Warehousing system for storing and retrieving goods in container

Abstract

An automated product lorry unstacker tool includes a frame having a coupling configured to mate the automated product lorry unstacker tool with a robot end such that the automated product lorry unstacker tool provides an end effector for a robot; an array of pick heads of shipping box pick heads movably connected to and dependent on the frame, the array of pick heads configured to simultaneously hold the array of shipping boxes to the robot wherein different respective shipping boxes in the array of shipping boxes are held by the respective shipping box pick heads, mutually different shipping box picking heads hold mutually different respective shipping boxes in the array of shipping boxes, wherein each shipping box picking head has a shipping box gripper that engages a shipping box corresponding to the shipping box picking head; and a drive section connected to the frame and operably coupled to each shipping box picking head to move the shipping box picking head as a unit.

Description

[0001] Cross-reference to related applications This application is a non-provisional application and claims the benefit of U.S. Provisional Patent Application No. 63 / 452,758, filed on March 17, 2023, the full text of which is incorporated herein by reference. Technical Field

[0002] The disclosed embodiments generally relate to material handling systems, and more specifically to the transport and storage of articles within a material handling system. Background Technology

[0003] It is well known that integrating automated storage and retrieval systems into the logistics chain, particularly goods-to-people systems, is highly advantageous in terms of both overall efficiency and cost. Even with a high level of integration of automated storage and retrieval systems in a logistics facility, conventional systems typically operate by storing product (e.g., supply) containers, which include the container body, packaging, etc., and contain common types of goods (also referred to as products). Product containers can arrive at pallets (e.g., pallets of common supply containers) or be loaded onto trucks and unloaded or depalletized from trucks, and stored in the logistics facility, distributed throughout the entire storage volume of the logistics facility (e.g., in a three-dimensional array of storage racks) via automated storage and retrieval systems.

[0004] Order fulfillment from logistics facilities, particularly in cases where mixed product containers are expected (e.g., where any given order container may contain mixed / different products or product types stored in common containers, such as in direct-to-consumer fulfillment, or in indirect-to-consumer fulfillment, such as via a retail order pickup location, where the mixed products in the order container are generated at the logistics facility at least in part before being shipped from the logistics facility), typically achieves the generation of mixed product containers in a goods-to-person configuration using automated storage and retrieval systems. This is done by having the automated storage and retrieval system output product / supply containers (each containing one or more goods of a common goods type, i.e., each goods item in the product container is identical or substantially similar) from storage locations at various points in a three-dimensional array of storage racks to workstations (manually or automatically) to pick and remove goods from the different product / supply containers, which are then delivered to the given workstation according to a given fulfilled (or completed) order, and whereby the different picked goods (mixed goods or common goods, if the included given order is filled out in this way) are placed into the order container. This type of workstation can be called an unpacking station, where product containers are "disassembled" and their contents can be placed, in whole or in part, into order containers, or into containers that can be called unpacked storage containers, such as when product containers are unsuitable for continued storage of remaining product items after the unpacking operation, and such remaining products (i.e., remaining products in the "disassembled" product containers) should be returned by an automated storage and retrieval system for storage in a three-dimensional array of storage racks. Typically, containers are manually unpacked and placed at the unpacking station by operators or automated guided vehicles for system completion. Attached Figure Description

[0005] The foregoing aspects and other features of the disclosed embodiments are explained in the following description, in conjunction with the accompanying drawings, wherein: Figure 1 This is a schematic illustration of an automated storage and retrieval system according to aspects of the disclosed embodiments; Figure 2 , Figure 3 and Figure 4 These are schematic illustrations of some portions of an automated storage and retrieval system according to aspects of the disclosed embodiments; Figure 5 This is a schematic illustration of a hybrid pallet loading formed by an automated storage and retrieval system according to aspects of the disclosed embodiments; Figure 6 This is a schematic illustration of a portion of an automated storage and retrieval system according to aspects of the disclosed embodiments; Figure 7 This is a schematic illustration of a portion of an automated storage and retrieval system according to aspects of the disclosed embodiments; Figure 8 , Figure 9 , Figure 10 , Figure 11 and Figure 12 These are schematic illustrations of some portions of a storage and retrieval system according to aspects of the disclosed embodiments; Figure 13 These are schematic illustrations of a transport vehicle according to aspects of the disclosed embodiments; Figure 14 These are schematic illustrations of a transport vehicle according to aspects of the disclosed embodiments; Figure 15 This is a schematic illustration of a tote in a partially closed configuration according to aspects of the disclosed embodiments; Figure 16A and Figure 16B This is a schematic illustration of a container unloading system for an automated product container unloading machine tool having an automated storage and retrieval system, according to aspects of the disclosed embodiments; Figure 17-20 This is based on aspects of the disclosed embodiments. Figure 4 A schematic diagram of the various parts of an automated product loading and unloading container destabilizing machine; and Figure 21-22 This is an exemplary flowchart of a method according to an aspect of the disclosed embodiments. Detailed Implementation

[0006] Figure 1 This is a schematic illustration of an automated storage and retrieval system (also referred to herein as a warehousing / warehouse system or a product order fulfillment system) 100 according to aspects of the disclosed embodiments. While aspects of the disclosed embodiments will be described with reference to the accompanying drawings, it should be understood that aspects of the disclosed embodiments can be embodied in various forms. Furthermore, elements or materials of any suitable size, shape, or type can be used.

[0007] According to aspects of the disclosed embodiments, the automated storage and retrieval system 100 can operate in a retail distribution center or warehouse, for example, to fulfill orders for box units received from retail stores, such as those described in U.S. Patent No. 10,822,168, published November 3, 2020, the disclosure of which is incorporated herein by reference in its entirety. For example, a box unit is a box or cargo unit not stored in a pallet, shipping container 1510A-n, or on a pallet (e.g., unpacked). In other examples, a box unit is a box or cargo unit contained in any suitable manner, such as in a pallet, shipping container 1510A-n, container (e.g., a container of unpacked remaining goods, wherein the disassembled box unit structure is not suitable for transporting the remaining goods as units), or on a pallet. In still other examples, a box unit is a combination of unpacked and packed items. It should be noted that a box unit includes, for example, boxed cargo units (e.g., soup cans, cereal boxes, etc.) or individual goods adapted for removal from or placement on a pallet. According to aspects of the disclosed embodiments, the shipping containers for the container units (e.g., cartons, drums, boxes, crates, cans, or any other suitable equipment for holding the container units) can be of variable size and can be used to hold the container units during shipping, and can be configured such that they can be palletized for shipping. It should be noted that, for example, when a bundle or pallet of container units arrives at the storage and retrieval system 100, the contents of each pallet can be uniform (e.g., each pallet holds a predetermined number of the same items – one pallet holds soup while another holds cereals), and when the pallet leaves the storage and retrieval system 100, the pallet can contain any suitable number and combination of different container units (e.g., mixed pallets, where each mixed pallet holds different types of container units – a pallet holds a combination of soup and cereals), which are provided, for example, in a sorted arrangement to a palletizer to form mixed pallets. In aspects of the disclosed embodiments, the storage and retrieval system 100 described herein can be applied to any environment in which container units are stored and retrieved.

[0008] According to aspects of the disclosed embodiments, orders for filled items (e.g., pallets, boxes, containers, cargo packaging, individual (unpackaged) goods, etc.) can be random (e.g., the time of ordering and receiving the order is approximately random), and can be fulfilled by the automated storage and retrieval system 100 according to time (e.g., picking the ordered goods at a predetermined scheduled time before the order is shipped / fulfilled, or picking the goods in an immediate manner). These random orders determine the picking order of the items to be picked, such as for reference herein. Figure 5The construction of pallet loading or pallet PAL (see also, for example, U.S. Patent No. 8,965,559 entitled "Pallet Building System" and published February 24, 2015, the disclosure of which is incorporated herein by reference in its entirety). Although the pallet is in Figure 5 The illustration and description are mixed container pallets, but this illustration also represents pallet loading with mixed containers, mixed shipping containers, mixed packaging, mixed units (or individuals) of each shipping container, etc. Here, the sorted items are picked from a common storage array (e.g., a storage array formed by storage spaces 130S of storage structure 130). The automated storage and retrieval system 100 achieves maximum cargo throughput for each order (e.g., receiving it for processing by the automated storage and retrieval system 100) by using one or more orthogonal sorting tiers (such as those described in, for example, U.S. Patent Application No. 17 / 358,383, filed June 25, 2021, entitled “Warehousing System for Storing and Retrieving Goods in Containers,” the disclosure of which is incorporated herein by reference in its entirety) to process the order to the desired sorting level (e.g., controller 120 drills down / drives through the orthogonal sorting tiers to achieve the desired sorting level required for a given order—box-level sorting, package-level sorting, unit / individual-level sorting, or a combination thereof) from a common storage array, regardless of order type (e.g., pallet order, box order, package order, mixed order, etc.), order order sequence, and order time.

[0009] According to aspects of the disclosed embodiments, the automated storage and retrieval system 100 includes one or more unpacking modules or stations 266 (see...). Figure 10 The unpacking module 266 is configured to unpack product containers or container units (CUs). Figure 5 Disassembled into (one or more) unpacked cargo shipping containers 1510A-n (also referred to herein as cargo containers or mixed product unit containers; see also) Figure 2 and Figure 15 To fulfill orders. It should be noted that although the term "shipping container" is used throughout this specification, "shipping container" should be interpreted as including any type of shipping container, container, box, drum, carton, crate, etc. (One or more) Unpacked Goods Shipping Containers 1510A-n (brief reference) Figure 15For illustrative purposes (although the shipping container may have any suitable configuration), this is a container having a compartment section 264B and lid sections 264L1, 264L2. The compartment section 264B has a compartment opening 264OP and a bottom inner surface 264BS, in which goods are placed. The lid sections 264L1, 264L2 are attached to the compartment section 264B by corresponding hinges. The lid sections 264L1, 264L2 are interlocking lid sections, each having a corresponding upper locking portion and a corresponding lower locking portion. When the lid sections 264L1, 264L2 are closed, the corresponding upper locking portions and the corresponding lower locking portions interlock with each other by a cam mechanism to maintain the lid sections 264L1, 264L2 in a closed configuration. Here, products are placed into one or more unpacked cargo shipping containers 1510A-n by means of automation (as described herein), so that the products are loosely placed. To provide empty shipping containers to the unpacking module 266, the automated storage and retrieval system 100 includes at least one shipping container unpacking system 1000 (see, for example, Figure 1 (As shown in Figure 16), the container destacking system 1000 provides one or more unpacked cargo containers 1510A-n to the unpacking module 266 to perform the unpacking of one or more cargo containers 1510A-n, as will be further described herein. The container destacking system 1000 includes a robot 999 having an automated product container destacking tool 1050. The automated product container destacking tool 1050 includes a frame 1100 having a connector 1110 configured to engage with a robot end effector 999E of the robot 999, such that the automated product container destacking tool 1050 provides an end effector to the robot 999 to denest one or more containers 1510A-n from the stack 1505A-n, as will be further described herein.

[0010] In some aspects, the automated storage and retrieval system 100 may include (in addition to or in lieu of unpacking module 266) one or more individual picking modules that are substantially similar to those described in U.S. Patent No. 9,037,286, issued May 19, 2015 (the disclosure of which is incorporated herein by reference), wherein one or more unpacked shipping containers 1510A-n are filled by human or robotic operators, and wherein one or more unpacked shipping containers 1510A-n are input from one or more container unpacking and stacking systems 1000 to the individual picking modules by container robot 110 in a manner substantially similar to that described herein with respect to unpacking module 266.

[0011] One or more unpacking modules 266 and one or more container unpacking systems 1000 for unpacking (one or more) shipping containers 1510A-n from stacks 1505A-n may be located on a common level 130L of the automated storage and retrieval system 100, wherein one or more levels of the automated storage and retrieval system 100 include at least one unpacking module 266 and at least one container unpacking system 1000. The container unpacking system 1000 may be one or more plug-and-play modules that can be coupled to any suitable part of the structure of the automated storage and retrieval system 100. For example, the container unpacking system 1000 may be coupled to the container transfer deck 130DC or one or more picking (or picking) aisles 130A of the automated storage and retrieval system 100. The container unpacking system 1000 may be arranged on any suitable number of stacked storage levels of the automated storage and retrieval system 100. Here, (one or more) container unloading and stacking systems 1000 have synchronous container transport devices or conveyors CTP (as described herein - see [link]). Figure 7 The system transports one or more shipping containers 1510A-n from robot 999 (equipped with automated product shipping container unloading tool 1050) to output interface station 1001. From output interface station 1001, the shipping containers 1510A-n are transferred to unpacking module 266 (or, for example, the unpacking placement wall described in U.S. Patent Application No. 17 / 657,705, filed April 1, 2022, entitled "Warehousing System for Storing and Retrieving Goods in Containers," the disclosure of which is incorporated herein by reference in its entirety) to receive products from the "disassembled" container unit CU. Each shipping container transport device CTP at each corresponding level 130L in the different levels 130L guides one or more shipping containers 1510A-n at the corresponding level 130L to output interface station 1001. As described herein, output interface station 1001 is configured to communicate with an asynchronous container transport unit (as described herein - see [link]). Figure 7This is to unload (one or more) containers 1510A-n from the container transport unit CTP to an asynchronous transport unit at each corresponding level 130L. In one aspect, the container transport unit CTP is in the form of a linear conveyor adapted to receive (one or more) containers 1510A-n placed thereon via system 1000. In another aspect (not shown), the container transport unit CTP is replaced by an output station or any other device adapted to receive (one or more) containers 1510A-n, such as directly receiving them from an automated guided vehicle (AGV). In yet another aspect, two container transport units CTP (or more) or other output devices are used.

[0012] The automated storage and retrieval system 100 can be configured, for example by any suitable controller (e.g., control server 120), to have selectable operating modes. In one operating mode, the automated storage and retrieval system 100 is configured to output product boxes, containers, and / or box units to a palletizer. In another operating mode, such as when employing one or more unpacking modules 266, the automated storage and retrieval system 100 is configured to disassemble product boxes, product containers, and / or box units and output the unpacked cargo containers, product boxes, containers, and / or box units to the palletizer, or in other respects, to re-enter one or more unpacked (order) containers and / or remaining product boxes, containers, and / or box units into the storage device of the palletizer (e.g., after disassembly) for later retrieval. At least one shipping container unpacking system 1000 is configured to automatically denest the stacks 1505A-n of shipping containers 1510A-n and then transport them to the unpacking module(s) 266 to be filled.

[0013] As will be appreciated, controller 120 is configured to implement the operation of container robot 110 and cargo robot 262 (both of which form at least part of an asynchronous transport system) (see also, for example, Figure 10This is used to assemble orders of unpacked cargo BPGs from supply container 265 into one or more unpacked cargo shipping containers 1510A-n, and to unload one or more unpacked cargo shipping containers 1510A-n via container unloading station TS. For example, controller 120 is configured to operate one or more container robots 110 at least between container storage location 130S, unpacking operation station 140, and shipping container unloading and stacking system 1000 positioned along unpacked cargo transfer deck 130DG. As another example, controller 120 is configured to operate one or more cargo robots 262 such that unpacked cargo BPGs are transported by cargo robots 262 traversing cargo transfer deck 130DG to corresponding unpacked cargo shipping containers 1510A-n (e.g., sorted at the unit / individual level). As another example, controller 120 is configured to implement the operation of container robots(s) 110, such that the container robots(s) 110 receive from output interface station 1001 the corresponding empty unpacking / loading containers(s) 1510A-n, and, for example, via robot lanes along container transfer deck 130DC or otherwise along adjacent placement walls 263W. Figure 10 The empty unpacked cargo shipping containers 1510A-n are transported to one or more unpacking modules 266, and after being filled, they are transported from one or more unpacking modules 266 to at least one of the container output / transfer station TS and the corresponding storage location 130S of the corresponding level 130L of the multi-level storage array.

[0014] Also refer to Figure 5It should be noted that, for example, when incoming bundles or pallets (e.g., from the manufacturer or supplier of the container units) arrive at the storage and retrieval system to replenish the automated storage and retrieval system 100, the contents of each pallet can be uniform (e.g., each pallet holds a predetermined quantity of the same items – one pallet holds soup, and another holds cereals). As can be appreciated, the containers loaded on such pallets can be substantially similar, or in other words, homogeneous containers (e.g., similar sizes), and can have the same SKU (otherwise, as previously mentioned, the pallet can be a “rainbow” pallet with layers formed by homogeneous containers). When the pallet PAL leaves the storage and retrieval system 100, the containers are filled with replenishment orders, and the pallet PAL can accommodate any suitable number and combination of different container units CU (e.g., each pallet can hold different types of container units – a pallet holding a combination of canned soup, cereals, beverage packets, cosmetics, and household cleaning products). Containers combined onto a single pallet can have different sizes and / or different SKUs. In one aspect of the disclosed embodiments, the storage and retrieval system 100 may be configured to typically include an infeed section, a storage and sorting section (wherein, in one aspect, the storage of items is optional), and an output section, as will be described in more detail below. As will be appreciated, in one aspect of the disclosed embodiments, the system 100, for example acting as a retail distribution center, may be used to receive a uniform pallet load of boxes, unpack the palletized goods or separate the boxes from the uniform pallet load into individual box units that are handled individually by the system, retrieve and sort the different boxes requested for each order into corresponding groups, and transport and assemble the corresponding box groups into items that may be referred to as a Mixed Container Pallet Load (MPL). It will also be appreciated that, in one aspect of the disclosed embodiments, system 100, for example, acting as a retail distribution center, can be used to receive a uniform pallet load of boxes, unpack the palletized goods or separate the boxes from the uniform pallet load into individual box units that are individually handled by the system, pick and sort the different boxes sought for each order into corresponding groups, and transport and sort the corresponding box groups in the manner described in U.S. Patent No. 9,856,083, published January 2, 2018, the disclosure of which is incorporated herein by reference in its entirety.

[0015] As will be described in more detail below, the storage and sorting section includes a multi-level automated storage system with an automated transport system that sequentially receives or delivers individual boxes into the multi-level storage array for storage in storage areas (such as storage space 130S of storage structure 130). The storage and sorting section also defines the outbound transport of box units from the multi-level storage array, such that desired box units are individually retrieved according to commands generated based on orders entering a warehouse management system (such as warehouse management system 2500) for transport to an output section. In other aspects, the storage and sorting section receives individual boxes, for example, by box-level sorting (e.g., using buffer stations and interface stations), and transfers individual boxes to the output section according to orders entering the warehouse management system. The sorting and grouping of boxes according to orders (e.g., order issuance order) can be implemented wholly or partially by the storage and retrieval section or the output section or both, limited by the convenience of description and the ability to implement sorting and grouping in any number of ways. The expected result is that the output section will assemble groups of ordered containers that may differ in SKU, size, etc., into mixed container pallet loading in a manner described, for example, in U.S. Patent No. 8,965,559, published on February 24, 2015, entitled “Pallet Building System,” the disclosure of which is incorporated herein by reference in its entirety.

[0016] In the disclosed embodiments, the output section generates a pallet load in a structured architecture that may be referred to as a hybrid container stack. The structured architecture of the pallet load described herein is representative, and in other respects, the pallet load may have any other suitable configuration. For example, the structured architecture may be any suitable predetermined configuration, such as a truck bay load or other suitable container or load container shell layer that maintains the structural load. The structured architecture of the pallet load may be characterized as having several flat container layers L121-L125, L12T, as described in U.S. Patent No. 9,856,083, which is previously incorporated herein by reference in its entirety.

[0017] Based on aspects of the disclosed embodiments, reference will be made again. Figure 1The automated storage and retrieval system 100 includes a storage array (e.g., a storage structure 130 with storage spaces 130S) having at least one elevated storage level 130L. Mixed product units are input and distributed in the storage array in the form of cabinets CU, each cabinet CU containing common types of product units (each cabinet input to system 100 holds common types of stock-keeping units (SKUs)). For example, the automated storage and retrieval system 100 includes an input station 160IN (which includes a depalletizer 160PA and / or a conveyor 160CA for transporting items (e.g., inbound supply containers) to a lifting module 150A for entry into the storage level 130L of the storage structure 130).

[0018] As will be described herein, the automated storage and retrieval system 100 includes an automated transport system (e.g., a robot, unpacking module, container unloading and stacking system 1000, and other suitable tiered transport described herein) having at least one asynchronous transport system for transporting containers / products on a given storage structure tier 130L (e.g., tiered transport). For example, the automated storage and retrieval system 100 includes at least one storage tier 130L having a storage aisle (also referred to herein as a picking aisle) 130A and a transport deck (also referred to herein as a container transport deck) 130DC connecting to the storage aisle 130A. At least one unpacking station 140 is communicatively coupled to the transfer deck 130DC. At least one container unloading and stacking system 1000 is communicatively connected to a transfer deck 130DC by an asynchronous transport system (described herein), and at least one autonomous traction vehicle (also referred to herein as a container robot) 110 (e.g., an autonomous traction vehicle of the asynchronous transport system) is configured to traverse the transfer deck 130DC (as described herein) and transport (one or more) containers 1510A-n from at least one container unloading and stacking system 1000 to at least one unpacking station 140.

[0019] As described herein, the storage and retrieval system 100 includes a nondeterministic container robot 110 that travels along one or more physical routes of the storage and retrieval system to provide at least one level of asynchrony. At least another level of asynchrony (as described herein) is provided such that, for example, the number of containers / products held in position is greater than the number of robots transporting the containers / products. At least one elevator 150 is provided for transporting containers / products between storage levels (e.g., between level transports). At least one elevator 150B is communicatively connected to the storage array as described herein to automatically retrieve and output product units from the storage array in a common portion (e.g., storage location 130S of the corresponding storage level 130L) of at least one elevated storage level 130L of the storage array. The output product units are one or more of mixed single-unit product units in mixed packaging groups and mixed containers. As an example, the automated storage and retrieval system 100 includes output stations 160UT and 160EC (which include a palletizer 160PB, an operator station 160EP, and / or a conveyor 160CB for transporting items (e.g., outbound supply containers and filled unpacked goods (order) containers) from a lifting module 150B for removal from storage (e.g., removal to a palletizer (for palletizer loading) or removal to a truck (for truck loading)). Here, output station 160EC is an individual fulfillment (or e-commerce) output station, where, for example, the transport includes individual goods items and / or small bundles of goods. The containerized and unpacked goods (orders) are used to fulfill individual fulfillment orders (such as orders placed by consumers via the internet). The output station 160UT is a commercial output station where large quantities of goods are typically placed on pallets to fulfill orders from commercial entities (e.g., commercial shops, warehouse clubs, restaurants, etc.). As will be appreciated, the automated storage and retrieval system 100 includes both commercial output stations 160UT and individual fulfillment output stations 160EC; while in other respects, the automated storage and retrieval system includes one or more of commercial output stations 160UT and individual fulfillment output stations 160EC.

[0020] The automated storage and retrieval system 100 also includes input and output vertical lifting modules 150A, 150B (generally referred to as lifting module 150 – it should be noted that although input and output lifting modules are shown, a single lifting module can be used to input and remove container units from the storage structure), a storage structure 130 (which may have at least one storage level raised as described above, and in some respects, forms a multi-level storage array), and at least one autonomous container transport vehicle 110 (referred to herein as a “container robot” or “autonomous traction vehicle”, and forming at least part of an asynchronous transport system for hierarchical transport), which can be confined to the corresponding storage level of the storage structure 130 and is distinct from the transfer deck 130DC on which it travels. It should be noted that a depalletizer 160PA can be configured to remove container units from pallets so that input station 160IN can transport items to lifting module 150 for input into storage structure 130. A palletizer 160PB can be configured to place items removed from storage structure 130 onto pallet PAL (… Figure 5 The lifting module 150, storage structure 130, and container robot 110, as used herein, may be collectively referred to herein as the aforementioned multi-level automated storage system (e.g., storage and sorting sections) with integrated "on-the-fly sorting" (e.g., sorting container units during transport), allowing container unit sorting and throughput to occur substantially simultaneously without the need for a dedicated sorter as previously described in U.S. Patent No. 9,856,083, which is incorporated herein by reference in its entirety.

[0021] Also refer to Figure 1 , Figure 6 , Figure 8 and Figure 10 The storage structure 130 may include one or more autonomous container transport loops 233, 233A disposed at corresponding levels of the storage structure 130 (e.g., formed on and along the container transfer deck 130DC). It should be noted that the elevator 150 is connected to the container transfer deck 130DC via a transfer station TS (also referred to herein as a container loading station when the elevator 150 is an inbound elevator 150A, or a container outbound station when the elevator 150 is an outbound elevator 150B), and each elevator is configured to supply containers 26 (empty or filled) (see [reference needed]). Figure 10 ) and unpacked cargo shipping containers 1510A-n (empty or filled) (see Figure 10One or both of the containers can be raised or lowered into at least one elevated storage level 130L of the storage structure 130. Container storage locations (or spaces) 130S are arranged along the perimeter of the container transfer deck 130DC. For example, multiple storage rack modules RM configured as a high-density three-dimensional rack array RMA can be accessed 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 nondeterministic open shelving distributed along the picking aisle 130A, wherein, in some aspects, multiple stacked shelving units can be accessed from a common picking aisle travel surface or picking aisle level, as described in U.S. Patent No. 9,856,083, which is previously incorporated herein by reference in its entirety.

[0022] Each storage level 130L includes picking surface storage / handling spaces 130S (referred to herein as storage spaces 130S or container storage locations 130S) arranged along the periphery of the container transfer deck 130DC. In one aspect, the storage spaces 130S are formed by rack modules RM, wherein the rack modules include shelves arranged along storage or picking aisles 130A (connected to the container transfer deck 130DC), the storage or picking aisles 130A extending linearly through the rack module array RMA, for example, and enabling the container robot 110 to access the storage spaces 130S and(one or more) transfer decks 130B. In one aspect, the shelves of the rack modules RM are arranged as multi-level shelves distributed along the picking aisles 130A. As can be appreciated, the container robot 110 travels along the picking aisle 130A and container transfer deck 130DC on the corresponding storage level 130L to transfer container units between any storage space 130S of the storage structure 130 (e.g., the level where the container robot 110 is located) and any lifting module 150 (e.g., each of the container robots 110 can access each storage space 130S on the corresponding level and each lifting module 150 on the corresponding storage level 130L). The transfer deck 130B is arranged at different levels (corresponding to each level 130L of the storage and retrieval system), which can be stacked vertically or horizontally offset from each other, such as at one end or side of the storage rack array RMA, RMAE1. Figure 8 Alternatively, a container transfer deck 130DC may be provided at several ends or sides of the storage rack array RMA, such as as described, for example, in U.S. Patent No. 10,822,168, published November 3, 2020, the disclosure of which is incorporated herein by reference in its entirety.

[0023] The container transfer deck 130DC is substantially open and configured for the nondeterministic traversal of the container robot 110 along multiple travel lanes that span and along the transfer deck 130B. As described in U.S. Patent No. 10,556,743, filed February 11, 2020, and application No. 15 / 671,591 (the disclosure of which is incorporated herein by reference in its entirety), these multiple travel lanes can be configured to provide multiple access paths or routes to each storage location 130S (e.g., picking face, container unit, container, or other items stored on storage shelves of the racking module RM), allowing the container robot 110 to reach each storage location using, for example, secondary paths when the primary path to the storage location is blocked. As will be appreciated, one or more transfer decks 130B at each storage level 130L are in communication with each picking lane 130A on the corresponding storage level 130L. The container robot 110 traverses bidirectionally between one or more container transfer decks 130DC and picking aisles 130A on each corresponding storage level 130L, so as to travel along the picking aisles and reach storage spaces 130S in the racks located next to each picking aisle 130A (e.g., the container robot 110 can reach storage spaces 130S distributed on both sides of each aisle, so that the container robot 110 can have different orientations when traversing each picking aisle 130A, for example, see reference). Figure 13 (The drive wheel 202 leads the direction of travel, or the drive wheel follows the direction of travel). As described above, the container transfer decks 130DC (one or more) also enable the container robot 110 to access each of the elevators 150 on the corresponding storage level 130L, wherein the elevator 150 delivers container units into and / or removes container units from each storage level 130L, and wherein the container robot 110 performs container unit transfer between the elevator 150 and the storage space 130S.

[0024] As mentioned above, also refer to Figure 8In one aspect, storage structure 130 includes a plurality of storage rack modules RM configured as a three-dimensional array RMA, wherein the racks are arranged in aisle 130A. Aisle 130A is configured to allow container robot 110 to travel within aisle 130A. Container transfer deck 130DC has a nondeterministic transport surface on which container robot 110 travels, wherein the nondeterministic transport surface (also referred to herein as deck surface) 130BS has a plurality of travel lanes (e.g., more than one juxtaposed travel lane (e.g., high-speed robot travel path HSTP)) to allow container robot 110 to travel along one or more container autonomous transport travel loops 233, 233A formed by container transfer deck 130DC, wherein the plurality of travel lanes connect aisle 130A. The container autonomous transport loop 233A provides the container robot 110 with random access to any and every picking lane 130A, and random access to any and every elevator 150A, 150B on the corresponding level 130L of the storage structure 130. The direction of travel of at least one of the plurality of travel lanes is opposite to the direction of travel of another of the plurality of travel lanes (in order to form the container autonomous transport loop 233).

[0025] The storage and retrieval system 100 may include one or more bypass aisles 132 extending generally laterally to the picking aisles 130 to allow the container robot 110 to move between the picking aisles 130 instead of traversing the container transfer decks 130DC, 130DC2. The bypass aisle 132 may be generally similar to the travel lanes of the container transfer decks 130DC, 130DC2 as described herein, and may allow the container robot to travel bidirectionally or unidirectionally via the bypass aisle 132. The bypass aisle 132 may provide one or more container robot travel lanes, each lane having a floor and suitable guides for guiding the robot along the bypass aisle 132 in a manner similar to that described herein with respect to transfer decks 130DC, 130DC2. In other respects, the bypass aisle 132 may have any suitable configuration to allow the container robot 110 to traverse between the picking aisles 130. It should be noted that although a bypass channel 132 is shown with respect to a storage and retrieval system having transfer decks 130DC, 130DC2 at opposite ends of the storage structure, in other respects, a storage and retrieval system 100 having only one transfer deck may also include one or more bypass channels 132.

[0026] As described herein, one or more of the unpacking module 266 and / or the container destacking system 1000 may be located in one or more picking lanes 130A. For example, the unpacking module 266AL may be located on one side of the picking lane 130A of the container transfer deck 130DC, and one or more picking lanes 130A may extend into the unpacking module 266AL to form one or more container robot driving surfaces 266RS. The container destacking system 1000 may be located in the robot lane adjacent to the container output 1001 of the container transfer deck 130DC (adjacent to the placement wall 263W). Figure 10 On one side of the picking lane 130A, and one or more picking lanes 130A extend into the container destabilization system 1000 to form the travel surface of the container robot. When the container robot 110A is to deliver the supply container 265 from the container destabilization system 1000 to the unpacking module 266AL or the unpacking container 1510A-n and the picking lane 133 extending into the unpacking module or the picking lane 134 extending into the container destabilization system 1000 is blocked by the container robot 110D, a bypass lane 132 may be used to provide an auxiliary or alternative route for the container robot 110 to transport the supply container 265 from the container destabilization system 1000 to the unpacking module 266AL or the unpacking container 1510A-n.

[0027] It should be noted that the storage and retrieval systems shown and described herein are merely exemplary configurations; and in other respects, the storage and retrieval systems may have any suitable configuration and components for storing and retrieving items as described herein. For example, in other respects, the storage and retrieval systems may have any suitable number of storage sections, any suitable number of transfer decks, any suitable number of unpacking modules, and corresponding input / output stations.

[0028] As can be seen, the juxtaposed travel lanes are positioned along the common, non-deterministic transport surface 130BS between the opposite sides 130BD1 and 130BD2 of the container transfer deck 130DC. Figure 8As illustrated, in one aspect, aisle 130A is connected to container transfer deck 130DC on one side 130BD2 of container transfer deck 130DC; however, in other aspects, the aisle is connected to more than one side 130BD1, 130BD2 of container transfer deck 130DC in a manner substantially similar to that described in U.S. Patent No. 10,822,168, published November 3, 2020, the disclosure of which is previously incorporated herein by reference in its entirety. As will be described in more detail below, other sides 130BD1 of container transfer deck 130DC may include deck storage racks (e.g., interface stations (also called transfer stations) TS and buffer stations BS) distributed along other sides 130BD1 of container transfer deck 130DC, such that at least a portion of the transfer deck is inserted between the deck storage racks (such as, for example, buffer stations BS or transfer stations TS) and aisle 130A. The deck storage racks are arranged along the other sides 130BD1 of the container transfer deck 130DC such that the deck storage racks are in communication with the container robot 110 and the lifting module 150 from the container transfer deck 130DC (e.g., the container robot 110 and the lifting module 150 from the container transfer deck 130DC reach the deck storage racks to pick and place picking surfaces, such that the picking surfaces are transferred between the container robot 110 and the deck storage racks, and between the deck storage racks and the lifting module 150, and thus between the container robot 110 and the lifting module 150).

[0029] Refer again Figure 1 Each storage tier 130L may also include a charging station 130C for charging the onboard power supply of the container robot 110 on the storage tier 130L, as described, for example, in U.S. Patent Application No. 14 / 209,086, filed March 13, 2014, and U.S. Patent No. 9,082,112, published July 14, 2015, the disclosures of which are incorporated herein by reference in their entirety.

[0030] refer to Figure 1 , Figure 8 , Figure 10As described above, the automated storage and retrieval system 100 includes one or more unpacking modules 266. In one aspect, each unpacking module 266 has a container robot driving surface 266RS that forms a portion 130DCP of the container transfer deck 130DC, wherein the driving surface 266RS is substantially similar to the driving surface of the container transfer deck 130DC, while in other aspects, the container robot driving surface 266RS may be substantially similar to the driving surface of the picking aisle 130A. For ease of explanation, aspects of the disclosed embodiments refer to the container robot driving surface 266RS within the unpacking module 266 as a portion of the container transfer deck 130DC. In aspects where the robot driving surface 266RS is formed by a portion (or an extension thereof) of the container transfer deck 130DC, it should be noted that although the container transfer deck 130D is... Figure 10 The diagram shows a single-path transport loop, but in other respects, the transport loop of the unpacking module 266 can be roughly similar to... Figure 8 The diagram illustrates a multi-lane transport loop on a container transport deck. For example, see reference... Figure 12 The container robot's travel surface 266RS is an open, nondeterministic travel surface with multiple entry and exit lanes. For example, there are multiple entry lanes TL1 and TL2, where lane TL2 is a bypass lane used to navigate around obstacles on lane TL1 (or vice versa). There may also be multiple exit lanes TL3, TL4, and TL5. Here, lane TL5 defines the queuing lane 130QL for the container robot 110 at the unpacking interface 263. Figure 10 ), while travel lanes TL4 and TL5 can be used to exit from unpacking module 266, where travel lane TL5 is a bypass for traveling around obstacles on travel lane TL4 (or vice versa).

[0031] Each of the unpacking modules 266 includes an unpacked cargo autonomous transport loop 234 (see exemplary unpacked cargo autonomous transport loops 234A-234E, formed on and along the cargo deck or cargo transfer deck 130DG), at least one unpacking operation station 140, and an unpacked cargo interface 263 disposed between the cargo transfer deck 130DG and the container transfer deck 130DC, thereby interface-connecting them. For illustrative purposes only, the cargo deck 130DG is illustrated as having three lanes forming (variable length) travel loops 234A-234E; however, in other respects, the cargo deck may have any suitable number of travel lanes forming any suitable number of unpacked cargo autonomous transport loops 234. Each unpacking module 266 can be nondeterministically coupled to the automated storage and retrieval system 100 in any suitable manner (e.g., to form part of it) (e.g., unpacking module 266 can be coupled to the automated storage and retrieval system 100 at any suitable location, such as to one or more ends 130BE1, 130BE2, or such as replacing picking channel 130 (and storage location) or being centered between the two ends 130BE1, 130BE2 at any other suitable location). Although the unpacking module 266 is nondeterministically coupled to the structure of the automated storage and retrieval system 100, each component of the unpacking module 166 is independent (e.g., independent as a unit) and / or independently automated in terms of the guidance and movement of a robot (e.g., cargo robot 262) from the components of the automated storage and retrieval system, such that the interface between the components of the unpacking module 266 and the components of the automated storage and retrieval system 100 is nondeterministic.

[0032] One or more unpacking modules 266 can be coupled to the structure of the automated storage and retrieval system 100 at any suitable location and at any suitable level(s) 130L. For example, as described above, the unpacking module 266 can be located at one or more ends 130BE1, 130BE2 of the container transfer deck 130DC or at one or more sides 130BD1, 130BD2 of the container transfer deck 130DC (such as replacement storage rack modules RM / picking aisles 130A or elevators 150A, 150B, or as an extension of one or more picking aisles 130A). Each of the unpacking modules 266 is a plug-and-play module that is integrated with (or otherwise connected to) the container transfer deck 130DC, such that the container transfer deck 130DC is communicatively coupled to the container robot travel surface 266RS. In one aspect, the container transfer deck 130DC extends into the unpacking module to form a container robot travel surface 266RS (e.g., the unpacking module forms a modular portion of the container transfer deck 130DC), such that the container robot 110 traverses or moves into and out of the unpacking module 266 along the nondeterministic container transfer deck 130DC, and at least one of the plurality of travel lanes of the container transfer deck 130DC defines a queuing lane 130QL for the container robot 110 at the unpacking cargo interface 263. Figure 10 In one aspect, the output interface station 1001 is connected to the container robot travel surface 266RS, enabling the asynchronous container transport device (container robot 110) to unload (one or more) containers 1510A-n from the container transport device CTP to the asynchronous transport device. In other aspects, the container robot travel surface 266RS includes a track 1200S (see...). Figure 4 Track 1200S extends from container transport deck 130DC in a manner similar to that of picking channel 130A, allowing container robot 110 to traverse or move into and out of unpacking module 266 along track 1200S, and track 1200S defines queuing lane 130QL for container robot 110 at unpacking cargo interface 263. Figure 10 It should be noted that when the container robot's travel surface 266RS is formed by the track 1200S, the travel surface may include a nondeterministic turning area 1200UTA (which is similar to the open nondeterministic container transfer deck 130DC), in which the container robot 110 turns to transition between different travel sections (e.g., inbound and outbound) of the unpacked cargo autonomous transport travel loop 234. Figure 10As can be seen, the container robot travel surface 266RS of the unpacking module 266 forms a travel loop 233. The container robot 110 travels around the travel loop 233 to transport supply containers (e.g., container units, picking surfaces, remaining containers, etc.) between storage location 130S and unpacking operation station 140 (and / or vice versa) along the travel loop 233 of the container robot travel surface 266RS, and to transport unpacked cargo containers (also called unpacked containers) 264 between the unpacked cargo interface 263 and container storage location 130S or elevator 150A (and / or vice versa). The travel loop 233 provides the container robot 110 with random paths along the robot travel surface 266RS to any and each unpacked cargo interface location 263L of the unpacked cargo interface 263, wherein the unpacked cargo interface locations 263L form an asynchronous product distribution system.

[0033] The cargo transfer deck 130DG forms a cargo autonomous transport loop 234 located at the storage level 130L. The cargo transfer deck 130DG is separate from and distinct from the travel loop 233 formed by the container robot travel surface 266RS, and has a cargo unpacking interface 263 that connects the corresponding edges of the container autonomous transport loop 233 of the container transfer deck 130DC and the cargo unpacking autonomous transport loop 234 of the cargo transfer deck 130DG. The autonomous cargo transport loop 234 formed by the cargo transfer deck 130DG is disposed on the deck surface 130DGS of the deck (e.g., cargo transfer deck 130DG) at the corresponding storage level 130L, and one or more unpacking cargo autonomous transport loops 234 of the cargo transfer deck 130DG are disposed on different deck surfaces 130DGS of the deck (e.g., cargo transfer deck 130DG), which are separate from and different from the deck surface 130BS of the container robot travel surface 266RS (formed by container transfer deck 130DC and / or track 1200S) where the container autonomous transport loop 233 is disposed. The unpacking cargo autonomous transport loop 234 formed by the cargo transfer deck 130DG (and therefore the cargo travel deck 130DG) is configured to confine at least one autonomous unpacking cargo transport vehicle (also referred to as a cargo robot or cargo transport vehicle) 262 to the corresponding storage level 130L. At least one cargo robot 262 is arranged or otherwise configured to transport one or more unpacked cargo BPGs (e.g., packages unpacked from supply containers at the packaging level or units / individuals unpacked from packaging at the unit / individual level) between unpacking operation station 140 and unpacking cargo interface 263 along an autonomous unpacking cargo transport loop 234 formed by cargo transfer deck 130DG. One or more container robots 110 are also configured to autonomously pick and place one or more unpacked cargo shipping containers 1510A-n at unpacking cargo interface 263, as described herein. Unpacking cargo interface 263 may be substantially similar to one or more of the transfer station TS and buffer station BS described herein and includes a nondeterministic surface (similar to the surface of the rack storage space 130S described herein), on which one or more unpacked cargo shipping containers 1510A-n are placed to form a nondeterministic interface between cargo transfer deck 130DG and container transfer deck 130DC.

[0034] In one aspect, the cargo transfer deck 130DG facilitates the tilting process, where cargo is picked from a container (such as a supply container 265 or any other suitable standard container 265S) at the unpacking operation station 140 and merged with cargo (typically of the same type) from another (e.g., outgoing) supply container 265 or standard container 265S, as described above, at the unpacking cargo interface 263, whereby the other supply container 265 or standard container 265S is returned to the storage device. Typically, supply containers 265 entering the station are picked up to the unpacking module 266 until empty, but only some (not all) of the cargo from the entering supply containers can be tilted. Here, containers (such as shipping containers, pallets, etc.) that may be referred to as outbound (i.e., outbound from unpacking module 266) supply containers 265 or standard containers 265S can also be placed on unpacking cargo interface 263 by one or more container robots 110 in a manner similar to that described herein for one or more unpacked cargo shipping containers 1510A-n to facilitate the tilting process. During the tilting process, cargo is removed from supply containers 265 (which may be original product / (one or more) cargo box packages) at unpacking operation station 140 and incorporated into one or more outbound supply containers 265 or standard containers 265S located on unpacking cargo interface 263 (e.g., having cargo of the same type as those removed at unpacking operation station 140). Consolidating the same type of cargo from multiple supply containers 265 into a smaller number of supply containers 265 (and then returning them to the storage unit by (one or more) container robots 110) can increase the storage density of the automated storage and retrieval system 100, because the supply containers 265 stored on the storage racks can be maintained at a substantially “full” state (rather than having multiple non-full containers containing the same type of cargo). In some aspects, the tilted cargo (in standard containers or outbound supply containers) is output from the storage and retrieval system 100 via elevator 150 for palletizing as part of a pallet load (such as at output station 160UT) or for individual transport (such as at output station 160EC).

[0035] Cargo robot 262 can be any suitable type of autonomous guided robot whose payload is configured to hold unpacked cargo, rather than product containers (e.g., container units, picking surfaces, etc.). The payload holding configuration of each of cargo robots 262 differs from that of container robot 110. Cargo robot 262 is configured to autonomously travel along and across one or more unpacked cargo autonomous transport loops 234 formed by cargo deck 130DG. Cargo robot 262 is configured to automatically unload one or more unpacked cargo BPGs (picked from unpacking operation station 140) from cargo robot 262 onto one or more unpacked cargo loading containers 1510A-n at unpacked cargo interface 263. Suitable examples of cargo robots 262 are those manufactured by Tompkins International, Inc., Raleigh, North Carolina, USA, for example, see U.S. Patent No. 10,248,112, issued April 2, 2019. The unpacked cargo autonomous transport loop 234 formed by cargo deck 130DG has multiple travel lanes (see...) Figure 10 This is used to enable the cargo robot 262 to travel along one or more unpacked cargo autonomous transport loops 234 (see, for example, travel loops 234A-234E) formed by the cargo deck 130DG. As described herein, three travel lanes are illustrated for illustrative purposes only, and in other respects, there may be more or fewer than three travel lanes. At least one of these multiple travel lanes is a through lane for enabling the cargo robot 262 to travel through obstacles in another of the multiple travel lanes in a manner similar to that described herein with respect to the multiple travel lanes of the container transfer deck 130DC. The one or more unpacked cargo autonomous transport loops 234 provide the cargo robot 262 with random pathways to any and each unpacked cargo interface location 263L of the unpacked cargo interface 263.

[0036] In one or more aspects, one or more portions of the cargo transfer deck 130DG (such as adjacent unpacked cargo interface location 263L) may be retained to provide exit (or departure) ramps or entry (or arrival) ramps from or to the travel loop 234A-234E to facilitate the transfer of unpacked cargo BPG from or to one or more unpacked cargo loading containers 1510A-n (or supply containers 265, 265S) at the unpacked cargo interface location 263L. Exit ramps (referred to herein as ramps 222, 222C, 222R) will be described herein; however, it should be understood that the direction of the entry ramps is generally opposite to that of the exit ramps 222, 222C, 222R (e.g., providing access to the travel loop, rather than access from the travel loop). One or more ramps 222, 222C, 333R are provided based on, for example, the kinematics (velocity, direction, etc.) of robot 110 and the location(s) of the unpacking cargo interface 263L reached by cargo robot 262 (e.g., near a corner of cargo transfer deck 130DG, away from a corner of cargo transfer deck 130DG, etc.). For illustrative purposes only, ramp 222 is a general description of an entry / exit ramp that can be located anywhere on cargo transfer deck 130DG and has any suitable length. Ramp 222C is located at a corner of cargo transfer deck 130DG. Ramp 222R is a “rolling” ramp that moves to follow the path of cargo robot 262 traveling along ramp 222R.

[0037] Ramps 222, 222C, and 222R (both entry and exit ramps) can be temporarily "closed" to prevent the normal access of cargo robot 262 (e.g., only predetermined cargo robots that deliver unpacked goods to and from unpacked goods interface location 263L within the area designated by ramps 222, 222C, and 222R can access the corresponding entry and exit ramps). Typically, ramps 222, 222C, and 222R provide a passageway between the driveway and the destination unpacked goods interface location 263L. Each ramp 222, 222C, and 222R can be bidirectional (e.g., where cargo robot 2662 enters the ramp and travels along it in one direction to pick or place unpacked goods BPG, and then travels along it in the opposite direction to exit the ramp). In another scenario, the ramps can be "counter-current ramps," where the direction of travel along ramps 222, 222C, and 222R is substantially opposite to the direction of travel around one or more of the travel loops 234 (e.g., cargo robot 262 exits the travel loop and travels along ramps 222, 222C, and 222R in substantially the opposite direction). When ramps 222, 222C, and 222R are exit ramps, they can terminate at the destination unpacking interface position 263L. Similarly, when ramps 222, 222C, and 222R are entry ramps, they can begin at the destination unpacking interface position 263L. As described above, ramps 222, 222C, and 222R can be located anywhere on the cargo transfer deck 130DG, such that the ramp entry position varies within a lane that may be referred to as a parking lane (e.g., a lane or part of a travel loop where the cargo robot stops to pick or place an unpacked cargo BPG) based on one or more of the robot kinematics and the position of the available unpacking cargo interface 263L. It should be noted that while the turns to and from ramps 222, 222C, and 222R are illustrated as approximately 90º turns, in other respects, the turns may have an “S” shape similar to that described in U.S. Patent Application No. 16 / 144,668, filed September 27, 2018, entitled “Storage and Retrieval System,” the disclosure of which is incorporated herein by reference in its entirety.

[0038] Ramps 222, 222C, and 222R are dynamically generated and can be dynamically implemented (e.g., "rolling" ramps, such as ramp 222R) such that the ramps "roll" progressively, with an initial ramp length generated when the cargo robot enters, having sufficient clearance to avoid collisions with the cargo robot. In one or more aspects, assuming that the ramp to the destination unpacking cargo interface location 263L is "blocked" (or otherwise obstructed) by the active cargo robot 262 / active unpacking cargo interface location 263L, but it is expected that the obstruction will be cleared before the cargo robot 262 traveling along the ramp reaches the obstruction, then ramps 222, 222C, and 222R (at the robot entrance) are initiated. In one or more aspects, if the obstruction to ramps 222, 222C, 222R is cleared, ramps 222, 222C, 222R extend to the destination unpacking cargo interface location 263L; however, if the obstruction is not cleared, the cargo robot 262 traveling along ramps 222, 222C, 222R is redirected, for example, to a lane, and a new ramp is calculated / determined such that the cargo robot 262 can place the unpacked cargo BPG at the destination unpacking cargo interface location 263L or another destination unpacking cargo interface location 263L.

[0039] Also refer to Figure 13 Unpacking station 140 is configured such that one or more unpacked cargo BPGs are unpacked from one or more supply containers 265 at unpacking station 140, and at least one cargo robot 262 is configured to be loaded with one or more unpacked cargo BPGs at unpacking station 140. Unpacking station 140 includes any suitable support surface 140S for supply containers 265. In one aspect, support surface 140S is a nondeterministic surface generally similar to the surface of a storage shelf described herein, and includes slats 1210S forming support surface 140S. In other aspects, support surface 140S may be a nondeterministic roller conveyor (powered or unpowered) having rollers 140RL arranged similarly to the rollers 110RL of container robot 110 described herein (see [link to documentation]). Figure 4 A and Figure 4 B), so that the fork teeth 273A-273E of the picking head 270 of the container robot 110 ( Figure 4 A and Figure 4B) The rollers of the roller conveyor are interleaved to place the supply container 265 onto (or pick the supply container 265 from) the support surface 140S. Here, the container robot 110 is configured to autonomously transfer (one or more) supply containers 265 from the container robot 110 to the unpacking station 140 (such as to the support surface 140S) in a manner described herein. The support surface 140S can be configured such that when the container robot 110 places the supply container 265, the supply container 265 moves along the support surface 140S toward the operator 141 (e.g., a human operator or any suitable robotic operator (e.g., an articulated arm, gantry, etc.)) to pick unpacked goods (BPGs) from the supply container 265 in any suitable manner and place the picked unpacked goods into one or more of the cargo robot 262 or one or more of the unpacked goods shipping containers 1510A-n and standard containers 265S (such as shipping boxes, pallets, etc.) located at the operator assembly area 140A, to achieve one or more of the following: package-level sorting or unit / individual-level sorting of goods. The supply container 265 can move along the support surface 140S to the corresponding operator assembly area 140A, where the operator 141 picks unpacked goods (BPGs) from the supply container 265 for placement in the cargo robot 262 or another container 265S, 264. In one aspect, the operator assembly area 140A may be adjacent to and / or formed by the support surface 140S. As described herein, the container robot 110 may pick supply containers 265 containing remaining cargo after unpacking from the support surface 140S or assembly area 140A and return them to the storage unit or elevator 150. Empty supply containers 265 may be removed from the support surface 140S or assembly area 140A by the operator 141 and stored at the unpacking station 140 for later removal in any suitable manner. In one or more aspects, the container robot 110 may transport empty containers from the storage and retrieval system via elevator 150. In one or more aspects, the unpacking station 140 includes any suitable waste removal system 223 for removing waste (or garbage, e.g., shrink wrap, packaging, boxes, etc.) from the storage and retrieval system. In one or more aspects, the waste removal system 223 includes one or more of a chute, conveyor, elevator, or any other suitable transport device configured to move waste to a predetermined location; while in other aspects, waste may be placed in a container and removed from the storage and retrieval system by a container robot 110 via elevator 150. Figure 10 and Figure 13As can be seen, the unpacking cargo transfer deck 130DG connects the unpacking operation station 140 to the container transfer deck 130DC at separate locations (e.g., at the unpacking cargo interface location 263L) that separate the container transfer deck 130DC from the container robot 110 unpacking operation station 140 (e.g., at the common support surface 140S).

[0040] In one aspect, it also refers to Figure 11 One or more unpacking modules 266 include two or more (i.e., multiple levels) cargo transfer decks 130DG1-130DG3 stacked one on top of the other; however, in other respects, (one or more) unpacking modules may have a single level, wherein an elevated level of at least one unpacking module is connected to a container transfer deck level. Here, the unpacking cargo interface 263 may be generally similar to... Figure 2 The shelving shown includes multiple levels 130DGL1-130DGL3, each accessible from a common (level) container transfer deck 130DC. The container robot 110 can be any suitable, independently operable autonomous transport vehicle that carries and transfers container units along the X and Y throughput axes throughout the storage and retrieval system 100. In one aspect, the container robot 110 is an automated, independently (e.g., free-roaming) autonomous transport vehicle. Suitable examples of robots can be found in the following U.S. patents for illustrative purposes only: U.S. Patent No. 10,822,168, issued November 3, 2020; U.S. Patent No. 8,425,173, issued April 23, 2013; U.S. Patent No. 9,561,905, issued February 7, 2017; U.S. Patent No. 8,965,619, issued February 24, 2015; and U.S. Patent No. 8,696,010, issued April 15, 2014. The disclosures of U.S. Patent No. 9,187,244, issued November 17, 2015; U.S. Patent No. 11,078,017, issued August 3, 2021; U.S. Patent No. 9,499,338, issued November 22, 2016; U.S. Patent No. 10,894,663, issued January 19, 2021; and U.S. Patent No. 9,850,079, issued December 26, 2017, are incorporated herein by reference in their entirety. A container robot 110 (described in more detail below) can be configured to place container units (such as the retail goods described above) into picking inventory in one or more levels of storage structure 130, and then selectively retrieve ordered container units.

[0041] In one aspect, a picking face (which includes a supply container 265) is transported between an inbound section (such as, for example, input station 160IN) of the storage and retrieval system 100 and a load-filling section (such as, for example, output station 160UT or output station 160EC) of the storage and retrieval system 100. At the load-filling section, outbound picking faces from the array are arranged to fill loads according to a predetermined load-filling order sequence or to fill one or more individual fulfillment orders according to a predetermined individual fulfillment order sequence. In another aspect, a picking face (e.g., a picking face for supplying container 265) is transported between a storage space 130S of the storage and retrieval system 100 and a load-filling section (such as, for example, output station 160UT or output station 160EC) to fill loads according to a predetermined load-filling order sequence or to fill one or more individual fulfillment orders according to a predetermined individual fulfillment order sequence. In other aspects, one or more unpacked cargo containers 1510A-n (in one aspect, multiple unpacked cargo containers may be arranged therein and transported as picking faces) are transported between storage space 130S and load filling sections and / or between unpacked cargo interfaces 263 of unpacking modules 266 and load filling sections (such as, for example, output stations 160UT or 160EC) of storage and retrieval system 100 to fill loads according to a predetermined load filling order sequence or to fill one or more individual fulfillment orders according to a predetermined individual fulfillment order sequence.

[0042] The container robot 110, lifting module 150, and other suitable features of the storage and retrieval system 100 are controlled in any suitable manner by, for example, one or more central system control computers (e.g., control servers) 120 via, for example, any suitable network 180. In one aspect, 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, control server 120 includes a set of programs (e.g., system management software) running substantially concurrently to substantially automatically control the automated storage and retrieval system 100. This set of substantially concurrently running programs is configured, for example, to manage the storage and retrieval system 100, including, for illustrative purposes only, controlling, scheduling, and monitoring the activities of all active system components, managing inventory (e.g., entering and removing which container units, the order of container removal, and the storage location of container units) and picking surfaces (e.g., one or more container units that can be moved as units and handled as units by components of the storage and retrieval system), and interfaced with a warehouse management system 2500. In one aspect, the control server 120 can be configured to control the features of the storage and retrieval system in the manner described herein. For simplicity and ease of explanation, the term "(one or more) cabinet units" is generally used herein to refer to both individual cabinet units and the picking surface (formed by multiple cabinet units moving as units).

[0043] Also refer to Figure 2 and Figure 3The shelving module array RMA of storage structure 130 includes vertical support members 1212 and horizontal support members 1200, which define a high-density automated storage array, as will be described in more detail below. Tracks 1200S may be installed, for example, in one or more of the vertical and horizontal support members 1212, 1200 in picking aisle 130A, and are configured to allow a container robot 110 to travel along tracks 1200S through picking aisle 130A. At least one side of at least one picking aisle 130A of at least one storage level 130L may have one or more storage shelves (e.g., formed by tracks 1210, 1200 and slats 1210S). In one aspect, the one or more shelves may be provided at different heights to form multiple shelf levels 130LS1-130LS3 between storage or deck levels 130L defined by transfer deck 130B (and tracks 1200S forming the aisle deck). Therefore, corresponding to each storage level 130L, there are multiple rack levels 130LS1-130LS3 extending along one or more picking aisles 130A communicating with the container transfer deck 130DC of the corresponding storage level 130L. As will be appreciated, the multiple rack levels 130LS1-130LS3 enable each storage level 130L to have stacks of stored container units / supply containers 265 (or container layers) and / or stacks of stored (one or more) unpacked cargo shipping containers 1510A-n (or unpacking layers), accessible from the common deck 1200S of the corresponding storage level 130L (e.g., stacks of stored containers are located between storage levels).

[0044] As may be appreciated, the container robot 110 traversing the picking aisle 130A can access each available storage space 130S at each shelf level 130LS1-130LS3 (e.g., for picking and placing container units and / or unpacking cargo containers), wherein each shelf level 130LS1-130LS3 is located on one or more sides PAS1, PAS2 of the picking aisle 130A (see, for example, Figure 8 Between adjacent vertically stacked storage levels 130L on the container rack. As described above, the container robot 110 can access each storage shelf level 130LS1-130LS3 from the track 1200 (e.g., from the common picking channel deck 1200S corresponding to the container transfer deck 130DC on the respective storage level 130L). Figure 2 and Figure 3As can be seen, there are one or more intermediate shelving tracks 1210B, 1210C, which are vertically spaced from each other (and from track 1200) (e.g., along the Z direction) to form a plurality of stacked storage spaces 130S, each of which can be accessed by container robot 110 from a common track 1200S. As will be appreciated, horizontal support members 1200 also form shelving tracks (in addition to shelving track 1210), on which container units are placed.

[0045] Each stacked shelf level 130LS1-130LS3 (and / or each individual shelf level as described below) corresponding to storage level 130L defines an open and nondeterministic two-dimensional storage surface (e.g., as...). Figure 3 As shown, a container unit / unpacked container support plane (CUSP) facilitates the dynamic allocation of picking surfaces (e.g., supply container 265) and / or (one or more) unpacked cargo shipping containers 1510A-n longitudinally (e.g., along the length of the aisle or aligned with the robot travel path defined by the picking aisle) and laterally (e.g., transverse to the aisle or robot travel path relative to the shelf depth). The dynamic allocation of picking surfaces and the container units constituting the picking surfaces is provided, for example, in the manner described in U.S. Patent No. 8,594,835, published November 26, 2013, the disclosure of which is incorporated herein by reference in its entirety. While supply container 265 is in Figure 2 The containers are shown stored on the side PAS2 of the picking aisle 130A, and one or more unpacked cargo shipping containers 1510A-n are shown stored on the side PAS1 of the picking aisle 130A. However, in other respects, there may be a mixture of supply containers 265 and one or more unpacked cargo shipping containers 1510A-n stored on the common sides PAS1 and PAS2 of the picking aisle 130A (e.g., one or both of sides PAS1 and PAS2) and / or a mixture of supply containers 265 and one or more unpacked cargo shipping containers 1510A-n stored on the common shelf surface.

[0046] In one aspect, reference Figure 4 and Figure 14 Each storage level 130L includes a single level of storage shelves for storing container units (e.g., each storage level includes a single container unit support plane CUSP), and the container robot 110 is configured to transfer container units to and from the storage shelves of the corresponding storage level 130L. For example, Figure 14The container robot 110' illustrated herein is generally similar to the container robot 110 described herein; however, the container robot 110' lacks sufficient Z-axis travel of the transfer arm 110PA to place container units onto multiple storage shelf levels 130LS1-130LS3 (e.g., accessible from a common track 1200S) as described above. Here, the transfer arm actuator 250 (which may be generally similar to one or more of actuators 250A, 250B) includes only sufficient Z-axis travel to lift container units from the container unit support plane CUSP of a single level of the storage shelf for transferring container units to and from the payload area 110PL, and for transferring container units between the fingers 273 of the transfer arm 110PA and the payload bed 110PB. A suitable example of a container robot 110 can be found, for example, in U.S. Patent No. 9,499,338, published on November 22, 2016, the disclosure of which is incorporated herein by reference in its entirety.

[0047] Refer again Figure 8 Each container transfer deck 130DC or storage level 130L includes one or more lift-and-grab picking surface interface / transfer stations TS (referred to herein as interface stations TS), wherein one or more container units (e.g., individual container units, picking surfaces, supply containers, etc.) and one or more unpacked cargo loading containers 1510A-n are transferred on the container transfer deck 130DC between the lift-and-grab load handling equipment LHD and the container robot 110. The interface station TS is located on the side of the container transfer deck 130DC opposite to the picking aisle 130A and the racking module RM, such that the container transfer deck 130DC is inserted between the picking aisle and each interface station TS. As described above, each container robot 110 on each picking level 130L can access (via the corresponding container transfer deck 130DC) each storage location 130S, each picking aisle 130A, and each lift 150 on the corresponding storage level 130L, and thus, each container robot 110 can also access each interface station TS on the corresponding level 130L. In one aspect, the interface station is offset from the high-speed robot travel path HSTP along the container transfer deck 130DC, such that the arrival of the container robot 110 at the interface station TS is nondeterministic with respect to the robot speed on the high-speed travel path HSTP. Accordingly, each container robot 110 can move (one or more) container units (e.g., individual container units, picking surfaces (built by the robot), supply containers, etc.) and (one or more) unpacked cargo loading containers 1510A-n from each interface station TS to each storage space 130S corresponding to the deck level 130L, and vice versa.

[0048] In one aspect, the interface station TS is configured to passively transfer (e.g., hand over) container units (e.g., individual container units, picking surfaces, supply containers, etc.) and (one or more) unpacked cargo shipping containers 1510A-n between the container robot 110 and the load handling equipment LHD of the elevator 150 (e.g., the interface station TS has no moving parts for transporting container units), which will be described in more detail below. For example, also refer to Figure 9 The interface station TS and / or buffer station BS includes one or more stacked levels TL1, TL2 of the transfer rack shelf RTS (e.g., to utilize the lifting capacity of the container robot 110 relative to the stacked rack shelf RTS). In one aspect, the transfer rack shelf RTS is substantially similar to the storage shelves described above (e.g., each free track 1210, 1200 and slat 1210S is formed), such that the container robot 110 handover (e.g., picking and placing) occurs in a passive manner substantially similar to that between the container robot 110 and the storage space 130S (as described herein), wherein container units or shipping containers are transferred to and from the shelves. In one aspect, the buffer station BS on one or more of the stacked levels TL1, TL2 also acts as a handover / interface station for the load handling equipment LHD relative to the elevator 150. In one aspect, when a robot (such as a container robot 110') is configured to transfer container units (e.g., individual container units, picking surfaces, supply containers, etc.), one or more unpacked cargo shipping containers 1510A-n to a single level 130L of a storage shelf, the interface station TS and / or buffer station BS also include a single level of the transfer rack shelf (which is roughly similar to the above regarding, for example...). Figure 3The storage rack shelves of the storage level 130L are described herein. As will be appreciated, the operation of a storage and retrieval system with a container robot 110' serving a single-level storage and transfer shelf is generally similar to the operation described herein. As will also be appreciated, the load handling equipment LHD (or elevator) transfers (e.g., picking and placing) container units (e.g., individual container units, picking surfaces, supply containers, etc.) and (one or more) unpacked cargo shipping containers 1510A-n to the stacked rack shelves RTS (and / or single-level rack shelves) in a passive manner generally similar to that between the container robot 110 and the storage space 130S (as described herein), wherein the container units and (one or more) unpacked cargo shipping containers 1510A-n are transferred to and from the shelves. In other respects, the shelving may include a transfer arm for picking and placing container units, one or more unpacking and loading containers 1510A-n from one or more of the load handling equipment LHDs of the container robot 110 and the elevator 150. A suitable example of an interface station with an active transfer arm can be found, for instance, in U.S. Patent No. 9,694,975, published July 4, 2017, the disclosure of which is incorporated herein by reference in its entirety.

[0049] In one aspect, the positioning of the container robot 110 relative to the interface station TS occurs in a manner substantially similar to the positioning of the robot relative to the storage space 130S. For example, in one aspect, the positioning of the container robot 110 relative to both the storage space 130S and the interface station TS occurs in a manner substantially similar to that described in U.S. Patent No. 9,008,884, published April 14, 2015, and U.S. Patent No. 8,954,188, published February 10, 2015, the disclosures of which are incorporated herein by reference in their entirety. For example, see reference to Figure 1 and Figure 3 The container robot 110 includes one or more sensors 110S that detect slats 1210S or positioning features 130F (such as apertures, reflective surfaces, RFID tags, etc.) disposed on / in the track 1200. The slats and / or positioning features 130F are arranged to identify the position of the container robot 110 within the storage and retrieval system relative to, for example, storage space and / or interface station TS. In one aspect, the container robot 110 includes a controller 110C that, for example, counts the slats 1210S to at least partially determine the position of the container robot 110 within the storage and retrieval system 100. In other aspects, the positioning features 130F may be arranged to form an absolute or incremental encoder, providing position determination of the container robot 110 within the storage and retrieval system 100 when detected by the container robot 110.

[0050] If it can be realized, refer to Figure 9 Each interface / transfer station TS has a transfer rack RTS defining a multi-load station (e.g., having one or more storage container unit holding positions to hold a corresponding number of container units or shipping containers 1510A-n) on a common transfer rack RS. As described above, each load at the multi-load station is a single container unit / shipping container 1510A-n or multiple container picking surfaces (e.g., having multiple container units / shipping containers 510A-n that move as individual units) picked and placed by the container robot 110 or load handling equipment LHD. As may also be appreciated, the robot positioning described above allows the container robot 110 to position itself relative to the multi-load station in order to pick and place container units / shipping containers 1510A-n and picking surfaces from predetermined holding positions in the holding positions of the multi-load station. The interface / transfer station TS defines a multi-location buffer (e.g., a buffer with one or more container holding positions) where inbound and / or outbound container units / shipping containers 1510A-n / unpacked cargo containers and picking faces are temporarily stored when transferred between the container robot 110 and the load handling equipment LHD of the elevator 150.

[0051] In one aspect, one or more peripheral buffer / transfer stations (BS) (generally similar to interface stations TS, and referred to herein as buffer stations BS) are also located on the side of the container transfer deck 130DC opposite the picking aisle 130A and the racking module RM, such that the container transfer deck 130DC is inserted between the picking aisle and each buffer station BS. Peripheral buffer stations BS are scattered between interface stations TS, or in one aspect, as... Figure 8 and Figure 9 As shown, it is otherwise aligned with the interface station TS. In one aspect, the peripheral buffer station BS is formed by tracks 1210, 1200 and slats 1210S, and is a continuation of the interface station TS (but a separate section) (e.g., the interface station and the peripheral buffer station are formed by common tracks 1210, 1200). Accordingly, in one aspect, as described above with respect to the interface station TS, the peripheral buffer station BS also includes one or more stacked levels TL1, TL2 of the transfer rack shelf RTS, while in other aspects, the buffer station includes a single level of the transfer rack shelf. The peripheral buffer station BS defines a buffer zone in which container units / shipping containers 1510A-n and / or picking surfaces are temporarily stored when transferred from one container robot 110 to another different container robot 110 on the same storage level 130L, as will be described in more detail below. As may be appreciated, in one respect, the peripheral buffer station is located at any suitable location within the storage and retrieval system, including within the picking channel 130A and at any location along the container transfer deck 130DC.

[0052] Still referencing Figure 8 and Figure 9 In one aspect, at least the interface station TS is located on an extension of the container transfer deck 130DC or on the pier 130BD; however, in other aspects, the length of the interface station TS may be arranged and extended along the container transfer deck. In one aspect, the pier 130BD resembles a picking aisle, in which the container robot 110 travels along a track 1200S attached to a horizontal support member 1200 (in a manner generally similar to that described above). In other aspects, the travel surface of the pier 130BD may be generally similar to the travel surface of the container transfer deck 130DC. Each pier 130BD is located on one side of the container transfer deck 130DC (such as the side opposite to the picking aisle 130A and the racking module RM), such that the container transfer deck 130DC is interposed between the picking aisle and each pier 130BD. (One or more) of the piers 130BDs extend from the transfer deck at a non-zero angle relative to at least a portion of the high-speed robot transport path HSTP. In other respects, one or more of the convex quays 130BD extend from any suitable portion of the container transfer deck 130DC, including the ends 130BE1, 130BE2 of the container transfer deck 130DCD. As may be appreciated, the perimeter buffer station BSD (which is roughly similar to the perimeter buffer station BS described above) may also be located at least along a portion of the convex quay 130BD.

[0053] refer to Figure 13As described above, the container robot 110 transports container units between each lifting module 150 and each storage space 130S on the corresponding storage level 130L. The container robot 110 includes a frame 110F having a drive section 110DR and a payload section 110PL. The drive section 110DR includes one or more drive wheel motors, each drive wheel motor connected to a corresponding drive wheel(s) 202 to propel the container robot 110 along a traversing path on the container deck 130DC and / or picking aisle 130A. In this respect, the container robot 110 includes two drive wheels 202 located on opposite sides of the container robot 110 at its end 110E1 (e.g., a first longitudinal end) to support the container robot 110 on a suitable drive surface; however, in other respects, any suitable number of drive wheels may be provided on the container robot 110. In one aspect, each drive wheel 202 is independently controlled such that the container robot 110 can be turned by differential rotation of the drive wheels 202; in other aspects, the rotation of the drive wheels 202 can be coupled so that they rotate at approximately the same speed. Any suitable wheel 201 is mounted to the frame at an end 110E2 (e.g., a second longitudinal end) of the container robot 110, on the opposite side of the container robot 110, to support the container robot 110 on the drive surface. In one aspect, the wheel 201 is a caster that is free to rotate, thereby allowing the container robot 110 to pivot by differential rotation of the drive wheels 202 to change the direction of travel of the container robot 110. In other aspects, the wheel 201 is a steerable wheel that rotates under the control of, for example, a robot controller 110C (which is configured to implement control of the container robot 110 as described herein) to change the direction of travel of the container robot 110. In one aspect, the container robot 110 includes one or more guide wheels 110GW, located, for example, at one or more corners of frame 110F. The guide wheels 110GW may interface with storage structure 130 (such as guide rails (not shown) within picking channel 130A) on container transfer deck 130DC and / or at an interface or transfer station for interface connection with lifting module 150, to guide and / or position the container robot 110 at a predetermined distance from the location where one or more container units are placed and / or picked, as described, for example, in U.S. Patent No. 9,561,905, published February 7, 2017, the disclosure of which is incorporated herein by reference in its entirety.

[0054] As described above, the container robot 110 can enter picking channels 130A with different orientations to reach storage spaces 130S located on both sides of the picking channel 130A. For example, the container robot 110 can enter the picking channel 130A with its end 110E2 leading the direction of travel, or the robot can enter the picking channel 130A with its end 110E1 leading the direction of travel.

[0055] The payload section 110PL of the container robot 110 includes a payload bed 110PB, a fence or reference member 110PF, a transfer arm 110PA, and a push rod or member 110PR. In one aspect, the payload bed 110PB includes one or more rollers 110RL, which are laterally mounted (e.g., relative to the longitudinal axis LX of the container robot 110) to the frame 110F such that one or more container units and / or unpacked cargo containers carried within the payload section 110PL can be moved longitudinally along the robot's longitudinal axis (e.g., aligned with a predetermined position relative to the frame / payload section and / or a reference reference of one or more container units), for example, to position the container units and / or unpacked cargo containers at predetermined positions within the payload section 110PL and / or relative to other container units and / or unpacked cargo containers within the payload section 110PL (e.g., longitudinal forward / backward alignment of the container units). In other respects, the container robot 110 includes one or more longitudinally movable push rods (generally similar to those described, for example, in U.S. Patent 11,078,017, published August 3, 2021, the disclosure of which is previously incorporated herein by reference in its entirety) for pushing (one or more) container units and / or (one or more) unpacked cargo containers via rollers 110RL to move the container units and / or unpacked containers to predetermined positions within the payload section 110PL.

[0056] Still referencing Figure 13Container units and / or unpacked cargo containers are placed on and removed from the payload bed 110PB by means of transfer arms 110PA. Transfer arms 110PA include a lifting mechanism or unit 200 located generally within the payload section 110PL, as described, for example, in U.S. Patent No. 9,850,079, previously incorporated herein by reference in its entirety, published December 26, 2017. Lifting mechanism 200 provides coarse and fine positioning of picking surfaces (which may include container units or unpacked cargo containers, or both) carried by container robot 110, which will be vertically lifted to appropriate positions within storage structure 130 to pick and / or place picking surfaces and / or individual container units into storage space 130S (e.g., the corresponding storage level 130L where container robot 110 is located). For example, the lifting mechanism 200 provides for picking and placing container units at multiple raised storage shelf levels 130LS1-130LS3, TL1, TL2 accessible from a common picking aisle or interface station deck 1200S (see, for example, Figure 2 , Figure 9 and Figure 11 ).

[0057] Still referencing Figure 13 The picking head 270 of the container robot 110 is located at the picking / placing position of the container robot 110 with container units and / or unpacked cargo containers (such as, for example, storage space 130S, peripheral buffer station BS, BSD, interface station TS (see...) Figure 8-9 ), unpacking operation station 140 (see) Figure 1 and Figure 10 ), container unloading and stacking system 1000 and / or unpacking cargo interface 263 (see Figure 1 and Figure 10 The container unit is transferred between, and in other respects substantially directly between the container robot 110 and (one or more) lifting modules 150. In one aspect, the picking head 270 includes a base member 272, one or more forks or fingers 273A-273E, and one or more actuators 274A, 274B. The base member 272 is mounted to the mast 200M as described above for travel along guide rails 280A, 280B. One or more forks 273A-273E are mounted to the base member 272 at their proximal ends such that the distal ends (e.g., free ends) of the forks 273A-273E cantilevered out from the base member 272. (See again) Figure 3The forks 273A-273E are configured to be inserted between the slats 1210S of the box unit support plane CUSP that forms the storage shelf (and similar slats of the surrounding buffer stations BS, BSD, interface station TS, unpacking operation station 140 and / or unpacking cargo interface 263).

[0058] Refer again Figure 13 It should be noted again that push rod 110PR is movable independently of transfer arm 110PA. Push rod 110PR is movably mounted to the frame in any suitable manner (such as by, for example, guide rods and sliding arrangements) and is actuated along the Y direction (e.g., along a lateral direction generally parallel to the extension / retraction direction of transfer arm 110PA). In one aspect, at least one guide rod 360 is mounted within the load section 110PL such that it extends laterally relative to the longitudinal axis LX of frame 110F. Push rod 110PR may include at least one sliding member 360S configured to engage and slide along the respective guide rod 360. In one aspect, at least the guide rod / sliding arrangement retains push rod 110PR within the load section 110PL. Push rod 110PR is actuated by any suitable motor and drive (such as by motor 303 and drive 303T). In one aspect, motor 303 is a rotary motor, and transmission 303T is a belt and pulley drive. In other aspects, push rod 110PR can be actuated by a linear actuator with substantially no rotating parts. Push rod 110PR can achieve alignment of container units CY in payload bed 110PB along the lateral axis of the container robot, and can achieve gripping of container units CU within payload bed 110PB (e.g., gripping between push rod 110PB and fence 110PF).

[0059] Now for reference Figure 1 , Figure 7 , Figure 8 , Figure 10 , Figure 12 and Figure 16A-B, and as described above, at least one container destacking system 1000 can be coupled to the structure of the automated storage and retrieval system 100 at any suitable location and at any suitable level(s) 130L. For example, the container destacking system 1000 can be located at one or more ends 130BE1, 130BE2 of the container transfer deck 130DC, or at one or more sides 130BD1, 130BD2 of the container transfer deck 130DC (such as alternative storage rack modules RM / picking lanes 130A or elevators 150A, 150B, or as an extension of one or more picking lanes 130A), or on one side of the robot lane adjacent to the placement wall 263W. Each of the (one or more) container destabilization and stacking systems 1000 is a plug-and-play module integrated with (or otherwise connected to) the container transfer deck 130DC, such that the container transfer deck 130DC is communicatively connected to at least one output interface station 1001 of the container destabilization and stacking system 1000, enabling the container robot 110 to transfer (one or more) unpacked and stacked containers 1510A-n from at least one container destabilization and stacking system 1000 to at least one unpacking station 266 via the container transport deck 130DC. In other aspects, the output interface station 1001 is connected to a picking aisle extending from the container transport deck 130DC (see...). Figure 8 The traveling container robot 110 interfaces and is communicatively connected to these picking lanes, enabling the container robot 110 to transfer (one or more) unpacked shipping containers 1510A-n from at least one loading / unloading system 1000 to at least one unpacking station 266 via picking lane 130A. It should be noted that when the output interface station 1001 interfaces with the picking lane 130A, the picking lane 130A may include a nondeterministic turning area (similar to an open nondeterministic container transfer deck 130DC) on which the container robot 110 turns to pick (one or more) unpacked shipping containers 1510A-n from the output interface station 1001. When the output interface station 1001 is connected to the container transfer deck 130DC interface, the container transfer deck includes a transfer lane in which the container robot 110 can be "parked parallel" near the predetermined output interface station 1001 to transfer (one or more) unpacked and transported containers 1510A-n between the container robot 110 and the output interface station 1001.

[0060] As will be described herein, each container destabilization system(s) 1000 includes a container transport unit (CTP) for transporting containers(s) 1510A-n from robot(s) 999 to output interface station(s). The container transport unit (CTP) is configured to transport unpacked containers(s) 1510A-n within the respective container destabilization system(s) 1000. The container transport unit (CTP) includes a container feed 1010 formed at least partially by a stack 1505A-n of robot(s) 999 and containers(s) 1510A-n, configured to load containers(s) 1510A-n onto the container transport path. The container transport unit (CTP) also includes an output interface station 1001, which is configured to communicate with an asynchronous container transport unit (such as a container robot 110) to unload (one or more) containers 1510A-n for transport to the unpacking module 266. The CTP is any suitable conveying device configured to transport (one or more) unpacked cargo containers 1510A-n between the robot 999 and one or more of the output interface station 1001 and the rejection / manual loading station 1007. The CTP can be a roller conveyor, belt conveyor, ball conveyor, and / or any other suitable conveyor type or combination of conveyor types for transporting (one or more) unpacked cargo containers 1510A-n within the corresponding (one or more) container unpacking and stacking system 1000. The robot 999 and the output interface station 1001 are communicatively connected via the CTP.

[0061] A container transport device (CTP) may include at least one barcode scanner 1005 and a transport controller 1006. The transport controller 1006 is capable of controllably selecting a container transport route to guide one or more containers 1510A-n to at least one of an output interface station 1001 and a rejection / manual loading station 1007. The transport controller 1006 is communicatively coupled to at least one barcode scanner 1005 configured to scan and track one or more containers 1510A. The transport controller 1006 is arranged to controllably select a container transport route to guide one or more containers 1510A-n to at least one of an output interface station 1001 and a rejection / manual loading station 1007 based on the scanning results (containers without barcodes or with damaged barcodes may be rejected). The transport controller 1006 may include another barcode scanner 1005A, configured to scan and track one or more containers 1510A-n manually placed on the container transport unit CTP by an operator at the rejection / manual loading station 1007. The transport controller 1006 may also include additional barcode scanners downstream or upstream of the rejection / manual loading station 1007 for scanning and tracking containers 1510A-n.

[0062] Each of the container unloading and stacking systems 1000 includes at least an output interface station 1001, a container transport device (CTP), a robot 999, and stacks 1505A-n of containers 1510A-n(s). The output interface station 1001 may be a passive interface, and its structure is generally similar to... Figure 3 and Figure 9 The structure illustrated in the diagrams regarding the storage shelves of the rack module RM and the buffer and transfer stations BS and TS allows the container robot 110 to transfer one or more unpacked containers 1510A-n between the output interface station 1001 and the transfer arm 110PA in a manner generally similar to that described herein. The output interface station 1001 includes any suitable container drive device (e.g., pusher, driven spaced rollers (spaced in a manner similar to slats 1210S, with the fingers of the transfer arm 110PA inserted into the space between the rollers)) configured to move the unpacked containers from the respective output interface station 1001 to the container robot 110. In other respects, the output interface station 1001 may be a passive interface, allowing a human operator to initiate a transfer to the unpacking module 266.

[0063] Now refer to Figure 16A-20This description describes a container destabilization system 1000 for unstabilizing (denesting) one or more shipping containers 1510A-n from stack(one or more) 1505A-n. As previously described, robot 999 is adapted to and equipped with an end-effector (end-effector) in the form of an automated product shipping container destabilizer tool 1050, which is adapted to pick / denestify one or more shipping containers 1510A-n from stack(one or more) 1505A-n and transfer one or more shipping containers 1510A-n to the shipping container transport unit CTP for transport to unpacking module 266. In this specification, the terms 'robot' and 'robotic arm' are used interchangeably to refer to a programmable system including a standard 4-axis or 6-axis industrial articulated arm that receives, controls, and moves the end-effector tool. For example, robot 999 could be a Comau NJ 165-3.4 SH robot, or any similar robotic arm. Furthermore, although the robot is described and illustrated as a stationary articulated robotic arm, the robot can be any suitable robotic system, such as a gantry system or any other system. Alternatively, the robotic arm and tool 1050 can be integrated into a single device, thus providing the combined features of robot 999 and automated product loading container destacking tool 1050. Robot 999 may include other well-known systems and components that allow its operation, including, for example, a robot controller 900. Since these systems and components are well-known in the art, they will not be described in further detail herein for the sake of brevity.

[0064] In the container destacking system 1000, the robot 999 is typically positioned near the container unloading station 1600, which includes one or more container arrays 1500 having one or more stacks 1505A-n of containers 1510A-n, which are positioned for picking / unstacking by the robot 999 (although the container array 1500 is illustrated as having four stacks, the container array 1500 may have any suitable number of stacks, which may coincide with or not coincide with the picking head array 1200 of the automated product container destacking machine tool 1050 (i.e., the container array 1500 may have more or fewer stacks than the picking head array 1200)). The container array 1500 can be placed in the container unloading station 1600 by a lift truck, an input container conveyor or any other suitable device (not shown) to transport an array of stacks 1505A-n having one or more containers 1510A-n.

[0065] As described, the automated product shipping container destacking machine tool 1050 includes a picking head array 1200 movably connected to and dependent on a shipping container picking head 1250 of a frame 1100. The picking head array 1200 is configured to destacking / unnesting (one or more) shipping containers 1510A-n (i.e., including components for destacking / unnesting shipping containers 1510A-n), wherein each corresponding shipping container picking head 1250A-n destacking (one or more) shipping containers 1510A-n one by one from a corresponding stack 1505A-n of shipping containers 1510A-n in the shipping container stack array 1500 (i.e., destacking from the topmost shipping container array to the bottommost shipping container array of the stack 1505A-n of the shipping containers 1510A-n in the shipping container stack array 1500). For example, the picking head array 1200 is configured to simultaneously hold a single-layer shipping box array 1500 to the robot 999. Different corresponding shipping boxes 1510A-n in the shipping box array 1500 are held by corresponding picking heads 1250A-n, and different picking heads 1250A-n hold different corresponding shipping boxes 1510A-n in the shipping box array 1500. As will become more apparent from the following description, the system 1000 is not limited to destacking “shipping boxes”, and as previously stated, the term “shipping box” is used herein for convenience, but includes any type of stacked shipping box, container, box, drum, carton, crate, etc. Furthermore, although the system 1000 is described as picking from a stack 1505A-n of shipping boxes(one or more) that are tightly stacked together, it can also be used to pick arrays of unstacked shipping boxes(one or more) (such as the bottom layer).

[0066] Referring still at least to Figures 16-20, the picking head array 1200 includes packer picking heads 1250A-n movably connected to and dependent on the frame 1100. For example, a drive section 1300 may be connected to the frame 1100 (so as to depend on the frame 1100) and operatively coupled to each picking head 1250A-n to drive the picking head 1250A-n relative to the frame 1100. The picking heads 1250A-n are moved by the drive section 1300 as units or individually relative to the robot 999 along at least one direction LS and according to the hierarchy of the corresponding packers 1510A-n, as will be further described below. In one aspect, the drive section 1300 may be a linear slider 1900 or a prism joint having at least a drive motor 1901 and a guide rail 1902. The drive motor 1901 and the guide rail 1902 are generally coupled to the frame 1100 in any suitable manner (such as by means of fasteners). Picking head 1250A-n can be directly coupled to each of drive motor 1901 and guide rail 1902, or it can be coupled to carriage such that drive motor 1901 linearly drives picking head 1250A-n along guide rail 1902 in at least one direction LS. In other aspects, drive section 1300 can be any other suitable actuator to move picking head 1250A-n relative to robot 999 in at least one direction LS. Additionally, drive section 1300 can include another actuator to move picking head 1250A-n relative to robot 999 in a direction different from the at least one direction LS, such as to pivot or rotate picking head 1250A-n.

[0067] Each picking head 1250A-n has a corresponding shipping gripper 1260A-n that engages and grips the corresponding shipping container 1510A-n. In the illustrated example, the automated product shipping container de-stacking machine tool 1050 is shown as having four picking heads 1250A-D, each with a corresponding shipping gripper 1260A-D. However, it should be noted that the automated product shipping container de-stacking machine tool 1050 may include any number of picking heads 1250A-n, each with any number of shipping grippers 1260A-n. Furthermore, regardless of whether the container array 1500 includes one stack, four stacks, or any number of stacks, and regardless of whether that number matches the picking head array 1200 of the automated product container destacking tool 1050, the automated product container destacking tool 1050 functions (i.e., the container array 1500 may have more or fewer stacks than the picking head array 1200, and the picking head array 1200 still picks the topmost container in the stack reached by the picking head array). In one aspect, container grippers 1260A-n are active grippers configured to capture and hold corresponding containers 1510A-n to corresponding picking heads 1250A-n. Container grippers 1260A-n are typically illustrated as vacuum grippers; however, gripping can be achieved by any suitable means, such as pneumatic grippers, hydraulic grippers, adaptive grippers, etc., or a combination of various types of grippers. In the aspect where the shipping box gripper 1260A-n is a vacuum gripper, the shipping box gripper 1260A-n can be a distributed gripper (i.e., having multiple gripping contacts 1265A1-nm distributed around the picking head 1250A-n to provide distributed gripping). The multiple gripping contacts 1265A1-nm are configured to engage with the corresponding shipping box 1510A-n gripped by the picking head 1250A-n. For example, the gripping contacts 1265A1-nm are resilient compliant suction cups with bellows to accommodate uneven or tilted (one or more) shipping boxes 1510A-n. It should be noted that in the illustrated example, the picking heads 1250A-D are illustrated as having container grippers 1260A-D each having four gripping contacts 1265A1-D4. However, it should be noted that the automated product container unloading machine tool 1050 may include any number of container grippers each having any number of gripping contacts (including fewer than four, such as three, two, or one contact).

[0068] When the container gripper 1260A-n is actuated, it actively generates an upward gripping force GF on the container 1510A-n. Figure 19 ), wherein the gripping contact 1265A1-nm abuts against the inner bottom surface 264BS of the gripped shipping container 1510A-n ( Figure 15The picking head 1250A-n is installed to enable box picking, thereby lifting the corresponding box 1510A-n off the stack 1505A-n. In one aspect, a plurality of gripping contacts 1265A1-nm of the picking head 1250A-n lift the corresponding box 1510A-n off the stack 1505A-n, wherein at least one of the plurality of gripping contacts 1265A1-nm of the picking head 1250A-n is inactive (i.e., each picking head 1250A-n grips and picks boxes independently of each other, such that if one picking head 1250A-n is inactive or operates in the absence of a corresponding box stack in the box stack array, or if a picking head malfunctions due to interference from a box stack captured by one picking head, the other picking heads 1250A-n still pick their respective boxes). As described, each gripping contact 1265A1-nm of the container gripper 1260A-n is resiliently compliant and is configured to be mounted on the inner bottom surface 264BS of the container 1510A-n. Figure 15 On the ), the picking head 1250A-n reaches the shipping container 1510A-n through the opening 264OP of the shipping container 1510A-n.

[0069] In one aspect, the shipping box gripper 1260A-n is a vacuum gripper generated by a venturi tube 1261, providing robust and metered suction (vacuum) to grip the corresponding shipping box 1510A-n. The venturi suction prevents suction loss due to obstruction such as debris and fragments present in the shipping box. During metering of the active gripper, the shipping box 1510A-n and the shipping box gripper 1260A-n are configured to automatically disengage when the picking head 1250A-n initiates a picking operation for more than one shipping box 1510A-n (i.e., if two shipping boxes are picked in a single operation (due to nesting adhesion), the shipping box gripper will automatically disengage from the shipping box, and may be indicated as a failed pick). Automatic disengagement occurs because the weight of the two shipping boxes exceeds the picking head's picking suction (e.g., via the venturi vacuum). The picking head 1250A-n is metered (equipped with a shipping box picking meter) such that, for each shipping box picking from the stack 1505A-n of shipping boxes 1510A-n, the picking head 1250A-n automatically and repeatedly picks only (single or individually) the corresponding shipping box 1510A-n from the stack 1505A-n, essentially covering each unpacking and picking of the stack 1505A-n of shipping boxes 1510A-n from the top to the bottom of the stack 1505A-n by the automated product shipping box unpacking machine tool 1050. In one aspect, each individual picking head 1250A-n is metered (configured with a shipping box picking meter) such that each individual picking head 1250A-n individually picks from the stacked shipping boxes 1510A-n, thereby grabbing only the corresponding shipping box from the corresponding picking head 1250A-n for each shipping box picking that is substantially simultaneously performed by the picking head array 1200, and substantially simultaneously unpacking the stack 1505A-n of shipping boxes 1510A-n by means of the automated product shipping box unpacking machine tool 1050. When picking head 1250A-n initiates picking of more than one shipping box 1510A-n from the stack 1505A-n of shipping box 1510A-n, the picking head metering configuration enables the automatic shipping box to be disengaged from the shipping box gripper 1260A-n of picking head 1250A-n, so that each picking head 1250A-n that performs the picking of shipping boxes only grips the corresponding shipping box 1510A-n, thereby unloading the stack 1505A-n.

[0070] refer to Figure 18-20The automated product container destacking machine tool 1050 also includes a first sensor system 1270 having one or more sensors 1275 positioned above the container array 1500 relative to the picking head array 1200 during picking of one or more containers 1510A-n. The one or more sensors 1275 are typically arranged to determine the bottom 264BS of the corresponding container 1510A-n in the stack 1505A-n. For example, the sensor system 1270 may include any suitable vertical distance sensor arranged such that the container array 1500 is within the field of view of the sensor 1275 (e.g., in the case of an imaging sensor) or within the electromagnetic beam (e.g., in the case of a reflective beam sensor). The first sensor system 1270 is not limited to being fixed to the frame 1100 above the container unloading station 1600 and may be arranged in any suitable manner to determine the vertical distance between the picking head array 1200 and the container array 1500.

[0071] Sensor 1275 is configured to detect a stack 1505A-n of shipping containers 1510A-n and determine one or more of the following: the height of stack 1505A-n, the distance of picking head array 1200 from stack 1505A-n, the distance from the bottom of the topmost shipping container 1510A-n to the bottom of the picking head array, whether one stack 1505A-n contains more shipping containers than another stack 1505A-n, or any other suitable vertical distance that helps to achieve picking of one or more shipping containers 1510A-n from stack 1505A-n. For example, the first sensor system 1270 is configured to acquire sufficient mapping data to determine the vertical orientation of the shipping container array 1500, such as from above. Sensor 1275 can be any suitable sensor for capturing map data, such as an ultrasonic sensor, IR sensor, LIDAR sensor, reflective sensor, optical sensor, etc. In this specification, the term "map" or "cartographic data" includes any type of data that forms a two-dimensional (2D) or three-dimensional (3D) representation of one or more shipping boxes, including 2D or 3D conventional grayscale or color images, depth maps, terrain images, height data, and so on. Map or depth values ​​obtained from the sensor system can be used to evaluate, verify, and / or correct gripping points on selected layers of shipping boxes 1510A-n for the corresponding picking heads 1250A-n of the picking head array 1200. The robot 999 is configured to position sensor 1275 above the shipping box array 1500 to determine, for example, the depth of one or more shipping boxes 1510A-n and the height of the stack 1505A-n. This determination typically occurs before gripping and picking the first (one or more) shipping boxes 1510A-n; however, it can also occur at any point in time between picking operations until the shipping box array 1500 is depleted. This generates a dynamic depth map of the uppermost (one or more) shipping containers 1510A-n in the shipping container array 1500, which the controller 900 uses to determine, for example, the coordinates / position / orientation of the uppermost (one or more) shipping containers 1510A-n.

[0072] Sensor 1275 is connected to controller 900, which is configured to transmit captured map data between sensor 1275 and controller 900. Controller 900 is configured or programmed to analyze the map acquired by the first sensor system 1270, analyzing characteristics to determine the coordinates of individual uppermost (one or more) shipping containers An in stacks 1505A-n. Examples of characteristics analyzed by controller 900 include the depth of shipping containers An, the height of stacks An, the number of stacks An, etc. Controller 900 can be wired or wirelessly coupled to robot 999 and configured to send maps to it for picking of uppermost (one or more) shipping containers An 1510A-n. "Controller" should be understood to include one or more electronic devices, such as one or more computers, processors, microcontrollers, etc., configured with components that generate one or more functions for implementing the picking / denesting of shipping containers 1510A-n and / or programmed with instructions that generate one or more functions for implementing the picking / denesting of shipping containers(one or more) 1510A-n.

[0073] The controller 900 can be programmed to request new data acquisition from the first sensor system 1270 based on predetermined criteria, such as the arrival of a new array of shipping boxes at the shipping box unloading station 1600, a problematic scan, a failed pick, etc. As an example, the first sensor system 1270 maps two side-by-side stacks 1505A-n of shipping boxes(s) 1510A-n in the shipping box array 1500. In this case, the controller 900 is configured to evaluate the array 1500 and instruct the robot 999 to pick (one or more) shipping boxes(s) 1510A-n. In the event of a failed pick, the controller 900 can be programmed to request new data acquisition from the first sensor system 1270 based on, for example, a non-operating picking head that would otherwise have made it difficult to identify and pick the next(s) shipping boxes(s) 1510A-n.

[0074] In one aspect, the picking head 1250A-n includes a second sensor system 1280 having one or more ranging sensors 1285. The second sensor system 1280 can cooperate with the first sensor system to map the one or more shipping boxes 1510A-n before or immediately after the picking head 1250A-n is inserted into the shipping box(s) 1510A-n through the shipping box opening 264OP. This map detects and identifies the boundaries, edges 264E, bottom 264BS, orientation, etc., of the shipping box sides 264S. The second sensor system 1280 includes any suitable ranging sensors (such as ultrasonic sensors, IR proximity sensors, laser sensors, optical sensors, etc.) to be picked and placed in the shipping box transport device (CTP). Figure 7 The positioning and orientation of one or more shipping boxes 1510A-n are determined before insertion into the stack 1505A-n. In one aspect, a second sensor system 1280 is typically disposed on the bottom surface 1299 (i.e., the surface facing the shipping box array 1500) of the corresponding picking head 1250A-n and is oriented to map the shipping boxes 1510A-n before or immediately after insertion into the stack 1510A-n. As described, one or more ranging sensors 1285 are arranged to detect the sides 264S, edges 264E, and openings 264OP of the corresponding shipping boxes 1510A-n in the stack 1505A-n. Figure 15 At least one of the following. In some aspects, the sensor system 1280 also confirms that one or more shipping containers 1510A-n are picked by the automated product shipping container unloader tool 1050.

[0075] Sensor system 1280 may include any suitable ranging sensor configured such that the shipping box array 1500 is within the field of view of sensor 1285 (e.g., in the case of an imaging sensor) or within the electromagnetic beam (e.g., in the case of a reflective beam sensor). The second sensor system 1280 is not limited to being fixed to the bottom surface 1299 of the respective picking heads 1250A-n, and may be arranged in any suitable manner to determine the distance between the picking head array 1200 and the shipping box array 1500. In one aspect, the second sensor system 1280 may include a cover (such as a bracket 1290) to protect the sensor in the event of, for example, a collision with a shipping box.

[0076] For example, each picking head 1250A-n approaches a different stack 1505A-n substantially simultaneously, such that the picking head array 1200 approaches the shipping box array 1500 of stack 1505A-n, and each different picking head 1250A-n and the different picking heads 1250A-n of the picking head array 1200 pick shipping boxes 1510A-n from the corresponding stack 1505A-n of the shipping box array 1500 substantially simultaneously enter, capture, and pick shipping boxes corresponding to the picking head 1250A-n. Typically, the second sensor system 1280 determines the orientation and position of each corresponding shipping box 1510A-n relative to the picking head array 1200, such that the robot 999 moves the corresponding shipping box 1510A-n to the shipping box transport device (CTP) in a predetermined manner. Figure 7 The transfer on the container transport device (CTP) generates a flow of empty containers 1510A-n aligned with the desired orientation on the container transport device (CTP).

[0077] The second sensor system 1280 is wired or wirelessly connected to the controller 900 and configured to transmit the collected map data to the controller 900. Once the controller 900 determines the position of one or more shipping boxes 1510A-n relative to the picking head array 1200, the controller 900 identifies a movement displacement command to the robot 999, which precisely places the picking head array 1200 in a predetermined position and orientation above the shipping box array 1500.

[0078] 0090 also references Figure 22 The flowchart of the shipping box picking method 2000 will now be described in more detail with reference to the operation of system 1000.

[0079] In box 2001, at the box unloading station 1600, an array 1500 of stacks 1505A-n containing one or more boxes 1510A-n is forwarded to the robot 999. A first sensor 1270 maps the upper (one or more) boxes 1510A-n in the stack 1505A-n, and more specifically, obtains a depth map of the upper (one or more) boxes 1510A-n (box 2002). Additionally, a second sensor 1280 can measure the box array 1500 to detect the edges 264E, sides 264S, and openings 264OP of the corresponding boxes 1510A-n. In step 2003, the controller 900 uses the depth map to determine the next (one or more) boxes 1510A-n to pick / denest.

[0080] The controller 900 selects the highest (one or more) shipping boxes 1510A-n, or, if all the upper (one or more) shipping boxes 1510A-n are at the same depth, instructs the robot to pick the upper array of (one or more) shipping boxes 1510A-n (box 2003). The uppermost layer is determined using a bottom surface detection method. Alternatively or additionally, for example when the depth is uncertain, the edges 264E and sides 264S of (one or more) shipping boxes 1510A-n can be detected.

[0081] Then, controller 900 sends instructions to robot 999 (box 2004), and robot 999 then uses the picking head array 1200 of destacking tool 1050 to pick from container array 1500 (see box 2004). Figure 16B In each corresponding stack 1505A-n, only one corresponding (one or more) shipping container 1510A-n is grabbed, and the shipping container array is moved to the shipping container feed 1010 (box 2005) (see See Figure 2 ).

[0082] If one or more shipping containers 1510A-n cannot be identified in step 2003, stack 1505A-n is considered empty (box 2007), and system 1000 waits for a new shipping container array 1500 to arrive with stack 1505A-n containing one or more shipping containers 1510A-n (box 2008).

[0083] In box 2006, the second sensor system 1280 acquires map data and sends it to the controller 900, which helps determine the position and orientation of one or more shipping boxes 1510A-n relative to the picking head array 1200. The controller 900 uses this information to determine the displacement required for the robot 999 to pick one or more shipping boxes 1510A-n.

[0084] Whenever an array of containers (one or more) 1510A-n is moved on the container transport unit (CTP), the method proceeds to box 2002, where controller 900 determines whether container array 1500 is empty, and if empty, waits for a newly loaded container array 1500. If not empty, the method returns to box 2003. For example, stack 1505A-n is determined to be empty when the maximum depth is equal to a known distance from the bottom of stack 1505A-n.

[0085] It should be noted that many other modifications can be made to the shipping box picking system 1000 and method described above and illustrated in the accompanying drawings. For example, to improve productivity, two robotic arms and two or more shipping box transport devices (CTPs) can be used.

[0086] According to one aspect of the disclosed embodiments, an automated product shipping container de-stacking machine tool is provided. The automated product shipping container de-stacking machine tool includes: a frame having a coupling member configured to engage with a robot end effector, such that the automated product shipping container de-stacking machine tool provides an end effector to the robot; and an array of picking heads for shipping containers, the array of picking heads being movably connected to and dependent on the frame, the array of picking heads being configured to simultaneously hold an array of shipping containers to the robot, wherein different corresponding shipping containers in the shipping container array are held by corresponding shipping container picking heads, and different shipping container picking heads hold different corresponding shipping containers in the shipping container array. Each container picking head has a container gripper that engages the container corresponding to the container picking head; and a drive section connected to the frame and operatively coupled to each container picking head to move as a unit relative to the frame according to the hierarchy of the corresponding container; wherein the container picking heads are metered such that for each container picking from the container stack, the container picking head automatically and repeatedly picks only the corresponding container from the stack, substantially throughout each unpacking and picking operation of the automated product container unpacking machine tool from the top container to the bottom container in the stack.

[0087] According to one aspect of the disclosed embodiments, when a shipping box picking head initiates the picking of more than one shipping box from a shipping box stack, the picking head metering configuration enables automatic shipping box disengagement from the shipping box gripper of the shipping box picking head, such that each shipping box picking head that performs the picking only grips the corresponding shipping box, thereby unloading the stack.

[0088] According to one aspect of the disclosed embodiments, the shipping box gripper is an active gripper configured to capture and hold a corresponding shipping box to the shipping box picking head, and the active gripper is metered such that when the shipping box picking head initiates the picking of more than one shipping box, the shipping box and the gripper are disengaged.

[0089] According to one aspect of the disclosed embodiments, the shipping box grippers are distributed such that, for each shipping box picking head, the shipping box grippers form a plurality of gripping contacts, the gripping contacts being configured to engage with a corresponding shipping box gripped by the shipping box picking head.

[0090] According to one aspect of the disclosed embodiment, each gripping contact of the shipping container gripper is resiliently compliant and is configured to be disposed on the inner bottom surface of the shipping container, wherein the shipping container picking head reaches the shipping container through the opening of the shipping container.

[0091] According to one aspect of the disclosed embodiment, each gripping contact actively generates an upward gripping force on the shipping container when actuated, wherein the gripping contact is mounted against the inner bottom surface of the gripped shipping container.

[0092] According to one aspect of the disclosed embodiment, a shipping box gripper is configured such that an upward force grips a corresponding shipping box to a shipping box picking head to perform shipping box picking, thereby lifting the corresponding shipping box off the stack, wherein at least one of the plurality of gripping contacts of the shipping box picking head is inactive.

[0093] According to one aspect of the disclosed embodiments, the shipping container gripper is a vacuum gripper generated by a venturi tube, thereby providing metered suction to grip the corresponding shipping container.

[0094] According to one aspect of the disclosed embodiments, the picking head array has at least one distance sensor arranged to determine the bottom of a corresponding shipping box in a stack.

[0095] According to one aspect of the disclosed embodiments, the picking head array has at least one distance sensor arranged to determine one or more of the sides, edges, and openings of a corresponding shipping box in a stack.

[0096] According to one aspect of the disclosed embodiments, each carton picking head in the picking head array has a corresponding distance sensor among at least one distance sensor configured to determine the position of the picking head array relative to a group of stacks, wherein each carton picking head substantially simultaneously reaches a different stack, such that the picking head array reaches the stack group, and each different carton picking head and the different carton picking heads in the picking head array pick cartons from the corresponding stacks in the group substantially simultaneously enter, capture, and pick the carton corresponding to the carton picking head.

[0097] According to one aspect of the disclosed embodiments, an automated product shipping container destacking tool is provided. The automated product shipping container destacking tool includes: a frame having a coupling member configured to engage with a robot end effector, such that the automated product shipping container destacking tool provides an end effector to the robot; and an array of picking heads for shipping containers, the array of picking heads being movably connected to and dependent on the frame, the array of picking heads being configured to simultaneously hold an array of shipping containers to the robot, wherein different corresponding shipping containers in the shipping container array are held by corresponding shipping container picking heads, and different shipping container picking heads hold different corresponding shipping containers in the shipping container array. The shipping boxes are to be loaded, wherein each shipping box picking head has a shipping box gripper that engages with the shipping box corresponding to the shipping box picking head; each shipping box picking head is movably coupled to a frame such that the shipping box picking head moves as a unit relative to the robot according to the hierarchy of the corresponding shipping box; wherein the shipping box picking heads are metered such that each individual shipping box picking head that picks shipping boxes from stacked shipping boxes grasps the corresponding shipping box individually from the corresponding shipping box picking head for each shipping box picking that is substantially simultaneous by the array of picking heads, and the stack of shipping boxes is destabilized substantially simultaneously by means of an automated product shipping box destabilizer.

[0098] According to one aspect of the disclosed embodiments, the drive section is dependent on the frame and operatively coupled to each box picking head, such that the box picking head is actuated relative to the robot in at least one direction.

[0099] According to one aspect of the disclosed embodiments, the shipping container picking head is metered such that for each shipping container picking from the shipping container stack, the shipping container picking head automatically and repeatedly picks only the corresponding shipping container from the stack, substantially throughout each unpacking and picking of the automated product shipping container unpacking machine tool from the topmost shipping container to the bottommost shipping container in the stack.

[0100] According to one aspect of the disclosed embodiments, when a shipping box picking head initiates the picking of more than one shipping box from a shipping box stack, the picking head metering configuration enables automatic shipping box disengagement from the shipping box gripper of the shipping box picking head, such that each shipping box picking head that performs the picking only grips the corresponding shipping box, thereby unloading the stack.

[0101] According to one aspect of the disclosed embodiments, the shipping box gripper is an active gripper configured to capture and hold a corresponding shipping box to the shipping box picking head, and the active gripper is metered such that when the shipping box picking head initiates the picking of more than one shipping box, the shipping box and the gripper are disengaged.

[0102] According to one aspect of the disclosed embodiments, the shipping box grippers are distributed such that, for each shipping box picking head, the shipping box grippers form a plurality of gripping contacts, the gripping contacts being configured to engage with a corresponding shipping box gripped by the shipping box picking head.

[0103] According to one aspect of the disclosed embodiment, each gripping contact of the shipping container gripper is resiliently compliant and is configured to be disposed on the inner bottom surface of the shipping container, wherein the shipping container picking head reaches the shipping container through the opening of the shipping container.

[0104] According to one aspect of the disclosed embodiment, each gripping contact actively generates an upward gripping force on the shipping container when actuated, wherein the gripping contact is mounted against the inner bottom surface of the gripped shipping container.

[0105] According to one aspect of the disclosed embodiment, a shipping box gripper is configured such that an upward force grips a corresponding shipping box to a shipping box picking head to perform shipping box picking, thereby lifting the corresponding shipping box off the stack, wherein at least one of the plurality of gripping contacts of the shipping box picking head is inactive.

[0106] According to one aspect of the disclosed embodiments, the shipping container gripper is a vacuum gripper generated by a venturi tube, thereby providing metered suction to grip the corresponding shipping container.

[0107] According to one aspect of the disclosed embodiments, the picking head array has at least one distance sensor arranged to determine the bottom of a corresponding shipping box in a stack.

[0108] According to one aspect of the disclosed embodiments, the picking head array has at least one distance sensor arranged to determine one or more of the sides, edges, and openings of a corresponding shipping box in a stack.

[0109] According to one aspect of the disclosed embodiments, each carton picking head in the picking head array has a corresponding distance sensor among at least one distance sensor configured to determine the position of the picking head array relative to a group of stacks, wherein each carton picking head substantially simultaneously reaches a different stack, such that the picking head array reaches the stack group, and each different carton picking head and the different carton picking heads in the picking head array pick cartons from the corresponding stacks in the group substantially simultaneously enter, capture, and pick the carton corresponding to the carton picking head.

[0110] According to one aspect of the disclosed embodiments, a method for unloading shipping containers using an automated product shipping container destabilizer is provided. The method includes: providing a frame for the automated product shipping container destabilizer, the frame having a connector configured to engage the automated product shipping container destabilizer with a robot end effector, such that the automated product shipping container destabilizer provides an end effector to the robot; providing an array of picking heads for shipping containers, the array of picking heads being movably connected to and dependent on the frame, the array of picking heads being configured to simultaneously hold an array of shipping containers to the robot, wherein different corresponding shipping containers in the shipping container array are held by corresponding shipping container picking heads, and mutually different shipping container picking heads hold mutually different corresponding shipping containers in the shipping container array, wherein each shipping container... The container picking head has a container gripper that engages a container corresponding to the container picking head; and provides a drive section that is connected to a frame and operatively coupled to each container picking head to allow the container picking head to move as a unit relative to the frame according to the hierarchy of the corresponding container; automatically and repeatedly picking containers from a container stack, wherein the container picking head is metered such that for each container picking from the container stack, the container picking head automatically and repeatedly picks only the corresponding container from the stack, essentially covering each unpacking and picking operation of the automated product container unpacking machine tool from the top container to the bottom container in the stack.

[0111] According to one aspect of the disclosed embodiments, when a shipping box picking head initiates shipping box picking of more than one shipping box from a shipping box stack, the automatic shipping box is disengaged from the shipping box gripper of the shipping box picking head by means of a picking head metering configuration, so that each shipping box picking head that performs shipping box picking only grips the corresponding shipping box, thereby unloading the stack.

[0112] According to one aspect of the disclosed embodiments, the shipping box gripper is an active gripper configured to capture and hold a corresponding shipping box to the shipping box picking head, and the active gripper is metered such that when the shipping box picking head initiates the picking of more than one shipping box, the shipping box and the gripper are disengaged.

[0113] According to one aspect of the disclosed embodiments, the shipping box grippers are distributed such that, for each shipping box picking head, the shipping box grippers form a plurality of gripping contacts, the gripping contacts being configured to engage with a corresponding shipping box gripped by the shipping box picking head.

[0114] According to one aspect of the disclosed embodiments, each gripping contact of the shipping container gripper is resiliently compliant and is configured to be mounted on the inner bottom surface of the shipping container, through which the shipping container picking head reaches the shipping container.

[0115] According to one aspect of the disclosed embodiment, each gripping contact actively generates an upward gripping force on the shipping container when actuated, wherein the gripping contact is mounted against the inner bottom surface of the gripped shipping container.

[0116] According to one aspect of the disclosed embodiment, a shipping box gripper is configured such that an upward force grips a corresponding shipping box to a shipping box picking head to perform shipping box picking, thereby lifting the corresponding shipping box off the stack, wherein at least one of the plurality of gripping contacts of the shipping box picking head is inactive.

[0117] According to one aspect of the disclosed embodiments, the shipping container gripper is a vacuum gripper generated by a venturi tube, thereby providing metered suction to grip the corresponding shipping container.

[0118] According to one aspect of the disclosed embodiments, the picking head array has at least one distance sensor arranged to determine the bottom of a corresponding shipping box in a stack.

[0119] According to one aspect of the disclosed embodiments, the picking head array has at least one distance sensor arranged to determine one or more of the sides, edges, and openings of a corresponding shipping box in a stack.

[0120] According to one aspect of the disclosed embodiments, each carton picking head in the picking head array has a corresponding distance sensor among at least one distance sensor configured to determine the position of the picking head array relative to a group of stacks, each carton picking head substantially simultaneously accessing different stacks, such that the picking head array accesses the stack group, and each different carton picking head and the different carton picking heads in the picking head array pick cartons from the corresponding stacks in the group substantially simultaneously enter, capture, and pick the carton corresponding to the carton picking head.

[0121] According to one aspect of the disclosed embodiments, a method for unloading shipping containers using an automated product shipping container destabilizer is provided. The method includes: providing a frame for the automated product shipping container destabilizer, the frame having a connector configured to engage the automated product shipping container destabilizer with a robot end effector, such that the automated product shipping container destabilizer provides an end effector to the robot; providing an array of picking heads for shipping containers, the array of picking heads being movably connected to and dependent on the frame, the array of picking heads being configured to simultaneously hold an array of shipping containers to the robot, wherein different corresponding shipping containers in the shipping container array are held by corresponding shipping container picking heads, and different shipping container picking heads hold different corresponding shipping containers in the shipping container array. The system comprises a container, wherein each container picking head has a container gripper that engages with the container corresponding to the container picking head, each container picking head being movably coupled to a frame such that the container picking head moves as a unit relative to the robot in accordance with the hierarchy of the corresponding container; and container picking is performed from a stack of containers by means of each individually metered container picking head, wherein each individually metered container picking head is used to grasp the corresponding container individually from the corresponding container picking head for each container picking performed substantially simultaneously by the array of picking heads, and the stack of containers is unpacked substantially simultaneously by means of an automated product container unpacking machine.

[0122] According to one aspect of the disclosed embodiments, a drive section is also provided, which is dependent on the frame and operatively coupled to each box picking head, such that the box picking head is actuated relative to the robot in at least one direction.

[0123] According to one aspect of the disclosed embodiments, the shipping container picking head is metered such that for each shipping container picking from the shipping container stack, the shipping container picking head automatically and repeatedly picks only the corresponding shipping container from the stack, substantially throughout each unpacking and picking of the automated product shipping container unpacking machine tool from the topmost shipping container to the bottommost shipping container in the stack.

[0124] According to one aspect of the disclosed embodiments, when a shipping box picking head initiates shipping box picking of more than one shipping box from a shipping box stack, the automatic shipping box is disengaged from the shipping box gripper of the shipping box picking head by means of a picking head metering configuration, so that each shipping box picking head that performs shipping box picking only grips the corresponding shipping box, thereby unloading the stack.

[0125] According to one aspect of the disclosed embodiments, the shipping box gripper is an active gripper configured to capture and hold a corresponding shipping box to the shipping box picking head, and the active gripper is metered such that when the shipping box picking head initiates the picking of more than one shipping box, the shipping box and the gripper are disengaged.

[0126] According to one aspect of the disclosed embodiments, the shipping box grippers are distributed such that, for each shipping box picking head, the shipping box grippers form a plurality of gripping contacts, the gripping contacts being configured to engage with a corresponding shipping box gripped by the shipping box picking head.

[0127] According to one aspect of the disclosed embodiments, each gripping contact of the shipping container gripper is resiliently compliant and is configured to be mounted on the inner bottom surface of the shipping container, through which the shipping container picking head reaches the shipping container.

[0128] According to one aspect of the disclosed embodiment, each gripping contact actively generates an upward gripping force on the shipping container when actuated, wherein the gripping contact is mounted against the inner bottom surface of the gripped shipping container.

[0129] According to one aspect of the disclosed embodiment, a shipping box gripper is configured such that an upward force grips a corresponding shipping box to a shipping box picking head to perform shipping box picking, thereby lifting the corresponding shipping box off the stack, wherein at least one of the plurality of gripping contacts of the shipping box picking head is inactive.

[0130] According to one aspect of the disclosed embodiments, the shipping container gripper is a vacuum gripper generated by a venturi tube, thereby providing metered suction to grip the corresponding shipping container.

[0131] According to one aspect of the disclosed embodiments, the picking head array has at least one distance sensor arranged to determine the bottom of a corresponding shipping box in a stack.

[0132] According to one aspect of the disclosed embodiments, the picking head array has at least one distance sensor arranged to determine one or more of the sides, edges, and openings of a corresponding shipping box in a stack.

[0133] According to one aspect of the disclosed embodiments, each carton picking head in the picking head array has a corresponding distance sensor among at least one distance sensor configured to determine the position of the picking head array relative to a group of stacks, each carton picking head substantially simultaneously accessing different stacks, such that the picking head array accesses the stack group, and each different carton picking head and the different carton picking heads in the picking head array pick cartons from the corresponding stacks in the group substantially simultaneously enter, capture, and pick the carton corresponding to the carton picking head.

[0134] It should be understood that the foregoing description is merely illustrative of aspects of the disclosed embodiments. Those skilled in the art can conceive of various alternatives and modifications without departing from aspects of the disclosed embodiments. Therefore, aspects of the disclosed embodiments are intended to include all such alternatives, modifications, and variations falling within the scope of any of the appended claims. Furthermore, the fact that different features are recited in mutually different dependent or independent claims does not indicate that combinations of these features cannot be advantageously used, such combinations still remain within the scope of aspects of the disclosed embodiments.

Claims

1. An automated product loading and unloading container destacking machine, comprising: A frame having a connector configured to engage the automated product loading container de-stacking tool with a robot end effector, such that the automated product loading container de-stacking tool provides an end effector to the robot. A picking head array of shipping box picking heads, the picking head array of shipping box picking heads being movably connected to and dependent on the frame, the picking head array being configured to simultaneously hold a shipping box array to the robot, wherein different corresponding shipping boxes in the shipping box array are held by corresponding shipping box picking heads, and different shipping box picking heads holding different corresponding shipping boxes in the shipping box array, wherein each shipping box picking head has a shipping box gripper that engages the shipping box corresponding to the shipping box picking head; as well as A drive section, which is connected to the frame and operatively coupled to each shipping box picking head, such that the shipping box picking head moves as a unit relative to the frame according to the hierarchy of the corresponding shipping box. The container picking head is metered so that for each container picking from the container stack, the container picking head automatically and repeatedly picks only the corresponding container from the stack, essentially covering each unpacking and picking operation of the automated product container unpacking machine from the top to the bottom of the stack.

2. The automated product shipping container unloading and stacking machine tool according to claim 1, wherein when the shipping container picking head initiates the picking of more than one shipping container from the shipping container stack, the metering configuration of the picking head disengages from the automated shipping container of the shipping container gripper of the picking head, so that each shipping container picking head that performs the picking of the shipping container only grips the corresponding shipping container, thereby unloading the stack.

3. The automated product shipping container unloading and stacking machine tool according to claim 1, wherein the shipping container gripper is an active gripper, which is configured to capture and hold the corresponding shipping container to the shipping container picking head, and the active gripper is metered so that when the shipping container picking head initiates the picking of more than one shipping container, the shipping container and the gripper are disengaged.

4. The automated product container unloading and stacking machine tool according to claim 1, wherein the container grippers are distributed such that, for each container picking head, the container grippers form a plurality of gripping contacts, the gripping contacts being configured to engage with a corresponding container gripped by the container picking head.

5. The automated product shipping container unloading machine tool according to claim 4, wherein each gripping contact of the shipping container gripper is elastically compliant and is arranged to be mounted on the inner bottom surface of the shipping container, wherein the shipping container picking head reaches the shipping container through the opening of the shipping container.

6. The automated product loading container unloading machine tool according to claim 5, wherein each gripping contact actively generates an upward gripping force on the loading container when actuated, wherein the gripping contact is installed against the inner bottom surface of the gripped loading container.

7. The automated product shipping container unloading machine tool of claim 4, wherein the shipping container gripper is configured such that the upward force grips the corresponding shipping container to the shipping container picking head to perform the shipping container picking, thereby lifting the corresponding shipping container off the stack, wherein at least one of the plurality of gripping contacts of the shipping container picking head is inactive.

8. The automated product container unloading and stacking machine tool according to claim 1, wherein the container gripper is a vacuum gripper generated by a venturi tube, thereby providing metered suction to grip the corresponding container.

9. The automated product shipping container destacking machine tool according to claim 1, wherein the picking head array has at least one distance sensor arranged to determine the bottom of a corresponding shipping container in the stack.

10. The automated product shipping container destacking machine tool of claim 1, wherein the picking head array has at least one distance sensor arranged to determine one or more of the sides, edges, and openings of a corresponding shipping container in the stack.

11. The automated product container unloading machine tool of claim 10, wherein each container picking head in the picking head array has a corresponding distance sensor among the at least one distance sensor configured to determine the position of the picking head array relative to the group of stacks, wherein each container picking head substantially simultaneously reaches a different stack, such that the picking head array reaches the group of stacks, and each different container picking head and the different container picking heads in the picking head array enter, capture, and pick the container corresponding to the container picking head substantially simultaneously from the corresponding stack in the group.

12. An automated product loading and unloading container destacking machine, comprising: A frame having a connector configured to engage the automated product loading container destabilizer tool with a robot end effector, such that the automated product loading container destabilizer tool provides an end effector to the robot; and A picking head array of shipping box picking heads, the picking head array of shipping box picking heads being movably connected to and dependent on the frame, the picking head array being configured to simultaneously hold a shipping box array to the robot, wherein different corresponding shipping boxes in the shipping box array are held by corresponding shipping box picking heads, and different shipping box picking heads holding different corresponding shipping boxes in the shipping box array, wherein each shipping box picking head has a shipping box gripper that engages the shipping box corresponding to the shipping box picking head; Each shipping box picking head is movably connected to the frame, such that the shipping box picking head moves as a unit relative to the robot according to the hierarchy of the corresponding shipping box. The container picking heads are measured such that each individual container picking head that picks containers from stacked containers grasps the corresponding container from the corresponding container picking head alone for each container picking that is performed substantially simultaneously by the array of picking heads, and the stack of containers is unpacked substantially simultaneously by means of the automated container unpacking machine.

13. The automated product shipping container unloading machine tool of claim 12, further comprising a drive section dependent on the frame and operatively coupled to each shipping container picking head, such that the shipping container picking head is actuated relative to the robot in at least one direction.

14. The automated product loading and unloading container destacking machine tool according to claim 12, wherein, The container picking head is quantified so that for each container picking from the container stack, the container picking head automatically and repeatedly picks only the corresponding container from the stack, essentially covering each unpacking and picking operation of the automated product container unpacking machine tool from the top to the bottom of the stack.

15. The automated product shipping container unloading and stacking machine tool according to claim 12, wherein when the shipping container picking head initiates shipping container picking of more than one shipping container from the shipping container stack, the metering configuration of the picking head disengages from the automated shipping container of the shipping container gripper of the shipping container picking head, such that each shipping container picking head that performs the shipping container picking only grips the corresponding shipping container, thereby unloading the stack.

16. The automated product container unloading and stacking machine tool according to claim 12, wherein the container gripper is an active gripper configured to capture and hold the corresponding container to the container picking head, and the active gripper is metered such that when the container picking head initiates container picking of more than one container, the container and the gripper are disengaged.

17. The automated product container unloading and stacking machine tool of claim 12, wherein the container grippers are distributed such that, for each container picking head, the container grippers form a plurality of gripping contacts, the gripping contacts being configured to engage with a corresponding container gripped by the container picking head.

18. The automated product shipping container unloading machine tool of claim 17, wherein each gripping contact of the shipping container gripper is resiliently compliant and is configured to be disposed on the inner bottom surface of the shipping container, wherein the shipping container picking head reaches the shipping container through an opening in the shipping container.

19. The automated product loading container unloading machine tool according to claim 18, wherein each gripping contact actively generates an upward gripping force on the loading container when actuated, wherein the gripping contact is mounted against the inner bottom surface of the gripped loading container.

20. The automated product shipping container unloading machine tool of claim 17, wherein the shipping container gripper is configured such that the upward force grips the corresponding shipping container to the shipping container picking head to perform the shipping container picking, thereby lifting the corresponding shipping container off the stack, wherein at least one of the plurality of gripping contacts of the shipping container picking head is inactive.

21. The automated product shipping container unloading machine tool according to claim 12, wherein the shipping container gripper is a vacuum gripper generated by a venturi tube, thereby providing metered suction to grip the corresponding shipping container.

22. The automated product shipping container destacking machine tool of claim 12, wherein the picking head array has at least one distance sensor arranged to determine the bottom of a corresponding shipping container in the stack.

23. The automated product shipping container destacking machine tool of claim 12, wherein the picking head array has at least one distance sensor arranged to determine one or more of the sides, edges, and openings of a corresponding shipping container in the stack.

24. The automated product container unloading and stacking machine tool of claim 23, wherein each container picking head in the picking head array has a corresponding distance sensor among the at least one distance sensor configured to determine the position of the picking head array relative to the group of stacks, wherein each container picking head substantially simultaneously reaches a different stack, such that the picking head array reaches the group of stacks, and each different container picking head and the different container picking heads in the picking head array enter, capture, and pick the container corresponding to the container picking head substantially simultaneously from the corresponding stack in the group.

25. A method for unpacking shipping containers using an automated product shipping container destacking machine, the method comprising: A frame is provided for the automated product loading container unloader tool, the frame having a connector configured to engage the automated product loading container unloader tool with a robot end effector, such that the automated product loading container unloader tool provides an end effector for the robot; An array of picking heads is provided for picking boxes, the array being movably connected to and dependent on the frame, the array being configured to simultaneously hold an array of shipping boxes to the robot, wherein different corresponding shipping boxes in the shipping box array are held by corresponding shipping box picking heads, and mutually different shipping box picking heads hold mutually different corresponding shipping boxes in the shipping box array, wherein each shipping box picking head has a shipping box gripper that engages with the shipping box corresponding to the shipping box picking head; and A drive section is provided, which is connected to the frame and operatively coupled to each shipping box picking head, such that the shipping box picking head moves as a unit relative to the frame according to the hierarchy of the corresponding shipping box. Automatic and repetitive picking of shipping containers from a stack of shipping containers, wherein the shipping container picking head is metered such that for each picking of a shipping container from the stack, the shipping container picking head automatically and repeatedly picks only the corresponding shipping container from the stack, substantially covering each unpacking and picking of the automated product shipping container unpacking machine tool from the topmost shipping container to the bottommost shipping container in the stack.

26. The method of claim 25, further comprising, when the shipping box picking head initiates picking of more than one shipping box from the shipping box stack, disengaging the automatic shipping box from the shipping box gripper of the shipping box picking head by means of the picking head metering configuration, such that each shipping box picking head that performs the picking of the shipping box only grips the corresponding shipping box, thereby unloading the stack.

27. The method of claim 25, wherein the shipping box gripper is an active gripper configured to capture and hold a corresponding shipping box to the shipping box picking head, and the active gripper is metered such that when the shipping box picking head initiates shipping box picking of more than one shipping box, the shipping box and the gripper are disengaged.

28. The method of claim 25, wherein the shipping box grippers are distributed such that, for each shipping box picking head, the shipping box grippers form a plurality of gripping contacts, the gripping contacts being configured to engage with a corresponding shipping box gripped by the shipping box picking head.

29. The method of claim 28, wherein each gripping contact of the shipping box gripper is resiliently compliant and is configured to be mounted on the inner bottom surface of the shipping box, the shipping box picking head reaching the shipping box through an opening in the shipping box.

30. The method of claim 29, wherein each gripping contact actively generates an upward gripping force on the shipping container upon actuation, wherein the gripping contact is mounted against the inner bottom surface of the gripped shipping container.

31. The method of claim 28, wherein the shipping box gripper is configured such that the upward force grips the corresponding shipping box to the shipping box picking head to perform the shipping box picking, thereby lifting the corresponding shipping box off the stack, wherein at least one of the plurality of gripping contacts of the shipping box picking head is inactive.

32. The method of claim 25, wherein the shipping container gripper is a vacuum gripper generated by a venturi tube, thereby providing metered suction to grip the corresponding shipping container.

33. The method of claim 25, wherein the picking head array has at least one distance sensor arranged to determine the bottom of a corresponding shipping box in the stack.

34. The method of claim 25, wherein the picking head array has at least one distance sensor arranged to determine one or more of the sides, edges, and openings of a corresponding shipping box in the stack.

35. The method of claim 34, wherein each carton picking head in the picking head array has a corresponding distance sensor among the at least one distance sensor configured to determine the position of the picking head array relative to the group of stacks, each carton picking head substantially simultaneously accessing a different stack, such that the picking head array accesses the group of stacks, and each different carton picking head and the different carton picking heads in the picking head array substantially simultaneously enter, capture, and pick cartons corresponding to the carton picking head from the corresponding stack in the group.

36. A method for unpacking shipping containers using an automated product shipping container destacking machine, the method comprising: A frame is provided for the automated product loading container de-stacking machine tool, the frame having a coupling member configured to engage the automated product loading container de-stacking machine tool with a robot end effector, such that the automated product loading container de-stacking machine tool provides an end effector to the robot; and An array of picking heads is provided for picking boxes, the array of picking heads being movably connected to and dependent on the frame, the array of picking heads being configured to simultaneously hold an array of boxes to the robot, wherein different corresponding boxes in the array of boxes are held by corresponding picking heads, and different picking heads hold different corresponding boxes in the array of boxes, wherein each picking head has a picking gripper that engages the box corresponding to the picking head, and each picking head is movably connected to the frame such that the picking head moves as a unit relative to the robot according to the hierarchy of the corresponding boxes; Picking from a stack of shipping boxes is achieved by means of each individually metered shipping box picking head, wherein each individual shipping box picking head is metered so that for each shipping box picking performed substantially simultaneously by the array of picking heads, only the corresponding shipping box is picked up from the corresponding shipping box picking head alone, and the stack of shipping boxes is unpacked substantially simultaneously by means of the automated product shipping box unpacking machine.

37. The method of claim 36, further comprising providing a drive section dependent on the frame and operatively coupled to each box picking head such that the box picking head is actuated relative to the robot in at least one direction.

38. The method of claim 36, wherein the container picking head is metered such that for each container picking from the container stack, the container picking head automatically and repeatedly picks only the corresponding container from the stack, substantially throughout each unpacking and picking operation of the automated product container unpacking machine tool from the topmost container to the bottommost container in the stack.

39. The method of claim 36, further comprising, when the shipping box picking head initiates picking of more than one shipping box from the shipping box stack, disengaging the automatic shipping box from the shipping box gripper of the shipping box picking head by means of the picking head metering configuration, such that each shipping box picking head that performs the picking of the shipping box only grips the corresponding shipping box, thereby unloading the stack.

40. The method of claim 36, wherein the shipping box gripper is an active gripper configured to capture and hold a corresponding shipping box to the shipping box picking head, and the active gripper is metered such that when the shipping box picking head initiates shipping box picking of more than one shipping box, the shipping box and the gripper are disengaged.

41. The method of claim 36, wherein the shipping box grippers are distributed such that, for each shipping box picking head, the shipping box grippers form a plurality of gripping contacts, the gripping contacts being configured to engage with a corresponding shipping box gripped by the shipping box picking head.

42. The method of claim 41, wherein each gripping contact of the shipping box gripper is resiliently compliant and is configured to be mounted on the inner bottom surface of the shipping box, the shipping box picking head reaching the shipping box through an opening in the shipping box.

43. The method of claim 42, wherein each gripping contact actively generates an upward gripping force on the shipping container upon actuation, wherein the gripping contact is mounted against the inner bottom surface of the gripped shipping container.

44. The method of claim 41, wherein the shipping box gripper is configured such that the upward force grips the corresponding shipping box to the shipping box picking head to perform the shipping box picking, thereby lifting the corresponding shipping box off the stack, wherein at least one of the plurality of gripping contacts of the shipping box picking head is inactive.

45. The method of claim 36, wherein the shipping container gripper is a vacuum gripper generated by a venturi tube, thereby providing metered suction to grip the corresponding shipping container.

46. ​​The method of claim 36, wherein the picking head array has at least one distance sensor arranged to determine the bottom of a corresponding shipping box in the stack.

47. The method of claim 36, wherein the picking head array has at least one distance sensor arranged to determine one or more of the sides, edges, and openings of a corresponding shipping box in the stack.

48. The method of claim 47, wherein each carton picking head in the picking head array has a corresponding distance sensor among the at least one distance sensor configured to determine the position of the picking head array relative to the group of stacks, each carton picking head substantially simultaneously accessing a different stack, such that the picking head array accesses the group of stacks, and each different carton picking head and the different carton picking heads in the picking head array substantially simultaneously enter, capture, and pick cartons corresponding to the carton picking head from the corresponding stack in the group.

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