Storage rack

Abstract

The present disclosure relates to a storage rack for an automated storage and retrieval system, the storage rack comprising: a frame; and a first container receiving element and a second container receiving element, wherein each of the container receiving elements is supported by the frame, wherein the second container receiving element is arranged above the first container receiving element in the frame, and wherein each of the container receiving elements is movable between a first configuration relative to the frame in which the container receiving element is configured to receive a storage container from a container handling vehicle, and a second configuration relative to the frame in which the container receiving element is oriented such that the storage container is supported in a presentation position in which an item stored in the storage container is accessible by a user.

Description

Technical Field

[0001] This disclosure relates to a storage rack. More specifically, the present invention relates to a storage rack for an automated storage and retrieval system. This disclosure also relates to an automated storage and retrieval system including a storage rack, and to a method of controlling one or more container handling vehicles in an automated storage and retrieval system including a storage rack. Background Technology

[0002] Traditional storage solutions typically involve arranging goods on rows of shelves within a warehouse. The shelf location of each item is recorded in inventory, and goods are retrieved from the shelves by a goods picker. Shelves are replenished and inventory is updated as needed when goods enter and leave the warehouse.

[0003] Robotic pickers and automated inventory management systems can assist warehouse workers. Automated transport systems can also be implemented in traditional warehouse setups to move goods from their storage locations to picking and / or packing stations.

[0004] An alternative to traditional warehouse setups is an automated storage and retrieval system (AS / RS), in which robots retrieve items from their recorded locations within the warehouse and transport them to packing stations or ports. Such systems can reduce or eliminate the space required to navigate between rows of shelves to access inventory, thus eliminating the need for wide aisles within the warehouse. One example of such a system involves arranging goods in boxes or containers configured to be stacked side-by-side within a three-dimensional grid. A track system is arranged on top of the grid, along which robotic container handling vehicles configured to lift containers from the grid can travel. The container handling vehicles are configured to transport containers from the grid to ports or stations at the periphery of the grid, allowing the goods within the containers to be picked up and packed.

[0005] Items frequently picked up during order processing are commonly referred to as "high runners." It should be understood that repeatedly transporting containers storing frequently picked-up items between the grid and the pick-up port reduces the efficiency of automated storage and retrieval systems. Specifically, a significant amount of robot movement is required to repeatedly transport these containers between the grid and the port.

[0006] One solution to minimize the time spent waiting for high-turnover items to be delivered to the port (and to minimize robot movement within the automated storage and retrieval system) is to store high-turnover items outside the automated storage and retrieval system. For example, high-turnover items could be stored in pallet storage units on the warehouse floor, in a digital pickup system (DPS), or in "light-to-pick" shelves. However, storing high-turnover items in an additional storage system outside the automated storage and retrieval system requires a separate system to manage the inventory of the additional storage system and to replenish high-turnover items once they are depleted. For example, a small load system could be implemented to replenish high-turnover items in the DPS shelves.

[0007] The claims set forth one or more aspects of the invention of this application. Attached Figure Description

[0008] This disclosure will now be described in more detail with reference to several exemplary embodiments shown in the accompanying drawings, in which: Figure 1 A perspective view of a storage system is shown, which includes a grid and multiple robotic container handling vehicles configured to retrieve and / or rearrange goods stored within the grid. Figure 2 It shows Figure 1 A top view of the system; Figure 3A It shows that it is suitable for use in Figure 1 Side view of the first robotic container handling vehicle used in the system; Figure 3B It shows that it is suitable for use in Figure 1 Side view of the second robotic container handling vehicle used in the system; Figure 3C yes Figure 3B A three-dimensional side view of the robot; Figure 4 A computing device for implementing the operations described herein is shown; Figure 5 A perspective view of the storage rack is shown; Figure 6 It shows the neighbor Figure 1 The port location of the storage system shown Figure 5 A 3D view of the storage rack; Figure 7 It shows the neighbor Figure 1 The port location of the storage system shown Figure 5 A three-dimensional view of multiple units of the storage rack; Figure 8 The storage area located on the shelf is shown. Figure 5 A three-dimensional view of multiple units of the storage rack; Figure 9 A flowchart is shown showing the method executed by the processing system of the storage system described herein; Figure 10 A flowchart is shown of another method performed by the processing system of the storage system described herein. Detailed Implementation

[0009] Generally, this disclosure relates to a storage rack for an automated storage and retrieval system. The storage rack includes a frame and a plurality of container receiving elements, such as shelves. The shelves are supported by the frame such that one shelf is positioned above another. Each shelf is movable between a first configuration relative to the frame and a second configuration relative to the frame. In its first configuration, the shelf receives containers from a robot. In its second configuration, the shelf is oriented such that the container is supported in a presentation position, allowing items within the container to be retrieved.

[0010] Storage racks can be used to store containers that hold frequently picked items (“high-turnover items”). When an order includes one or more high-turnover items, these items can be picked from the storage racks instead of waiting for containers containing them to be delivered to the port. When one or more storage racks are positioned adjacent to the port, waiting time at the port is reduced because high-turnover items can be picked from the storage racks while waiting for containers containing other items to be delivered to the port. Therefore, orders including high-turnover items can be processed more quickly at the port of the automated storage and retrieval system.

[0011] Furthermore, for orders that include one or more high-turnover items, fewer containers need to be transported to the port, thus reducing the number of robot movements in the automated storage and retrieval system. This reduces robot traffic within the system, thereby reducing delays caused by robot traffic, and also reduces the number of robots required in the system, thus improving operational efficiency.

[0012] Moving the shelf from its second configuration to its first configuration allows containers to be supported outside the frame of the storage rack, making them collectable by one of the robots. For example, empty boxes or boxes containing infrequently picked items can be returned to the grid. Similarly, moving the shelf from its first configuration to its second configuration allows containers to be conveyed to the shelf and then moved to their display position. This means the robot can replenish high-turnover items. Furthermore, containers storing lower-frequency picked items can be replaced with containers storing higher-frequency picked items.

[0013] Allowing containers to move between storage racks and grids also allows the inventory on the storage racks to be monitored by an automated storage and retrieval system. Therefore, a single system can be used to monitor the inventory on both the grids and storage racks, eliminating the need for separate systems for inventory management and replenishing high-turnover items. Furthermore, with one or more storage racks positioned adjacent to ports, the integrated formation between the storage racks and the automated storage and retrieval system allows the system to assign orders comprising one or more high-turnover items to ports adjacent to the one or more storage racks containing the highest proportion of those high-turnover items. This minimizes the amount of robot movement within the automated storage and retrieval system.

[0014] Overview of Automated Storage and Retrieval Systems

[0015] refer to Figure 1 In the embodiment shown, the grid 100 comprises a frame formed by a plurality of substantially linear adjacent vertical columns 102, which are formed between vertical frame members 104 and extend in the X and Y directions 108, 110. The grid elements can be made of any suitable material; for example, the frame members can be formed from extruded aluminum. Storage containers or boxes 112 are stacked one on top of another in the storage columns 102 in the Z direction 114, preferably stacked in a self-supporting manner, thereby forming storage volumes for storage units of the respective boxes 112 extending in the X, Y, and Z directions 108, 110, 114.

[0016] A track system or network 116 is formed on top of grid 100 and includes pairs of vehicle tracks or rails 118a, 118b and 120a, 120b extending in the X and Y directions 108, 110, respectively. A robotic container handling vehicle or robot (or robot) 122 is provided, which may have various sizes, shapes, and functions, and is configured to run on tracks 118, 120 and transport boxes 112 in both the X and Y directions 108, 110. Robot 122 is also configured to lift / lower boxes 112 from column 102 in the Z direction 114, with boxes 112 optionally guided by vertical frame members 104. Robot 122 approaches boxes 112 via access openings 124 formed above column 102 and between tracks 118, 120.

[0017] Some columns 102 can be used for alternative purposes beyond bin storage. For example, port columns 126, 128 include ports or access columns that allow bins 112 to be moved into and / or out of grid 100. Port columns 126, 128 provide vertical channels for raising bins 112 from or lowering bins 112 into one or more ports 130, 132. Ports 130, 132... Figure 1The diagram shows the lowest level of the grid; however, the ports can be located at any vertical position along the columns. The corresponding port columns 126, 128 can be assigned for removing (“unloading”) box 112 from grid 100 and / or returning or conveying (“picking up”) the box to the grid. Therefore, ports 130, 132 are configured to allow box 112 to be removed and (horizontally) reintroduced into the associated port column. Thus, ports 130, 132 can include conveyors ( Figure 1 (Not shown in the image) Box 112 can be lowered onto a conveyor and transported horizontally out of the port column. Port columns 126, 128 include openings or access points through which box 112 can enter and exit the column.

[0018] Box 112 can be transported by robot 122 along the top of grid 100 to and / or from port columns 126, 128, and from ports 130, 132 to a location outside grid 100, which may be an access station (not shown) for handling box 112 or its contents, such as a pick-up station for adding or removing contents from box 112. In alternative instances (not shown), box 112 can be transported to a port of another grid at the same or another level, or to an external facility. Transport of box 112 to and from ports 130, 132 can be carried out by any suitable means (not shown), including conveyors, transport vehicles, elevators, or robots.

[0019] refer to Figure 2 The illustrated embodiment provides a more detailed view of the XY configuration 200 of the track system 116 and the various types of robots 202, 204. The track system includes tracks 206 that define vertical column access openings 124 for accessing the bin 112. Tracks 206 can be of any suitable type for allowing robots 202, 204 to travel in the X and Y directions 108, 110, including (not shown) recessed tracks for receiving vehicle wheels, or raised tracks for engaging wheel recesses. Each track 206 may include a single track or multiple parallel tracks in each of the X and Y directions 108, 110.

[0020] The first "cantilever" type robot 202 Figure 3AThe diagram is shown in more detail and includes a body 300, a set of wheels 302, and a lifting device 304. The body 300 contains operating equipment (not shown) for the robot 202, which includes a drive system, a power system, and a control system. The wheels 302 allow the robot 202 to move in one of the X and Y directions, and an additional set of wheels (not visible in this view) allows movement in the other direction, both along corresponding tracks or rails 206. One or both sets of wheels can be raised or lowered to allow selective engagement of tracks for movement in the desired direction. The lifting device 304 includes a cantilever element 306 extending in the XY plane from the top of the body 300, and a gripping device 308 capable of being raised and lowered from the cantilever element 306. The gripping device 308 is configured to grip or engage a box 112; for example, by gripping a portion of the box 112, or by passively or actively engaging a suitable configuration portion of the box 112.

[0021] The second "internal cavity" type robot 204 is in Figure 3B As shown in more detail below, and as an alternative to a cantilever-type lifting system, it includes an inner cavity 310 within the main body 300, and a lifting device 312 including a clamping device (not shown) is located within this inner cavity. In this case, the main body 300 includes the robot's operating equipment and storage space for one or more boxes 112 for use, for example, when transporting the boxes 112.

[0022] Figure 3C It shows Figure 3B A stereoscopic side view of the robot, in which one can see Figure 3B The first set of wheels, 302. Mentioned above but not mentioned in... Figure 3B The additional set of wheels shown in Figure 3C The wheel 303 is shown in the middle. The additional set of wheels 303 is arranged perpendicular to the first set of wheels 302 to allow the robot 204 to move in the X and Y directions via the first set of wheels and the second set of wheels 302 and 303, respectively. Figure 3C The first set of wheels and the second set of wheels 302, 303 shown can be configured to independently lower to engage with the track (and conversely raise to disengage from the track), thereby allowing the robot 202 to traverse... Figure 2 The track arrangement shown moves in both the X and Y directions. Although Figure 3C The 3D diagram shown has Figure 3B Robot 204, but it should be understood that a similar vertical wheel arrangement can be applied to Figure 3A Robot 202.

[0023] Control and monitoring system

[0024] The control and monitoring of the automated storage and retrieval system (including monitoring and storing box positions, controlling box delivery, retrieval and transport, and robot path planning and collision avoidance) is handled by, for example, Figure 4 The control system shown communicates with the robot and / or other controllable system components. Control can be performed locally or remotely and can be implemented by a processing system, such as a computing device. Therefore, the methods described herein can form all or part of a computer-implemented method, or a system configured to perform the methods described herein.

[0025] refer to Figure 4 A processing system 400 suitable for performing the methods described herein will now be described. Figure 4 A block diagram of one implementation of a processing system 400 is shown, which takes the form of a computing device within which a set of instructions can be executed to cause the computing device to perform any or more of the methods described herein. In some implementations, the computing device may be connected (e.g., networked) to other machines in a local area network, intranet, extranet, or the Internet. The computing device may operate at the capacity of a server or client machine in a client-server network environment, or at the capacity of a peer-to-peer machine in a peer-to-peer (or distributed) network environment. The computing device may be a personal computer (PC), tablet computer, set-top box (STB), personal digital assistant (PDA), cellular phone, networked home appliance, server, network router, switch, or bridge, or any machine capable of executing a set of instructions (sequentially or otherwise) specifying the actions to be taken by the machine. Furthermore, although only a single computing device is illustrated, the term "computing device" should also be understood to include any set of machines (e.g., computers) that individually or collectively execute one or more sets of instructions to perform any or more of the methods described herein.

[0026] The instance processing system 400 includes a processor 402, a main memory 404 (e.g., read-only memory (ROM), flash memory, dynamic random access memory (DRAM) such as synchronous DRAM (SDRAM) or Rambus DRAM (RDRAM), etc.), a static memory 406 (e.g., flash memory, static random access memory (SRAM), etc.), and a secondary memory (e.g., a data storage device 418), which communicate with each other via a bus 430.

[0027] Processor 402 represents one or more general-purpose processors, such as microprocessors, central processing units, etc. More specifically, processor 402 may be a Complex Instruction Set Computing (CISC) microprocessor, a Reduced Instruction Set Computing (RISC) microprocessor, a Very Long Instruction Word (VLIW) microprocessor, a processor implementing other instruction sets, or a processor implementing combinations of instruction sets. Processor 402 may also be one or more special-purpose processors, such as application-specific integrated circuits (ASICs), field-programmable gate arrays (FPGAs), digital signal processors (DSPs), network processors, etc. Processor 402 is configured to execute processing logic (instruction 422) to perform the operations and steps described herein.

[0028] The processing system 400 may also include a network interface device 408. The processing system 400 may also include any of the following devices: a video display unit 410 (e.g., a liquid crystal display (LCD) or a cathode ray tube (CRT)), an alphanumeric input device 412 (e.g., a keyboard or a touch screen), a cursor control device 414 (e.g., a mouse or a touch screen), and an audio device 416 (e.g., a speaker).

[0029] Obviously, Figure 4 Some features of the processing system 400 shown may be absent. For example, the processing system 400 may not require a display device 410 (or any associated adapter). This may be the case, for example, for a particular server-side computer device used only for its processing capabilities and not required to display information to a user. Similarly, a user input device 412 may not be necessary. In its simplest form, the processing system 400 includes a processor 402 and main memory 404.

[0030] Data storage device 418 may include one or more machine-readable storage media (or more specifically one or more non-transitory computer-readable storage media) 428 storing one or more instruction sets 422 embodying any or more of the methods or functions described herein. The instructions 422 may also reside wholly or at least partially in main memory 404 and / or processor 402 during execution by processing system 400, which also constitute computer-readable storage media 428.

[0031] The various methods described herein can be implemented by a computer program. A computer program may include computer code arranged to instruct a computer to perform one or more of the various methods described herein. The computer program and / or code for performing such methods may be provided to a device, such as a computer, on one or more computer-readable media or more generally on a computer program product. The computer-readable media may be transient or non-transient. One or more computer-readable media may be, for example, an electronic system, a magnetic system, an optical system, an electromagnetic system, an infrared system, or a semiconductor system, or a propagation medium for data transmission, such as for downloading code via the Internet. Alternatively, one or more computer-readable media may take the form of one or more physical computer-readable media, such as semiconductor or solid-state memory, magnetic tape, removable computer disk, random access memory (RAM), read-only memory (ROM), rigid disk, or optical disk, such as CD-ROM, CD-R / W, or DVD.

[0032] A computer program can be executed by processor 402 to perform the functions of the system and methods described herein.

[0033] In implementation, the modules, components and other features described herein may be implemented as discrete components or integrally formed within the functionality of hardware components such as ASICs, FPGAs, DSPs or similar devices.

[0034] A "hardware component" is a tangible (e.g., non-transitory) physical component (e.g., a group or more processors) capable of performing certain operations and which can be configured or arranged in a particular physical manner. A hardware component may include a dedicated circuit system or logic permanently configured to perform certain operations. A hardware component may be or include dedicated processors, such as field-programmable gate arrays (FPGAs) or ASICs. A hardware component may also include programmable logic or circuit systems temporarily configured by software to perform specific operations.

[0035] Therefore, the phrase “hardware component” should be understood to encompass tangible entities that can be physically configured, permanently configured (e.g., hardwired), or temporarily configured (e.g., programmed) to operate in a particular manner or perform the specific operations described herein.

[0036] Furthermore, modules and components can be implemented as firmware or functional circuitry systems within a hardware device. Additionally, modules and components can be implemented as any combination of hardware devices and software components, or solely as software (e.g., code stored in or transmitted on a machine-readable medium or otherwise embodied in such media).

[0037] Operation of the automatic storage and retrieval system

[0038] In operation, each box 112 is assigned a unique identifier, which can be marked on the box 112 using a computer-readable identifier (e.g., a barcode, quick-response code, or RFID tag) for easy identification. The database of the processing system 400 stores the location of each box 112 associated with the unique identifier and optionally stores the contents of that box. When a box 112 is moved (e.g., when it is removed from grid 100), the database is updated to record the change in its location.

[0039] When it is desired to retrieve box 112 from grid 100, under the control of processing system 400, robots 202 and 204 are guided via track system 116 to vertical column 102, which includes storage units. Box 112 is positioned in the storage unit according to a database, and lifting devices 304 and 312 (depending on robot type) are positioned above the corresponding access opening 124, which is adjacent to or below robots 202 and 204. Robots 202 and 204 lower gripping device 308, which engages, grips, and lifts box 112. Robots 202 and 204 then transport box 112 to, for example, unloading port columns 126 and 128 for delivery to ports 130 and 132 for further processing outside grid 100. If the target or designated box 112 is located below other boxes in the stack, then robots 202, 204, or multiple robots possibly dedicated to this task, are controlled in a "digging" operation to temporarily or permanently lift and reposition the boxes above the target box 112 in sequence to retrieve the target box. It should be understood that other operations related to box 112 can be performed in a similar manner. For example, box 112 can be conveyed at ports 130, 132 of pick-up port columns 126, 128 for storage in grid 100, gripped and lifted by robots 202, 204, and conveyed to the desired storage unit, whereby, if necessary, the boxes above the desired location are repositioned as discussed above.

[0040] Storage rack

[0041] Figure 5 This is a schematic diagram of storage rack 502, which can be used with an automated storage and retrieval system by being integrally formed with grid 100. Specifically, storage rack 502 can be used to store bins 112 containing frequently picked items (also referred to as "high-turnover items"). Implementing storage rack 502 to store bins 112 containing high-turnover items means that processing an order that includes one or more high-turnover items stored in bins 112 within storage rack 502 also requires fewer bins 112 to be retrieved from the grid by robots 202, 204. This means that the items needed to process the order can be provided more quickly at ports 130, 132.

[0042] like Figure 5 As shown, the storage rack 502 includes a frame 504 having a horizontal frame member 506 and a vertical frame member 508. The horizontal frame member 506 provides support for multiple container receiving elements. Figure 5 The shelf 510 is shown in the middle. The vertical frame member 508 allows multiple shelves 510 to be supported in a single vertical column. Figure 5 In the example shown, three shelves 510 are supported in a single vertical column. It should be understood that alternative container receiving elements (e.g., guide rods) can be used instead of shelves 510.

[0043] Each shelf 510 is movable between the two configurations. Figure 5 The first shelf 510a is shown in a first configuration relative to the frame 504. The second shelf 510b and the third shelf 510c are each in a second configuration relative to the frame 504, but are obscured by the box 112 they support. Specifically, the second shelf 510b and the third shelf 510c are both parallel to the base of the box 112 they support.

[0044] When shelf 510 is in its first configuration, the shelf extends at least partially outside frame 504, thereby allowing the shelf to receive box 112. For example, as described above, when shelf 510 is in its first configuration, box 112 can be lowered onto shelf 510 by robots 202, 204.

[0045] When shelf 510 is in its second configuration, shelf 510 supports case 112 in a display position, in which the picker can access the items inside case 112. For example, shelf 510 can be rotated to support the base of case 112 in a position angled relative to the horizontal direction, such as... Figure 5 As shown, this allows the pickup to more easily access the items stored inside the box 112. To allow the box to be lowered to the lower shelf 510 (e.g., Figure 5 On the first shelf 510a), the shelf 510 can support the box 112 in the second configuration such that the shelf 510 and the box 112 they support do not obstruct the box 112 from descending onto the lower shelf 510 in its first configuration. As an alternative to supporting the box 112 in the display position, each shelf 510 in its second configuration can be oriented such that the box 112 is partially supported in the display position by the frame 504 (e.g., by the horizontal frame member 506) and partially by the shelf 510, or is entirely supported in the display position by the frame 504.

[0046] The movement of shelf 510 from its second configuration to its first configuration also allows box 112 to return to grid 100 (e.g., if box 112 is empty, contains damaged items, or contains items that are not retrieved as frequently as other items in box 112 stored in the grid). The movement of shelf 510 from its first configuration to its second configuration allows box 112 containing frequently retrieved items to be accommodated in storage rack 502, avoiding the need to repeatedly remove box 112 from the grid.

[0047] To allow shelf 510 to move between its first configuration and its second configuration, storage rack 502 may include one or more actuators (not shown). For example, one or more actuators may be coupled to frame 504. One or more actuators may be... Figure 4 The processing system 400 shown is controlled. For example, the processing system 400 may command one or more actuators to move shelf 510 from its second configuration to its first configuration before lowering box 112 onto shelf 510. Once box 112 has been lowered onto shelf 510, the processing system 400 may then command one or more actuators to move shelf 510 from its first configuration to its second configuration.

[0048] As an alternative to being controlled by the processing system 400, the one or more actuators can be controlled by a separate control system. For example, a pickup (or other operator) can press a button or other input device to control the one or more actuators to move the shelf 510 from its first configuration to its second configuration and / or from its second configuration to its first configuration.

[0049] Using an actuator to move shelf 510 from its second configuration to its first configuration allows box 112 to also return to the grid without manual handling of box 112. With the actuator controlled by the processing system 400, box 112 can also return to the grid without the action of a picker or other operator. Similarly, using an actuator to move shelf 510 from its first configuration to its second configuration allows for the replenishment of frequently picked items to storage rack 502 without the need for manual handling of box 112.

[0050] As an alternative to using an actuator, shelf 510 can be manually moved between its first and second configurations. For example, shelf 510 can allow a picker (or other operator) to slide shelf 510 out of its first configuration (e.g., using one or more handles (not shown)) and then rotate shelf 510 to its second configuration. As another alternative, both actuator-initiated movement and manually initiated movement of shelf 510 can be provided. For example, the one or more actuators can be configured to move shelf 510 from its second configuration to its first configuration, such that box 112 can also return to the grid 100. Once box 112 containing items is lowered onto shelf 510, the picker can manually pull shelf 510 out of its first configuration and then rotate shelf 510 to its second configuration. Other combinations of manually driven and actuator-driven movements between configurations are also possible. For example, shelf 510 can be manually returned to its first configuration for conveying box 112 to the grid, but shelf automatically returns (i.e., using one or more actuators) to its second configuration.

[0051] Storage rack 502 may also include one or more sensors configured to detect when shelf 510 is in its first configuration and / or its second configuration. The sensors may be implemented in particular if the movement of shelf 510 from its second configuration to its first configuration (and / or from its first configuration to its second configuration) is manually initiated or initiated by an actuator under the control of a control system separate from processing system 400. When one or more sensors detect that shelf 510 is in its first configuration, the sensors may indicate to processing system 400 that shelf 510 is in its first configuration and that the box 112 supported by shelf 510 should be collected by robots 202, 204. When one or more sensors detect that shelf 510 is in its second configuration, these sensors may indicate to processing system 400 that, if necessary, the box 112 may then be conveyed to other shelves 510 of storage rack 502.

[0052] Integration with the automated storage and retrieval system

[0053] like Figure 6As shown, storage rack 502 can be arranged adjacent to ports 130, 132. In this case, grid 100 also includes rack interface column 602, which has the same function as the aforementioned port columns 126, 128. That is, rack interface column 602 is an access column that allows the transfer of box 112 between the grid and storage rack 502. Rack interface column 602 provides vertical channels for lifting box 112 from shelf 510 of storage rack 502 when shelf 510 is in its first configuration, or for lowering box 112 onto shelf 510 of storage rack 502 when shelf 510 is in its first configuration. Rack interface column 602 includes one or more openings or access points aligned with shelf 510 of storage rack 502 to allow box 112 to enter or leave rack interface column 602. When the shelf 510 is in its first configuration, each shelf 510 of the storage shelf 502 extends into the rack interface column 602, and when the shelf 510 is in its second configuration, it does not extend into the rack interface column 602. Therefore, when the shelf 510 is in its second configuration, the shelf 510 (and the box 112 it supports) does not interfere with the box 112 being raised or lowered in the rack interface column 602. The rack interface column 602 thus allows the storage rack 502 to be integrally formed with the aforementioned automated storage and retrieval system.

[0054] like Figure 7 As shown, multiple ports 130, 132 may have one or more adjacent storage racks 502. Figure 7 A first port position 702 is shown, at which a first storage rack 502a and a second storage rack 502b are arranged on either side of first ports 130a and 132a, and a plurality of third storage racks 502c are arranged opposite to the first ports 130a and 132a. A second port position 704 is also shown, at which fourth and fifth storage racks 502d and 502c are arranged on either side of second ports 130b and 132b, and a plurality of sixth storage racks 502f are arranged opposite to the second ports 130b and 132b. Each of the storage racks 502 is integrally formed with the grid using a corresponding rack interface column 602. This means that the track system 116 extends at the first port positions 702 and 704, allowing robots 202 and 204 to transport boxes 112 / to the third and sixth storage racks from the third storage racks 502c and 502f.

[0055] As explained above, the database of processing system 400 stores the location and (optionally) contents of each box 112 in association with a unique identifier. Assuming that boxes 112 can also move between grid 100 and storage racks 502 via rack interface column 602, the location and contents of boxes 112 stored in storage racks 502 can be monitored by processing system 400. This means that, for a given order, processing system 400 can determine how many items in that order are stored in storage racks 502, and how many more items need to be retrieved from the grid. Multiple ports 130, 132 have one or more adjacent storage racks 502 (e.g., as shown in the image). Figure 7 In the case shown, the processing system 400 can identify ports 130 and 132 for a given order that have the highest proportion of items in the order stored in adjacent storage shelves 502. The processing system 400 can therefore assign the order to ports 130 and 132 that have the highest proportion of items in the order stored in their adjacent storage shelves 502, in order to also minimize the number of boxes 112 that need to be retrieved from the grid. For example, if the three items of the order are stored in… Figure 7 The storage racks 502a, 502b, and 502c at the first port position 702 are shown, but only the two items of the order are stored in the storage racks 502d, 502e, and 502f at the second port position 704. In this case, the order can be assigned to the first port position 702 in order to minimize the number of boxes 112 that need to be taken out of the grid so that the order can also be fulfilled.

[0056] As an alternative to the storage rack 502 located near ports 130 and 132, such as Figure 8 As shown, the storage rack 502, which forms a grid as a whole, can be located in a separate rack storage area 802. A track system 116 extends over the rack storage area 802, allowing robots 202, 204 to use the rack storage column 602 (i.e., in the same manner as described above for the storage rack 502 at adjacent ports 130, 132) to transport boxes 112 from the storage rack 502 in the rack storage area 802 to the rack. A conveyor system 804 can also be used to transport containers holding picked-up items (e.g., boxes or large crates) from ports 130, 132 to the rack storage area 802. With this arrangement, orders can be partially fulfilled at ports 130, 132. The container associated with the order (i.e., containing the items in the order) can then be transported to the rack storage area 802 (e.g., via the conveyor system 804), where one or more high-turnover items can be picked up from the storage rack 502 and added to the order.

[0057] Implementing one or more storage racks 502 adjacent to ports 130, 132 means that fulfilling an order for one of the frequently picked items, including those from boxes 112 stored in the storage racks 502, requires fewer boxes 112 to be removed from the grid and transported to ports 130, 132 by robots 202, 204. This means that the item needed to fulfill the order at ports 130, 132 becomes available more quickly, thereby increasing the rate of item retrieval, which is particularly beneficial for orders with shorter delivery times. This also occurs when one or more storage racks 502 are implemented in a separate rack storage area 802, as fewer boxes 112 need to be removed from the grid and transported to ports 130, 132 to partially fulfill the order. Furthermore, in both implementations, the number of box retrieval operations performed by robots 202, 204 is reduced, thereby also reducing robot traffic in the grid.

[0058] The integrated grid structure of the storage rack 502 for storing high-turnover items means that the contents of the boxes 112 within the rack 502 can be tracked, thus simplifying inventory management compared to systems where high-turnover items are stored in separate, non-integrated storage areas. Furthermore, items stored in the rack 502 can be replenished by robots 202, 204 using boxes 112 from the grid, instead of using a separate high-turnover item replenishment system. The processing system 400 can also identify which boxes 112 store frequently picked items (high-turnover items) and can move those boxes 112 to the rack 502 to reduce order processing time.

[0059] Furthermore, in the case where one or more storage racks 502 are implemented adjacent to ports 130, 132 (e.g., as... Figure 6 and Figure 7 As shown, the processing system 400 can determine ports 130 and 132 where orders should be processed to minimize the number of box retrieval operations performed by robots 202 and 204. This determination is based on consideration of the contents of boxes 112 stored in storage racks 502 adjacent to ports 130 and 132. Furthermore, when one or more storage racks 502 are implemented adjacent to ports 130 and 132, picking high-turnover items from boxes 112 in the storage racks 502 can be performed while the picker waits for boxes 112 storing other items in the orders to be transported to ports 130 and 132, thereby improving throughput at ports 130 and 132.

[0060] Figure 9 This is a flowchart of method 900, which can be executed by processing system 400 to transport box 112 to shelf 510 of storage rack 502.

[0061] Optionally, in step S902, the processing system 400 commands one or more actuators to move the shelf 510 from its second configuration to its first configuration. Alternatively, as described above, the shelf 510 can be moved manually, and the processing system 400 can detect (e.g., based on one or more sensors) that the shelf 510 has been moved to its first configuration.

[0062] With the shelf 510 supporting the box 112, the processing system 400 commands the robots 202 and 204 to remove the box 112 supported by the shelf 510 at step 904.

[0063] In step S906, the processing system 400 commands robots 202 and 204 to transport box 112 to shelf 510. Commanding robots 202 and 204 to transport box 112 to shelf may include determining that box 112 should be stored in storage shelf 502 based on the picking frequency of items stored in box 112 (e.g., based on the picking frequency relative to other boxes 112 stored in grid 100 and / or storage shelf 502, and / or based on an absolute picking frequency threshold).

[0064] Optionally, in step S908, the processing system 400 commands one or more actuators to move shelf 510 from its first configuration to its second configuration, thereby orienting the box 112 to its display position. Alternatively, as described above, shelf 510 can be moved manually, and the processing system 400 can detect (e.g., based on one or more sensors) that shelf 510 has moved to its second configuration.

[0065] Figure 10 This is a flowchart of method 1000, in which, when one or more storage racks 502 are located adjacent to ports 130, 132, the processing system 400 can perform the task of assigning orders to ports 130, 132.

[0066] In step S1002, the processing system 400 receives the order.

[0067] In step S1004, the processing system 400 determines for each port 130, 132 how many items in the order are stored in the storage rack 502 adjacent to that port 130, 132.

[0068] In step S1006, the processing system 400 selects ports 130 and 132, that is, ports 130 and 132 adjacent to the storage rack 502 that stores the highest proportion of items in the order.

[0069] In step S1008, the processing system 400 assigns the order to the selected ports 130, 132 for processing. Assigning the order to the selected ports 130, 132 for processing may include instructing robots 202, 204 to transport a box 112 containing items not stored in a storage rack 502 adjacent to the selected ports 130, 132 to the selected ports 130, 132.

[0070] Final Comments

[0071] An automated storage and retrieval system is disclosed, comprising: a plurality of storage locations, each configured to store a corresponding storage container among a plurality of storage containers, each storage container being configured to store one or more items; one or more robotic container handling vehicles configured to retrieve storage containers from the plurality of storage locations; a storage rack, comprising: a frame; and a first container receiving element and a second container receiving element, wherein each of the container receiving elements is supported by the frame, wherein the second container receiving element is disposed above the first container receiving element within the frame, and wherein each of the container receiving elements is movable between: a first configuration relative to the frame, wherein the container receiving element is configured to receive a storage container from a robotic container handling vehicle among the one or more robotic container handling vehicles; and a second configuration relative to the frame, wherein the container receiving element is oriented such that the storage container is supported in a display position, in which items stored in the storage container are accessible to a user; and a controller configured to command the robotic container handling vehicles among the one or more robotic container handling vehicles to transport the storage containers among the plurality of storage containers to the container receiving elements of the storage rack.

[0072] One or more robotic container handling vehicles can be configured to lower a storage container onto a container receiving element when the container receiving element of the storage rack is in its first configuration.

[0073] The controller can be further configured to actuate the container receiving element of the storage rack from its second configuration to its first configuration. The controller can also be further configured to actuate the container receiving element of the storage rack from its first configuration to its second configuration.

[0074] One or more robotic container handling vehicles may be configured to transport storage containers from multiple storage locations to a pick-up station adjacent to a storage rack. Alternatively, one or more robotic container handling vehicles may be configured to transport storage containers from multiple storage locations to a pick-up station, wherein the system also includes a conveyor for transporting items picked up from storage containers transported to the pick-up station to a rack storage area including storage racks.

[0075] The automated storage and retrieval system may include a storage grid comprising multiple storage locations. One or more robotic container handling vehicles may be arranged to traverse the storage grid.

[0076] A method for operating an automated storage and retrieval system is also disclosed, the method comprising: commanding one or more robotic container handling vehicles of the automated storage and retrieval system to transport storage containers of a plurality of storage containers stored in the automated storage and retrieval system to a container receiving element of a storage rack.

[0077] Commanding the robot to deliver the storage container to the container receiving element may include determining that the storage container should be stored in the storage rack based on the picking frequency of the items stored in the storage container. Determining that the storage container is stored in the storage rack based on the picking frequency of the items stored in the storage container may include: determining that the picking frequency of the items stored in the storage container exceeds a threshold frequency.

[0078] The method may further include commanding one or more actuators of the storage rack to move the container receiving element from a second configuration to a first configuration, in which the container receiving element is oriented such that the storage container is supported in a display position where items stored in the storage container can be accessed by a user, and in which the container receiving element is configured to receive the storage container from the robotic container transport vehicle. Alternatively or additionally, the method may include detecting that the container receiving element has been moved to its first configuration.

[0079] The method may also include commanding one or more robotic container handling vehicles to remove a container supported by the container receiving element in its first configuration.

[0080] The method may also include commanding one or more actuator container receiving elements of the storage rack to move from their first configuration to their second configuration. Alternatively or additionally, the method may include detecting that the container receiving element has moved to its second configuration.

[0081] An additional method for operating an automated storage and retrieval system is also disclosed, the method comprising: receiving an order comprising one or more items; for each of a plurality of ports of the automated storage and retrieval system, determining the quantity of items of the order stored in one or more storage racks adjacent to the port; selecting from the plurality of ports a port adjacent to one or more storage racks containing the highest proportion of items of the order; and assigning the order to the selected port for processing.

[0082] Assigning orders for processing at a selected port may include instructing one or more robotic container handling vehicles in an automated storage and retrieval system to transport one or more containers containing items not stored in one or more storage racks adjacent to the selected port to the selected port.

[0083] It should be understood that the above description is intended to be illustrative and not restrictive. Many other implementations will be apparent to those skilled in the art after reading and understanding the above description. Although this disclosure has been described with reference to specific exemplary embodiments, it should be recognized that this disclosure is not limited to the described embodiments, but can be implemented using variations and modifications within the spirit and scope of the appended claims. Therefore, the specification and drawings are to be regarded as illustrative and not restrictive. Accordingly, the scope of this disclosure should be determined by reference to the appended claims and the full scope of their equivalents.

Claims

1. A storage rack for an automated storage and retrieval system, the storage rack comprising: frame; as well as A first container receiving element and a second container receiving element, wherein each of the container receiving elements is supported by the frame, wherein the second container receiving element is arranged above the first container receiving element within the frame, and wherein each of the container receiving elements is movable between the following configurations: Relative to a first configuration of the frame, in which the container receiving element is configured to receive a storage container from a robotic container transport vehicle; as well as In a second configuration relative to the frame, the container receiving element is oriented such that the storage container is supported in a display position in which items stored in the storage container can be accessed by a user.

2. The storage rack according to claim 1, wherein, Each of the container receiving elements extends at least partially outside the frame when the container receiving element is in the first configuration of the container receiving element.

3. The storage rack according to claim 1 or 2, further comprising: One or more actuators are configured to move one or more of the container receiving elements.

4. The storage rack according to claim 3, wherein, The one or more actuators are configured to move each of the one or more container receiving elements from a second configuration of the container receiving element to a first configuration of the container receiving element.

5. The storage rack according to claim 3 or 4, wherein, The one or more actuators are configured to move each of the one or more container receiving elements from a first configuration of the container receiving element to a second configuration of the container receiving element.

6. The storage rack according to any one of claims 1 to 5, wherein, When the storage container is in the display position, the storage container is angled relative to the frame such that the base of the storage container is not horizontal.

7. The storage rack according to any one of claims 1 to 6, wherein, When the second container receiving element is in the second configuration of the second container receiving element, the second container receiving element does not obstruct the transport of the storage container to the first container receiving element in the first configuration of the first container receiving element.

8. An automatic storage and retrieval system, comprising: Multiple storage locations, each of which is configured to store a corresponding storage container among a plurality of storage containers, each of which is configured to store one or more items; One or more robotic container transport vehicles configured to retrieve storage containers from the plurality of storage locations; Storage rack according to any one of claims 1 to 7; as well as The controller is configured to command one or more robotic container handling vehicles to transport storage containers from the plurality of storage containers to the container receiving element of the storage rack.

9. The system according to claim 8, wherein, The robotic container handling vehicle in the one or more of the robotic container handling vehicles is configured to lower a storage container onto the container receiving element when the container receiving element of the storage rack is in a first configuration of the container receiving element.

10. The system according to claim 8 or 9, wherein, The controller is also configured to actuate the container receiving element of the storage rack, causing the container receiving element to move from a second configuration of the container receiving element to a first configuration of the container receiving element.

11. The system according to any one of claims 8 to 10, wherein, The controller is also configured to actuate the container receiving element of the storage rack, causing the container receiving element to move from a first configuration of the container receiving element to a second configuration of the container receiving element.

12. The system according to any one of claims 8 to 11, wherein, The one or more robotic container handling vehicles are configured to transport storage containers from the plurality of storage locations to a pick-up station adjacent to the storage rack.

13. The system according to any one of claims 8 to 11, wherein, The one or more robotic container handling vehicles are configured to transport storage containers from the plurality of storage locations to a pick-up station, and the system further includes a conveyor for transporting items picked up from the storage containers delivered to the pick-up station to a shelf storage area including the storage rack.

14. A method of controlling one or more robotic container handling vehicles in an automated storage and retrieval system according to any one of claims 8 to 13, wherein the method includes commanding the robotic container handling vehicles among the one or more container handling vehicles to deliver storage containers from the plurality of storage containers to a container receiving element of the storage rack.

15. A computer-readable medium storing instructions that, when executed by one or more processors of a controller of an automated storage and retrieval system according to any one of claims 8 to 13, cause the controller to command a robotic container transport vehicle in one or more container transport vehicles to transport a storage container from a plurality of storage containers to a container receiving element of the storage rack.

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