transport lanes may employ different containerization rules, e.g., based on customer order requirements. It should also be noted that the split-pack cargo containers 264 may include different types of containers (e.g., leak-proof containers, ventilated containers, etc.) placed at the picking wall, where product units are placed in different types of containers based on, for example, customer requirements and / or product group requirements (e.g., corrosive goods are placed in leak-proof containers, while food is placed in ventilated containers to maintain freshness).

[0076] Also refer to Figures 11A-11D , an exemplary containerization (also referred to as boxing) process will be described. The controller 120 is configured to optimize the containerization of ordered (e.g., three-dimensional) products in a manner that is differently configurable for different automated storage and retrieval systems 100 and for different customers 200 of the respective automated storage and retrieval systems 100. Containerization is the process of grouping / arranging ordered products in a bounded area (e.g., container 264) to minimize the costs associated with placing the products in the container 264.

[0077] The controller 120 is configured to loop through all customers 200 whose orders are batched together in a consolidated order ( Fig.11A , box 1102). For example, also refer to Fig.10, the controller 120 determines that the merged order 299C includes product units ordered by customers X, Y, A, and B. The controller 120 determines whether any of the customers X, Y, A, and B have already ordered product units that are still to be processed ( Fig.11A , block 1103). If all ordered product units for all customers have been processed, the containerization process is complete ( Fig.11A , block 1122). In this example, product units for customers X, Y, A, B still need to be processed, so the controller 120 sorts the picking orders (e.g., ordered product units) for the corresponding customer (using, for example, customer X) based on customer item category proximity (or default customer item category proximity, where the customer does not specify proximity) and descending order of product unit volume and weight for each customer X, Y, A, B ( Fig.11A , box 1104).

[0078] The controller 120 cycles (sequentially) through the uncontainerized picking order lines (e.g., items in a customer order) ( Fig.11A , block 1105), and determining whether there are any unprocessed order lines remaining in the sequence of order lines ( Fig. 11B , block 1106). In the absence of additional order lines for a customer (such as Customer X), the controller 120 closes any existing open containers 264 for the customer ( Fig. 11B , block 1124), and returns to block 1102 for processing the ordered product units for the remaining customers (e.g., customers Y, A, B). In the event that there are order lines still to be processed for, for example, customer X, the controller 120 determines whether there are any open containers 264 assigned to the customer ( Fig. 11B , box 1107). In the absence of any open containers, the controller 120 opens / assigns the container 264 to the customer ( Fig. 11B , box 1116), and adds the next pick order line in the sequence of pick order lines to container 264 ( Fig. 11B , box 1123), and returns to box 1105 to process the next subsequent picking order line in the sequence of picking order lines for, for example, customer X.

[0079] In the event that there is an open container 264 assigned to, for example, Customer X, the controller determines whether the items corresponding to the pick order line can fit in the container 264 based on the customer product mix rules (as described herein) or based on the default product mix rules if no customer rules are specified. Fig. 11B, block 1108). As mentioned above, the customer may specify rules for containerization (e.g., mix departments, do not mix departments, mix product categories, do not mix product categories, etc., while taking into account any rules related to product characteristics, such as, the location of corrosive products relative to the location of non-corrosive products within the container and the fragility of the products); however, if the customer does not provide / specify rules for containerization, then default product mixing rules (which may allow for mixing of products for different departments and / or commodity categories, for example, taking into account product characteristics, such as, the location of corrosive products relative to the location of non-corrosive products within the container and the fragility of the products) are applied to the containerization for that customer.

[0080] In the event that products in a pick order line fit in a container 264, the controller determines whether the items fit in the container based on any customer specified commodity category proximity rules (or if the customer does not specify category proximity, then the default category proximity rules are applied where commodity categories are intermixed with each other) Fig. 11B , block 1109). In the event that the product does not fit in a container 264 based on customer or default merchandise category proximity rules, the controller 120 closes the existing open container 264 for the customer ( Fig. 11B , box 1117), open new container 264 ( Fig. 11B , box 1116), and add the products for the picking order line to the new container ( Fig. 11B , box 1123). The controller 120 continues to box 1105 for processing the next subsequent picking order line in the sequence of picking order lines.

[0081] Where the controller determines that the products for the picking order line do fit in the container based on customer-specified (or default) commodity category proximity rules (e.g., and any rules related to product characteristics, such as the location of corrosive products relative to non-corrosive products within the container and the fragility of the products), the controller determines whether the warehouse package CU can fit in the container 264 based on volume and weight ( Fig. 11C , box 1110). In the case where the warehouse container CU can fit in the container, the controller adds the products for the picking order line to the container 264 ( Fig.11D , box 1115), and returns to box 1105 for processing the next subsequent picking order line in the sequence of picking order lines.

[0082] In the case where the controller determines that the warehouse package CU cannot fit in the container 264 based on the volume and weight, the controller 120 determines whether the volume or weight of the warehouse package CU is greater than the volume and weight of the empty container 264 ( Fig. 11C, box 1111). In the case where the volume or weight of the warehouse package CU is greater than the volume or weight of the empty container 264, the controller determines whether the quantity of the product in the order line is greater than 1 ( Fig. 11C , box 1118). In the case where the ordered quantity of the product is not greater than 1, the controller 120 marks the product as an exception product that cannot be containerized ( Fig. 11C , box 1119), and returns to box 1105 for processing the next subsequent picking order line in the sequence of picking order lines.

[0083] In the event that the ordered quantity of the product is greater than 1, the controller 120 determines whether the container 264 is empty ( Fig. 11C , box 1120). In the case that the container 264 is empty, the controller 120 divides the volume of the container 264 by the number of product orders ( Fig. 11C , block 1121), and returns to block 1110. In the event that container 264 is not empty, controller 120 determines whether there are products in container 264 that satisfy the product mix and proximity rules for the products in the picking order line being analyzed ( Fig. 11C , box 1113 and Fig.11D , block 1114). In the event that there are products in a container that meet the mix / proximity criteria, the controller 120 adds the products in the pick order line to the container 264 and returns to block 1105 for processing the next subsequent pick order line in the sequence of pick order lines. In the event that there are products in a container that meet the mix / proximity criteria, the controller 120 closes the existing container 264 for the customer ( Fig. 11B , box 1117), open new container 264 ( Fig. 11B , box 1116), and add the products for the picking order line to the new container ( Fig. 11B , box 1123). The controller 120 continues to box 1105 for processing the next subsequent picking order line in the sequence of picking order lines.

[0084] The controller determines based on volume and weight that the warehouse package CU cannot fit in the container 264 ( Fig. 11C , box 1110) and determine that the volume or weight of the warehouse package CU is not greater than the volume and weight of the empty container 264 ( Fig. 11C , box 1111), the controller determines whether the best fit algorithm is being used to containerize the product ( Fig. 11C , block 1112). In the event that the best fit algorithm is employed, the controller 120 determines whether there are products in the container 264 that satisfy the product mix and proximity rules for the products in the pick order line being analyzed ( Fig. 11C , box 1113 and Fig.11D, block 1114). In the event that there are products in a container that meet the mix / proximity criteria, the controller 120 adds the products in the pick order line to the container 264 and returns to block 1105 for processing the next subsequent pick order line in the sequence of pick order lines. In the event that there are products in a container that meet the mix / proximity criteria, the controller 120 closes the existing container 264 for the customer ( Fig. 11B , box 1117), open new container 264 ( Fig. 11B , box 1116), and add the products for the picking order line to the new container ( Fig. 11B , box 1123). The controller 120 continues to box 1105 for processing the next subsequent pick order line in the sequence of pick order lines. In the event that the best fit algorithm is not used, the controller closes the existing container 264 for the customer ( Fig. 11B , box 1117), open new container 264 ( Fig. 11B , box 1116), and add the products for the picking order line to the new container ( Fig. 11B , box 1123). The controller 120 continues to box 1105 for processing the next subsequent picking order line in the sequence of picking order lines.

[0085] As mentioned above, the filling of each container 264 for the ordered items is planned by the controller in the manner described above. Fig.12 An exemplary containerization for products ordered by customers A and B is illustrated in FIG. Here, customers A and B both place orders for products A, B, C, and D. Figures 11A-11C The containerization process described above is performed by the controller 120. Fig.10 ,exist Fig.12 An exemplary result of containerization is illustrated in FIG, where the best fit algorithm is employed, customer A specifies the following containerization rules for a sequence of commodity categories, and customer B specifies a mixed department containerization rule. Here, the containerization process provides containers 264A1, 264A2 in which the items ordered by customer A are placed (container 264A1 includes items A, B and container 264A2 includes items C, D). The containerization process also provides containers 264B1, 264B2 in which the items ordered by customer B are placed (container 264B1 includes items A, C and container 264B2 includes items B, D).

[0086] In the case where the container 264 (or the entire unretired warehouse package WHPK) of the customer order 299 in the consolidated order 299 is almost planned (i.e., containerization planned), the controller 120 is configured to determine the sequencing (e.g., the order of transportation) of the products from the product group PG stored on the storage level 130L assigned to the transportation lanes 260A-260n to achieve the completion of the customer order 299. Fig.13 and 14A -14B, sequencing assigns specific orders 299 to box units CU of products from the storage array 130SA to at least the split packing station 140 to fulfill the containerization plan and maintain the split packing goods BPG integrity (for example, the split packing goods BPG remains intact and usable after containerization (for example, containerizing the products) so that the corrosive is located below the non-corrosive and / or the least fragile products are located at the bottom of the container, which can promote product integrity after containerization). During the sequencing process, a customer order 299 / merged order 299C is received, and the orders 299, 299C specify (one or more) products to be used in the replenishment of the customer store (or to complete a direct-to-consumer e-commerce order). The controller 120 determines (for example, using any suitable software that may be included in one or more of the warehouse management software and the order management software) a plan for placing the products in the container (the containerization plan described above) and the transportation sequence of the products to the split packing station 140 (that is, the sequencing described herein) based on the orders 299, 299C. Figures 14A-14B In the example illustrated in , the consolidated order 299C is split into three segments 299CS (in a manner similar to that described herein), with containerization and sequencing performed by the controller 120 for each of the order segments 299CS. Based on the containerization and sequencing of the products, the controller 120 outputs the plan for picking execution for the split pack goods BPG transferred from the warehouse package WHPK to the split pack station 140 (via a suitable display at the split pack station for a human split pack operator or control commands for a robotic split pack operator) to the split pack goods container 264 for output from the storage structure 130 at the output station 160UT (for example, implemented by the corresponding asynchronous transport systems 255A-255n and the elevators 150A-150n of the corresponding transport channels 260A-260n). Figures 14A-14BIn the example illustrated in FIG, it should be noted that the consolidated order 299C is divided into three order segments 299CS, but in other aspects it may be divided into more or less than three order segments 299CS. It should also be noted that although the consolidated order is fulfilled by three orthogonal transport lanes 260A-260C, in other aspects there may be more or less than three transport lanes to complete the consolidated order 299C. Moreover, each transport lane 260A-260C is illustrated as having three corresponding storage levels 130L1-130L3, 130L4-130L6, 160L7-130L9 (each associated with a corresponding level of a corresponding split packing station 140), however, in other aspects, the transport lanes may have more or less than three storage levels.

[0087] Also refer to Figures 15A-15E , and an exemplary sequencing process will be described. During the sequencing process, the controller 120 checks the sequencing and bases the sequencing on one or more of the predetermined characteristics of the product BPG being sequenced and the hardware components. The predetermined characteristics of the product BPG being sequenced include, but are not limited to, the packaging type, the handling type, and the top strength of the packaging (for example, the characteristics include consideration of the position of the corrosive product relative to the position of the non-corrosive product in the container and the fragility of the product). Sequencing based on hardware components achieves one or more of the following: reducing the number of residual warehouse packages (for example, warehouse packages / box units that are not completely emptied at the split packaging station 140); utilizing the dual-task function of the container robot 110; reducing the congestion of the cargo robot 262 in the split packaging module 266; and optimizing the utilization of the seed wall 263W. The utilization of the dual-task function of the container robot 110 includes the transportation of the split packaging cargo BPG (in the warehouse package WHPK) to the split packaging station 140, and in the same robot 110, the journey transports the complete / filled split packaging container for output from the storage structure 130, or returns the residual box unit CU to the storage structure 130.

[0088] To achieve sequencing of the product BPG, the controller 120 reads the reserved tote 264RSV (see Fig. 14B ) of a predefined percentage PERTOTE (which may be configurable / reconfigurable) of a split pack container or tote 264 ( Fig.15A, block 1502). The reserve tote 264RSV is employed to receive overflow from other split pack containers 264 (e.g., such as where the other split pack containers would otherwise overflow if the product was not placed in the reserve tote) or to receive product for any other reason. The controller 120 retrieves (e.g., from any suitable memory) the maximum number MAX264 of split pack containers to operate for the corresponding transport lane 260A-260n ( Fig.15A , block 1503). The controller determines the maximum number MAXFILLCNT of split pack containers 264 that can be filled simultaneously for a given transport lane 260A-260n using the following formula: MAXFILLCNT = MAX264 x PERTOTE [Equation 5].

[0089] The controller 120 processes the sequencing ( Fig. 15B , block 1505), as provided below with respect to blocks 1506-1525. Parallel processing of product group sets PGSA-PGSn includes dynamically determining the number of customer orders to be processed in parallel, as determined by, for example, one or more of the customer included in the consolidated order 299C, the customer's gate time, and the number of available split pack containers at the seed wall 263W (see block 1504). For example, the controller 120 sorts the products to be containerized in ascending order by commodity category and then in descending order by warehouse package WHPK volume and warehouse package WHPK weight ( Fig. 15B , block 1506). The controller loops through all unordered products in order 299C ( Fig. 15B , block 1507), and determine whether there are any products in order 299C that have not been ordered ( Fig. 15B , block 1508). When all products in order 299C have been ordered, the ordering process ends ( Fig. 15B , box 1516).

[0090] In the case where there are products that still need to be sequenced ( Fig. 15B , block 1508), the controller 120 lists the product BPGs and corresponding split pack containers 264 (as determined from the containerization process) to be sequenced in the iteration ( Fig. 15C , block 1509). The controller determines whether the product BPG being sequenced requires a new split pack container to be opened (as determined during the containerization process) ( Fig. 15C , block 1510). In the event that a new split pack container is not required, each time containerization is performed, the controller 120 adds the product BPG and its assigned split pack container 264 to the list of items and containers to be sequenced ( Fig. 15C , box 1511), and returns to box 1508 for processing the next product BPG.

[0091] In the case where a new split pack container 264 is required ( Fig. 15C , block 1510), the controller 120 determines whether the number of open split pack containers NOBC (e.g., split pack containers with products that have been sequenced) plus the new split pack containers NBCO opened by the currently sequenced split pack cargo BPG is less than or equal to the maximum number MAXFILLCNT ( Fig. 15C , box 1512).

[0092] NOBC+NBCO<=MAXFILLCNT [Equation 6] In the event that Equation 6 is satisfied, the controller 120 adds the product BPG and its assigned split pack container 264 to the list of items and containers to be sequenced ( Fig. 15C , box 1511), and returns to box 1508 for processing the next product BPG.

[0093] In the case where Equation 6 is not satisfied, the controller 120 determines whether the currently processed split pack cargo BPG requires opening any of the split pack containers 264 ( Fig. 15C , box 1513). In the case where the currently processed split pack cargo BPG requires opening one of the split pack containers 264 ( Fig. 15C , block 1513), the controller 120 determines the number of split pack containers 264 of the current split pack cargo BPG that can be added to the list of split pack cargoes BPGs and their split pack containers to be sequenced without exceeding a threshold value of total split pack containers (i.e., the maximum number MAXFILLCNT of split pack containers 264 that can be filled simultaneously). Fig. 15C , block 1514). The controller 120 adds no more than MAXFILLCNT number of totes for the currently processed break-pack cargo BPG to the list of items and containers to be sequenced ( Fig. 15C , box 1511), and returns to box 1508 for processing the next product BPG.

[0094] In the case where the currently processed split pack cargo BPG does not require opening one of the split pack containers 264 ( Fig. 15C , block 1513), the controller 120 sequences the items in the list of split pack goods BPG to be sequenced and their split pack containers ( Fig. 15C, box 1515), as follows in boxes 1517-1525. For example, the controller 120 lists the split pack goods BPG that are still to be sequenced and their corresponding split pack containers 264 ( Fig.15D , box 1517), and loops through all the split pack cargoes BPG and their corresponding split pack containers 264 ( Fig.15D , block 1518). The controller 120 determines whether there are more unsequenced break-bulk pack goods BPG and their corresponding break-bulk pack containers 264 ( Fig.15D , block 1519). In the event that there are no break-pack cargoes BPG and their corresponding break-pack containers 264 that remain to be sequenced ( Fig.15D , box 1519), the controller 120 returns to box 1507 ( Fig.15D , box 1525).

[0095] In the absence of split pack goods BPG and their corresponding split pack containers 264 that are still to be sequenced ( Fig.15D , box 1519), the controller 120 determines whether the number of split packaged goods BPG currently being processed is equal to or greater than 3 ( Fig.15E , block 1520). In the case that the number of currently processed split pack cargo BPG is less than 3, the controller assigns the split pack cargo BPG and its corresponding split pack container 264 to the next sequence number ( ) in the sequence of items transported to the split pack station 140. Fig.15E , block 1521). In the case where the number of currently processed split package goods BPG is greater than or equal to 3, the controller 120 generates a list of split package containers 264 that can be satisfied by a threshold of 1 / 3 of the split package goods BPG (vendor package VNPK) for the split package goods BPG (i.e., SKU) ( Fig.15E , box 1523), and assigns the split package cargo BPG and its partial split package cargo container 264 to the next sequence number in the sequence of items transported to the split packing station 140 ( Fig.15E , box 1521). The controller increments the sequence number by 1 ( Fig.15D , box 1522), and returns to box 1519 to determine whether any split pack cargoes BPG and their corresponding split pack containers 264 still need to be sequenced ( Fig.15D , box 1519).

[0096] refer to Figure 1A , 1B , 2, 3A and 16, an exemplary method for fulfilling a product order for a mixed product unit will be described according to aspects of the disclosed embodiments. The method includes: inputting and distributing a mixed product unit BPG ( Fig.16 , block 1600). As described herein, the storage array 130SA has at least one elevated storage level 130L, and mixed product units BPG are input and distributed in the storage array 130SA in boxes (i.e., box units CU (also referred to herein as warehouse packages WHPK)) each having a common type of product unit. The product units BPG distributed in the boxes CU in the at least one elevated storage level 130L of the storage array 130SA are automatically retrieved and outputted from the storage array 130SA using the automated transport system 277 of the product order fulfillment system 100. Fig.16 , box 1601). The output product unit is one or more of the following: mixed singulated product units, in mixed packaging groups, and in mixed boxes. As described herein, the automated transport system 277 is communicatively connected to the storage array 130SA and has at least one asynchronous transport system 255A-255n for level transport and elevators 150A-150n for level transport. As described herein, the at least one asynchronous transport system 255A-255n and the elevators 150A-150n are configured to form more than one transport channel 260A, 260n, at least one of which is separate and different from another transport channel 260A-260n. Each transport channel 260A-260n is communicatively connected to the at least one elevated storage level 130L and an output (such as, an output station 160UT), and the at least one transport channel 260A-260n implements orthogonal transport output of product units BPG distributed in the storage array 130SA relative to each other transport channel 260A-260n.

[0097] The method further includes: utilizing the controller 120 communicatively coupled to the more than one shipping lanes 260A-260n, registering customer orders 299 for the product unit BPG and describing each order 299 in one or more product groups PGA-PGn of the product unit BPG ( Fig.16 , block 1602). Each product group PGA-PGn has a unique predetermined product group characteristic (as described herein) that characterizes the product group PGA-PGn and relates the product groups PGA-PGn to each other. The controller heuristically resolves the product groups PGA-PGn of more than one order 299C into product group sets PGSA-PGSn ( Fig.16 , block 1603). Each product group set PGSA-PGSn has a plurality of product groups PGA-PGn and is orthogonal to each other product group set PGSA-PGSn and has a maximum number of mergeable product groups PGA-PGn. The controller 120 is programmed with store rules (as described herein) that define the mergeability of product groups PGA-PGn and product groups PGA-PGn with each other.

[0098] The controller 120 implements dynamic resolution of the product group sets PGSA-PGSn based at least on the number of assigned product group sets PGSA-PGSn relative to a predetermined threshold value (e.g., the average supplier packaging requirement of Equation 2A or Equation 2B) of the product units BPG transported via the at least one transport channel 260A-260n and the number of other assigned product group sets PGSA-PGSn relative to the corresponding threshold value (e.g., the average supplier packaging requirement of Equation 2A or Equation 2B) of each other transport channel 260A-260n.

[0099] The controller 120 assigns each parsed product group set PGSA-PGSn to the at least one transport channel 260A-260n ( Fig.16 , box 1604) for retrieving and outputting product units BPG forming a product group set PGSA-PGSn into an order container 264 of mixed product units BPG via the at least one transport channel 260A-260n, wherein the product group set PGSA-PGSn is allocated so as not to exceed a predetermined threshold (e.g., an average supplier packaging requirement of Equation 2A or Equation 2B) of product units BPG transported via the at least one transport channel 260A-260n.

[0100] The controller 120 implements dynamic allocation of the product group set PGSA-PGSn to the at least one transport channel 260A-260n and balances the product group set PGSA-PGSn allocated to the at least one transport channel 260A-260n with the other allocated product group sets PGSA-PGSn allocated to each other transport channel 260A-260n. In the method, at least one of the parsing and allocation of the product group set PGSA-PGSn optimizes the transportation of the product unit BPG per customer order 299 using the asynchronous transportation system 255A-255n, as described herein. At least one of the parsing and allocation of the product group set PGSA-PGSn minimizes the robot 110 transportation of the box CU / split packaging container 264 of the product unit BPG per customer order 299.

[0101] refer to Figure 1A , 1B , 2, 3A and 17, provide an exemplary method for fulfilling a product order of a mixed product unit. The method includes: utilizing the at least one asynchronous transport system 255A-255n to distribute the mixed product unit BPG ( Fig.17, box 1700). As described herein, the storage array 130SA has at least one elevated storage and transportation level 130L, mixed product units BPG are distributed in the storage array 130SA in boxes CU / warehouse packages WHPK with common types of product units per box, the at least one asynchronous transportation system 255A-255n implements level (e.g., corresponding level 130L) transportation to automatically retrieve and output the product units BPG distributed in the boxes CU / warehouse packages WHPK from the storage array 130SA, and each of the at least one elevated storage and transportation level 130L is separate and different from each other elevated storage and transportation level 130L. As described herein, each elevated storage and transportation level 130L implements orthogonal transportation output of the product units BPG distributed in the storage array 130SA relative to each other elevated storage and transportation level 130L.

[0102] The controller 120, which is communicatively connected to the at least one elevated storage and transport level 130L, registers a customer order 299 of a product unit BPG represented by one or more product groups PGA-PGn of the product unit BPG. Fig.17 , block 1701). As described herein, each product group PGA-PGn has a unique predetermined product group characteristic that characterizes the product units BPG of the product group PGA-PGn and relates the product group PGA-PGn to each other product group PGA-PGn.

[0103] The controller 120 dynamically resolves the product groups PGA-PGn describing each customer order 299 into product group sets PGSA-PGSn ( Fig.17 , block 1702). Each product group set PGSA-PGSn has multiple product groups PGA-PGn and is orthogonal to each other product group set PGSA-PGSn. The controller 120 dynamically assigns each resolved product group set PGSA-PGSn to the at least one elevated storage and transportation level 130L ( Fig.17 , block 1703). The controller 120 dynamically binds (as described herein) the product units BPG of the assigned product group set PGSA-PGSn of the at least one elevated storage and transportation level 130L to predetermined boundaries ( Fig.17, box 1704), and wherein the other heuristic solution is based on at least one product group characteristic and a customer or default affinity rule (as described herein). The product group set PGSA-PGSn is dynamically allocated for retrieving and outputting the product units BPG forming the product group set PGSA-PGSn via the at least one storage and transportation level 130L into the order / split pack container 264 holding the batch of mixed product units, wherein the product group set PGSA-PGSn is dynamically allocated so as not to exceed a predetermined threshold (e.g., the average supplier packaging requirement of Equation 2A or Equation 2B) of the product units transported via the at least one elevated storage and transportation level 130L. The controller 120 implements dynamic resolution of the product group set PGSA-PGSn based at least on the number of allocated product group sets PGSA-PGSn relative to a predetermined threshold value (e.g., the average supplier packaging requirement of Equation 2A or Equation 2B) of the product units BPG transported via the at least one elevated storage and transportation level 130L and the number of other allocated product group sets PGSA-PGSn relative to the corresponding threshold value (e.g., the average supplier packaging requirement of Equation 2A or Equation 2B) of each other elevated storage and transportation level 130L, respectively. The controller 120 implements dynamic allocation of the product group set PGSA-PGSn to the at least one elevated storage and transportation level 130L and balances (as described herein) the product group set PGSA-PGSn allocated to the at least one elevated storage and transportation level 130L with the other allocated product group sets PGSA-PGSn allocated to each other elevated storage and transportation level 130L. As described herein, at least one of the parsing and allocation of the product group sets PGSA-PGSn optimizes the transportation of the product units BPG per customer order 299 using the asynchronous transportation systems 255A-255n. Also as described herein, at least one of the parsing and allocation of the product group sets PGSA-PGSn minimizes the robot 110 transportation of the boxes CU / warehouse packs WHPK of the product units BPG per customer order 299.

[0104] According to one or more aspects of the disclosed embodiment, a product order fulfillment system for mixed product units is provided. The product order fulfillment system comprises: a storage array having at least one elevated storage level, wherein mixed product units are input and distributed in boxes of a common type of product units per box in the storage array; an automated transportation system having at least one asynchronous transportation system for level transportation and an elevator for level transportation between levels, communicatively connected to the storage array so as to automatically retrieve and output from the storage array the product units distributed in the boxes in the at least one elevated storage level of the storage array, the output product units being one or more of the following: mixed singularized product units, in mixed packaging groups, and in mixed boxes; wherein the at least one asynchronous transportation system and the elevator are configured to form more than one transportation channel, at least one of which is separate and different from another transportation channel, each transportation channel being communicatively connected to the at least one elevated storage level and the output, and the at least one transportation channel being implemented in the storage orthogonal transport output of product units distributed in an array relative to each other transport channel; and a controller, communicatively connected to the more than one transport channel, the controller being configured to: register customer orders for product units and describe each order in one or more product groups of product units, each product group having a unique predetermined product group characteristic that characterizes the product group and that relates the product groups to each other; heuristically resolve the product groups of more than one order into product group sets based on the product group characteristics, each product group set having multiple product groups, being orthogonal to each other product group set, and having a maximum number of mergeable product groups; and assigning each resolved product group set to the at least one transport channel for retrieving and outputting the product units that form the product group set into an order container for mixed product units via the at least one transport channel, wherein the product group sets are assigned so as not to exceed a predetermined threshold of product units transported via the at least one transport channel.

[0105] According to one or more aspects of the disclosed embodiments, the controller is configured to implement dynamic parsing of the product group sets based at least on a number of assigned product group sets relative to a predetermined threshold of product units transported via the at least one transport channel and a number of other assigned product group sets relative to corresponding thresholds of each other transport channel, respectively.

[0106] According to one or more aspects of the disclosed embodiment, the controller is configured to implement dynamic allocation of the product group sets to the at least one transportation channel and balance the product group sets allocated to the at least one transportation channel with other allocated product group sets allocated to each other transportation channel.

[0107] According to one or more aspects of the disclosed embodiment, the customer order has a mix of product units, wherein each unit is stored in bins of the storage array with each bin having a common type of product unit.

[0108] According to one or more aspects of the disclosed embodiment, each customer order has at least one of the mixed product units.

[0109] According to one or more aspects of the disclosed embodiment, the at least one transport channel is independent of each other of the more than one transport channels such that output of product units from the at least one transport channel is orthogonal to output from each other transport channel.

[0110] According to one or more aspects of the disclosed embodiment, at least one of parsing and allocating the product group set optimizes the shipping of product units per customer order using the asynchronous shipping system.

[0111] In accordance with one or more aspects of the disclosed embodiment, the at least one asynchronous transport system includes an autonomously guided autonomous robot that asynchronously traverses the at least one elevated storage level.

[0112] In accordance with one or more aspects of the disclosed embodiment, each self-guided autonomous robot is configured to transport a box of a common type of product unit.

[0113] According to one or more aspects of the disclosed embodiments, at least one of parsing and assigning of product group sets minimizes robotic transportation of boxes of product units per customer order.

[0114] In accordance with one or more aspects of the disclosed embodiment, the at least one transport aisle is connected to at least one elevated storage level that is separate and distinct from each other transport aisle.

[0115] In accordance with one or more aspects of the disclosed embodiments, the at least one transport channel is connected to a corresponding one or more of the at least one elevated storage levels, the corresponding one or more being different from the elevated storage levels of the storage array connected to and corresponding to each other transport channel.

[0116] In accordance with one or more aspects of the disclosed embodiment, the controller is programmed with store rules that define product groups and the mergeability of product groups with each other.

[0117] According to one or more aspects of the disclosed embodiment, a product order fulfillment system for mixed product units is provided. The product order fulfillment system includes: a storage array having at least one elevated storage and transportation level, wherein the mixed product units are distributed in the storage array in boxes with common types of product units in each box using at least one asynchronous transportation system for level transportation so that the product units distributed in the boxes are automatically retrieved and output from the storage array; wherein each of the at least one elevated storage and transportation level is separate and different from each other elevated storage and transportation level, and each elevated storage and transportation level achieves orthogonal transportation output of the product units distributed in the storage array relative to each other elevated storage and transportation level; and a controller communicatively connected to the more than one elevated storage and transportation level, the controller being configured to: register customer orders for product units represented by one or more product groups of product units, each of which is ... a product group having a unique predetermined product group characteristic that characterizes the product units of the product group and relates the product group to each other product group; dynamically resolving the product group describing each customer order into a set of product groups based on the unique predetermined product group characteristic via a heuristic solution, each set of product groups having multiple product groups and being orthogonal to each other set of product groups; and dynamically assigning each resolved set of product groups to the at least one elevated storage and transportation level; and wherein via another heuristic solution, the product units of the assigned product group set of the at least one elevated storage and transportation level are dynamically bound into predetermined boundaries in a batch of mixed product units for each customer order corresponding to the assigned product group set, and wherein the other heuristic solution is based on at least one product group characteristic and a customer or default affinity rule.

[0118] According to one or more aspects of the disclosed embodiments, each resolved set of product groups is orthogonal to each other set of product groups and has a maximum number of mergeable product groups.

[0119] In accordance with one or more aspects of the disclosed embodiments, the product group sets are dynamically allocated for retrieving and outputting the product units forming the product group sets via the at least one storage and transportation level into order containers that hold batches of mixed product units, wherein the product group sets are dynamically allocated so as not to exceed a predetermined threshold of product units transported via the at least one storage and transportation channel.

[0120] In accordance with one or more aspects of the disclosed embodiments, the controller is configured to implement dynamic parsing of the product group sets based at least on a predetermined threshold number of assigned product group sets relative to product units transported via the at least one elevated storage and transportation level and a corresponding threshold number of other assigned product group sets relative to each other elevated storage and transportation level, respectively.

[0121] In accordance with one or more aspects of the disclosed embodiments, the controller is configured to implement dynamic allocation of the set of product groups to the at least one elevated storage and transportation level, and to balance the set of product groups allocated to the at least one elevated storage and transportation level with the other allocated sets of product groups allocated to each other elevated storage and transportation level.

[0122] According to one or more aspects of the disclosed embodiment, the customer order has a mix of product units, wherein each unit is stored in bins of the storage array with each bin having a common type of product unit.

[0123] According to one or more aspects of the disclosed embodiment, each customer order has at least one of the mixed product units.

[0124] According to one or more aspects of the disclosed embodiment, at least one of parsing and allocating the product group set optimizes the shipping of product units per customer order using the asynchronous shipping system.

[0125] In accordance with one or more aspects of the disclosed embodiment, the at least one asynchronous transport system includes an autonomously guided autonomous robot that asynchronously traverses the at least one elevated storage and transport level.

[0126] In accordance with one or more aspects of the disclosed embodiment, each self-guided autonomous robot is configured to transport a box of a common type of product unit.

[0127] According to one or more aspects of the disclosed embodiments, at least one of parsing and assigning of product group sets minimizes robotic transportation of boxes of product units per customer order.

[0128] In accordance with one or more aspects of the disclosed embodiment, the controller is programmed with store rules that define product groups and the mergeability of product groups with each other.

[0129] According to one or more aspects of the disclosed embodiment, a method for fulfilling a product order of mixed product units is provided. The method includes: inputting and distributing mixed product units in a storage array of a product order fulfillment system, the storage array having at least one elevated storage level, and the mixed product units are input and distributed in the storage array in boxes with common types of product units in each box; using an automated transportation system of the product order fulfillment system, automatically retrieving and outputting the product units distributed in the boxes in the at least one elevated storage level of the storage array from the storage array, the output product units being one or more of the following: mixed singularized product units, in mixed packaging groups, and in mixed boxes, wherein the automated transportation system is communicatively connected to the storage array and has at least one asynchronous transportation system for level transportation and an elevator for level transportation, wherein: the at least one asynchronous transportation system and the elevator are configured to form more than one transportation channel, at least one of which is separate and different from another transportation channel, each transportation channel being communicatively connected to the at least one elevated storage level and the output The storage array is connected to the at least one transport channel, and the at least one transport channel realizes orthogonal transport output of product units distributed in the storage array relative to each other transport channel; and using a controller that is communicatively connected to the more than one transport channel, registering customer orders for product units and describing each order in one or more product groups of product units, each product group having a unique predetermined product group characteristic that characterizes the product group and makes the product groups related to each other; using the controller, heuristically parsing the product groups of more than one order into product group sets based on the product group characteristics, each product group set having multiple product groups, and being orthogonal to each other product group set, and having a maximum number of mergeable product groups; and using the controller, assigning each parsed product group set to the at least one transport channel for retrieving and outputting the product units that form the product group set into an order container of mixed product units via the at least one transport channel, wherein the product group sets are assigned so as not to exceed a predetermined threshold of product units transported via the at least one transport channel.

[0130] According to one or more aspects of the disclosed embodiments, the controller implements dynamic parsing of the product group sets based at least on the number of assigned product group sets relative to a predetermined threshold of product units transported via the at least one transport channel and the number of other assigned product group sets relative to corresponding thresholds of each other transport channel, respectively.

[0131] According to one or more aspects of the disclosed embodiment, the controller implements dynamic allocation of the product group sets to the at least one transportation channel and balances the product group sets allocated to the at least one transportation channel with other allocated product group sets allocated to each other transportation channel.

[0132] According to one or more aspects of the disclosed embodiment, the customer order has a mix of product units, wherein each unit is stored in bins of the storage array with each bin having a common type of product unit.

[0133] According to one or more aspects of the disclosed embodiment, each customer order has at least one of the mixed product units.

[0134] According to one or more aspects of the disclosed embodiment, the at least one transport channel is independent of each other of the more than one transport channels such that output of product units from the at least one transport channel is orthogonal to output from each other transport channel.

[0135] According to one or more aspects of the disclosed embodiment, at least one of parsing and allocating the product group set optimizes the shipping of product units per customer order using the asynchronous shipping system.

[0136] In accordance with one or more aspects of the disclosed embodiment, the at least one asynchronous transport system includes an autonomously guided autonomous robot that asynchronously traverses the at least one elevated storage level.

[0137] In accordance with one or more aspects of the disclosed embodiment, each self-guided autonomous robot is configured to transport a box of a common type of product unit.

[0138] According to one or more aspects of the disclosed embodiments, at least one of parsing and assigning of product group sets minimizes robotic transportation of boxes of product units per customer order.

[0139] In accordance with one or more aspects of the disclosed embodiment, the at least one transport aisle is connected to at least one elevated storage level that is separate and distinct from each other transport aisle.

[0140] In accordance with one or more aspects of the disclosed embodiments, the at least one transport channel is connected to a corresponding one or more of the at least one elevated storage levels, the corresponding one or more being different from the elevated storage levels of the storage array connected to and corresponding to each other transport channel.

[0141] In accordance with one or more aspects of the disclosed embodiment, the controller is programmed with store rules that define product groups and the mergeability of product groups with each other.

[0142] According to one or more aspects of the disclosed embodiment, a method for fulfilling a product order of mixed product units is provided. The method includes: utilizing at least one asynchronous transportation system to distribute the mixed product units in a storage array, wherein: the storage array has at least one elevated storage and transportation level, the mixed product units are distributed in the storage array in boxes with common types of product units in each box, the at least one asynchronous transportation system implements level transportation to automatically retrieve and output the product units distributed in the box from the storage array, and each of the at least one elevated storage and transportation level is separate and different from each other elevated storage and transportation level, and each elevated storage and transportation level implements orthogonal transportation output of the product units distributed in the storage array relative to each other elevated storage and transportation level; utilizing a controller communicatively connected to the at least one elevated storage and transportation level, registering a customer order of product units represented by one or more product groups of product units, each product group having a plurality of product groups of product units, wherein each product group has ... A product group has a unique predetermined product group characteristic that characterizes the product units of the product group and makes the product group related to each other product group; using the controller, dynamically resolving the product group describing each customer order into a set of product groups based on the unique predetermined product group characteristic via a heuristic solution, each product group set having multiple product groups and being orthogonal to each other product group set; using the controller, dynamically assigning each resolved product group set to the at least one elevated storage and transportation level; and using the controller, dynamically binding the product units of the assigned product group set of the at least one elevated storage and transportation level into predetermined boundaries in a batch of mixed product units for each customer order corresponding to the assigned product group set via another heuristic solution, and wherein the other heuristic solution is based on at least one product group characteristic and a customer or default affinity rule.

[0143] According to one or more aspects of the disclosed embodiments, each resolved set of product groups is orthogonal to each other set of product groups and has a maximum number of mergeable product groups.

[0144] In accordance with one or more aspects of the disclosed embodiments, the product group sets are dynamically allocated for retrieving and outputting the product units forming the product group sets via the at least one storage and transportation level into order containers that hold batches of mixed product units, wherein the product group sets are dynamically allocated so as not to exceed a predetermined threshold of product units transported via the at least one storage and transportation channel.

[0145] According to one or more aspects of the disclosed embodiments, the controller implements dynamic parsing of the product group sets based at least on a predetermined threshold number of assigned product group sets relative to product units transported via at least one elevated storage and transportation level and a corresponding threshold number of other assigned product group sets relative to each other elevated storage and transportation level, respectively.

[0146] In accordance with one or more aspects of the disclosed embodiments, the controller implements dynamic allocation of the product group sets to the at least one elevated storage and transportation level, and balances the product group sets allocated to the at least one elevated storage and transportation level with other allocated product group sets allocated to each other elevated storage and transportation level.

[0147] According to one or more aspects of the disclosed embodiment, the customer order has a mix of product units, wherein each unit is stored in bins of the storage array with each bin having a common type of product unit.

[0148] According to one or more aspects of the disclosed embodiment, each customer order has at least one of the mixed product units.

[0149] According to one or more aspects of the disclosed embodiment, at least one of parsing and allocating the product group set optimizes the shipping of product units per customer order using the asynchronous shipping system.

[0150] In accordance with one or more aspects of the disclosed embodiment, the at least one asynchronous transport system includes an autonomously guided autonomous robot that asynchronously traverses the at least one elevated storage and transport level.

[0151] In accordance with one or more aspects of the disclosed embodiment, each self-guided autonomous robot is configured to transport a box of a common type of product unit.

[0152] According to one or more aspects of the disclosed embodiments, at least one of parsing and assigning of product group sets minimizes robotic transportation of boxes of product units per customer order.

[0153] In accordance with one or more aspects of the disclosed embodiment, the controller is programmed with store rules that define product groups and the mergeability of product groups with each other.

[0154] It should be understood that the above description only illustrates aspects of the disclosed embodiments. Various alternatives and modifications may be devised by those skilled in the art without departing from the aspects of the disclosed embodiments. Accordingly, the aspects of the disclosed embodiments are intended to cover all such alternatives, modifications and variations that fall within the scope of any appended claims. Further, the mere fact that different features are recited in mutually different dependent or independent claims does not indicate that a combination of these features cannot be used to advantage, and such a combination is still within the scope of the aspects of the disclosed embodiments.

Claims

1. A product order fulfillment system for mixed product units, the product order fulfillment system comprising: a storage array having at least one elevated storage level, wherein mixed product units are input and distributed in said storage array in bins having a common variety of product units per bin; an automated transport system having at least one asynchronous transport system for level transport and an elevator for between-level transport, communicatively coupled to said storage array for automatically retrieving and outputting from said storage array product units distributed in said bins in said at least one elevated storage level of said storage array, said output product units being one or more of: mixed singulated product units, in mixed packaging groups, and in mixed bins; wherein the at least one asynchronous transport system and the elevators are configured to form more than one transport lane, at least one of which is separate and distinct from another transport lane, each transport lane being communicatively connected to the at least one elevated storage level and the output, and the at least one transport lane enabling orthogonal transport output of product units distributed in the storage array relative to each of the other transport lanes; as well as A controller communicatively coupled to the more than one transport channel, the controller being configured to: registering customer orders for product units and describing each order in one or more product groups of product units, each product group having a unique predetermined product group characteristic that characterizes the product group and that relates the product groups to one another; Heuristically resolving the product groups of more than one order into product group sets based on the product group characteristics, each product group set having a plurality of product groups and being orthogonal to each other product group set and having a maximum number of mergeable product groups; and Each parsed product group set is assigned to the at least one transport channel for retrieving and outputting the product units forming the product group set into an order container of mixed product units via the at least one transport channel, wherein the product group set is assigned so as not to exceed a predetermined threshold of product units transported via the at least one transport channel.

2. A product order fulfillment system as described in claim 1, wherein the controller is configured to implement dynamic resolution of the product group sets based at least on the number of assigned product group sets relative to a predetermined threshold of product units transported via the at least one transportation channel and the number of other assigned product group sets relative to corresponding thresholds of each other transportation channel.

3. The product order fulfillment system of claim 1 , wherein the controller is configured to implement dynamic allocation of the product group sets to the at least one transportation lane and to balance the product group sets allocated to the at least one transportation lane with other allocated product group sets allocated to each other transportation lane.

4. The product order fulfillment system of claim 1 wherein the customer order has a mix of product units, wherein each unit is stored in boxes in the storage array with each box having a common type of product unit.

5. The product order fulfillment system of claim 1, wherein each customer order has at least one of the mixed product units.

6. The product order fulfillment system of claim 1, wherein the at least one transport lane is independent of each other of the more than one transport lanes such that output of product units from the at least one transport lane is orthogonal to output from each other transport lane.

7. The product order fulfillment system of claim 1, wherein at least one of parsing and allocating product group sets optimizes shipping of product units per customer order utilizing the asynchronous shipping system.

8. The product order fulfillment system of claim 1, wherein the at least one asynchronous transportation system comprises a self-guided autonomous robot that asynchronously traverses the at least one elevated storage level.

9. The product order fulfillment system of claim 8, wherein each self-guided autonomous robot is configured to transport a box of a common type of product units.

10. The product order fulfillment system of claim 8, wherein at least one of parsing and allocating the product grouping minimizes robotic transportation of boxes of product units per customer order.

11. The product order fulfillment system of claim 1 , wherein the at least one transport lane is connected to at least one elevated storage level that is separate and distinct from each other transport lane.

12. The product order fulfillment system of claim 1 , wherein the at least one transport channel is connected to a corresponding one or more of the at least one elevated storage levels, the corresponding one or more being different from the elevated storage levels of the storage array connected to and corresponding to each other transport channel.

13. The product order fulfillment system of claim 1 wherein the controller is programmed with store rules defining product groups and the combinability of product groups with one another.

14. A product order fulfillment system for mixed product units, the product order fulfillment system comprising: a storage array having at least one elevated storage and transport level, wherein mixed product units are distributed in said storage array in cases having a common variety of product units per case using at least one asynchronous transport system for level transport so that the product units distributed in said cases are automatically retrieved and outputted from said storage array; wherein each of said at least one elevated storage and transport level is separate and distinct from each other elevated storage and transport level, each elevated storage and transport level achieving an orthogonal transport output of product units distributed in said storage array relative to each other elevated storage and transport level; as well as a controller communicatively connected to the more than one elevated storage and transport levels, the controller being configured to: registering a customer order for a product unit represented by one or more product groups of product units, each product group having a unique predetermined product group characteristic that represents the product units of the product group and that relates the product group to each other product group; dynamically resolving the product group describing each customer order into product group sets via a heuristic solution based on the unique predetermined product group characteristics, each product group set having a plurality of product groups and being orthogonal to every other product group set; and dynamically assigning each resolved set of product groups to the at least one elevated storage and transportation level; and Wherein the product units of the assigned product group set of at least one elevated storage and transportation level are dynamically bounded into predetermined boundaries in batches of mixed product units for each customer order corresponding to the assigned product group set via another heuristic solution, and wherein the other heuristic solution is based on at least one product group characteristic and a customer or default affinity rule.

15. The product order fulfillment system of claim 14, wherein each resolved set of product groups is orthogonal to every other set of product groups and has a maximum number of mergeable product groups.

16. A product order fulfillment system as described in claim 14, wherein the product group set is dynamically allocated for retrieving and outputting the product units forming the product group set via the at least one storage and transportation level into order containers that hold batches of mixed product units, wherein the product group set is dynamically allocated so as not to exceed a predetermined threshold of product units transported via the at least one elevated storage and transportation channel.

17. A product order fulfillment system as described in claim 14, wherein the controller is configured to implement dynamic resolution of the product group sets based at least on the number of assigned product group sets relative to a predetermined threshold of product units transported via the at least one elevated storage and transportation level and the number of other assigned product group sets relative to corresponding thresholds of each other elevated storage and transportation level.

18. The product order fulfillment system of claim 14, wherein the controller is configured to implement dynamic assignment of the set of product groups to the at least one elevated storage and transportation level and to balance the set of product groups assigned to the at least one elevated storage and transportation level with other assigned sets of product groups assigned to each other elevated storage and transportation level.

19. The product order fulfillment system of claim 14, wherein the customer order has a mix of product units, wherein each unit is stored in bins of the storage array with each bin having a common type of product unit.

20. The product order fulfillment system of claim 14, wherein each customer order has at least one of the mixed product units.

21. The product order fulfillment system of claim 14, wherein at least one of parsing and allocating product group sets optimizes shipping of product units per customer order using the asynchronous shipping system.

22. The product order fulfillment system of claim 14, wherein the at least one asynchronous transportation system comprises a self-guided autonomous robot that asynchronously traverses the at least one elevated storage and transportation level.

23. The product order fulfillment system of claim 22, wherein each self-guided autonomous robot is configured to: transport a box of a common type of product units.

24. The product order fulfillment system of claim 22, wherein at least one of parsing and allocating the product grouping minimizes robotic transportation of boxes of product units per customer order.

25. The product order fulfillment system of claim 14, wherein the controller is programmed with store rules defining product groups and the combinability of product groups with each other.

26. A method for fulfilling a product order for mixed product units, the method comprising: inputting and distributing mixed product units in a storage array of a product order fulfillment system, the storage array having at least one elevated storage level, and the mixed product units are input and distributed in the storage array in cases having a common variety of product units per case; Utilizing an automated transport system of the product order fulfillment system, automatically retrieving and outputting product units distributed in the boxes in the at least one elevated storage level of the storage array from the storage array, the output product units being one or more of: mixed singulated product units, in mixed packaging groups, and in mixed boxes, wherein the automated transport system is communicatively connected to the storage array and has at least one asynchronous transport system for level transport and elevators for between-level transport, wherein: the at least one asynchronous transport system and the elevators being configured to form more than one transport lane, at least one of which is separate and distinct from another transport lane, each transport lane being communicatively connected to the at least one elevated storage level and the output, and the at least one transport lane enabling orthogonal transport output of product units distributed in the storage array relative to each other transport lane; and registering, with a controller communicatively coupled to the more than one transportation lanes, customer orders for product units and describing each order in one or more product groups of product units, each product group having a unique predetermined product group characteristic that characterizes the product group and that relates the product groups to one another; and utilizing the controller to heuristically resolve product groups of more than one order into product group sets based on the product group characteristics, each product group set having a plurality of product groups and being orthogonal to each other product group set and having a maximum number of mergeable product groups; and Using the controller, each parsed product group set is assigned to the at least one transport channel for retrieving and outputting product units forming the product group set into an order container of mixed product units via the at least one transport channel, wherein the product group set is assigned so as not to exceed a predetermined threshold of product units transported via the at least one transport channel.

27. A method as claimed in claim 26, wherein the controller implements dynamic parsing of the product group sets based at least on the number of assigned product group sets relative to a predetermined threshold of product units transported via the at least one transport channel and the number of other assigned product group sets relative to corresponding thresholds of each other transport channel.

28. The method of claim 26, wherein the controller implements dynamic assignment of the product group sets to the at least one transportation lane and balances the product group sets assigned to the at least one transportation lane with other assigned product group sets assigned to each other transportation lane.

29. The method of claim 26, wherein the customer order has a mix of product units, wherein each unit is stored in boxes in the storage array, each box having a common type of product unit.

30. The method of claim 26 wherein each customer order has at least one of said mixed product units.

31. The method of claim 26, wherein the at least one transport channel is independent of each other of the more than one transport channels such that output of product units from the at least one transport channel is orthogonal to output from each other transport channel.

32. The method of claim 26, wherein at least one of parsing and allocating product group sets optimizes shipping of product units per customer order utilizing the asynchronous shipping system.

33. The method of claim 26, wherein the at least one asynchronous transport system comprises a self-guided autonomous robot that asynchronously traverses the at least one elevated storage level.

34. The method of claim 33, wherein each self-guided autonomous robot is configured to transport a box of a common type of product units.

35. The method of claim 33, wherein at least one of parsing and allocating product group sets minimizes robotic transportation of boxes of product units per customer order.

36. The method of claim 26, wherein the at least one transport lane is connected to at least one elevated storage level that is separate and distinct from each other transport lane.

37. The method of claim 26, wherein the at least one transport channel is connected to a corresponding one or more of the at least one elevated storage levels, the corresponding one or more being different from the elevated storage levels of the storage array connected to and corresponding to each other transport channel.

38. The method of claim 26, wherein the controller is programmed with store rules that define product groups and the combinability of product groups with each other.

39. A method for fulfilling a product order for mixed product units, the method comprising: Mixed product units are distributed in a storage array using at least one asynchronous transport system, wherein: The storage array has at least one elevated storage and transport level, The mixed product units are distributed in the storage array in boxes having a common type of product units per box, The at least one asynchronous transport system implements level transport for automatically retrieving and outputting product units distributed in the boxes from the storage array, and each of said at least one elevated storage and transport level being separate and distinct from each other elevated storage and transport level, each elevated storage and transport level achieving an orthogonal transport output of product units distributed in said storage array relative to each other elevated storage and transport level; registering, with a controller communicatively connected to the at least one elevated storage and transportation level, a customer order for product units characterized by one or more product groups of product units, each product group having a unique predetermined product group characteristic that characterizes the product units of the product group and that relates the product group to each other product group; dynamically parsing, using the controller, via a heuristic solution, a product group describing each customer order into a set of product groups based on the unique predetermined product group characteristics, each product group set having a plurality of product groups and being orthogonal to each other product group set; dynamically assigning, with the controller, each resolved set of product groups to the at least one elevated storage and transportation level; and The controller is used to dynamically bind product units of the assigned product group set of at least one elevated storage and transportation level into predetermined boundaries in batches of mixed product units for each customer order corresponding to the assigned product group set via another heuristic solution, and wherein the other heuristic solution is based on at least one product group characteristic and a customer or default affinity rule.

40. The method of claim 39, wherein each resolved set of product groups is orthogonal to every other set of product groups and has a maximum number of mergeable product groups.

41. A method as claimed in claim 39, wherein the product group set is dynamically allocated for retrieving and outputting the product units forming the product group set via the at least one storage and transportation level into an order container that holds batches of mixed product units, wherein the product group set is dynamically allocated so as not to exceed a predetermined threshold of product units transported via the at least one elevated storage and transportation level.

42. A method as claimed in claim 39, wherein the controller implements dynamic parsing of the product group sets based at least on the number of assigned product group sets relative to a predetermined threshold of product units transported via the at least one elevated storage and transportation level and the number of other assigned product group sets relative to corresponding thresholds of each other elevated storage and transportation level.

43. A method as claimed in claim 39, wherein the controller implements dynamic allocation of the product group sets to the at least one elevated storage and transportation level, and balances the product group sets allocated to the at least one elevated storage and transportation level with other allocated product group sets allocated to each other elevated storage and transportation level.

44. The method of claim 39, wherein the customer order has a mix of product units, wherein each unit is stored in boxes in the storage array, each box having a common type of product unit.

45. The method of claim 39, wherein each customer order has at least one of said mixed product units.

46. ​​The method of claim 39, wherein at least one of parsing and allocating product group sets optimizes shipping of product units per customer order utilizing the asynchronous shipping system.

47. The method of claim 39, wherein the at least one asynchronous transport system comprises a self-guided autonomous robot that asynchronously traverses the at least one elevated storage and transport level.

48. The method of claim 47, wherein each self-guided autonomous robot is configured to transport a box of a common type of product units.

49. The method of claim 47, wherein at least one of parsing and allocating product group sets minimizes robotic transportation of boxes of product units per customer order.

50. The method of claim 39, wherein the controller is programmed with store rules defining product groups and the combinability of product groups with each other.

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