Automated buffer system for a storage and retrieval system

Abstract

P358542WO 40 ABSTRACT The present disclosure provides an automated buffer system (1) for a storage and retrieval system. The automated buffer system includes an input station (300) arranged to receive units of goods (4) from a mass storage system. The automated buffer system also includes a buffer storage area (206) arranged to receive units of goods from the input station. The 5 buffer storage area comprises a plurality of tile units (3) arranged in a grid having rows (5) and columns (6). Each tile unit is adapted to support a unit of goods and comprises a drive unit operable to move the units of goods to an adjacent tile unit in a row direction or in a column direction. The automated buffer system also includes an output station (7) for removal of goods from the buffer storage area. 10 [FIG. 2]

Description

AUTOMATED BUFFER SYSTEM FOR A STORAGE AND RETRIEVAL SYSTEM

[0001] This invention relates to an automated buffer system for a storage and retrieval system.BACKGROUND

[0002] Mass storage systems are used to store large quantities and / or large varieties of goods, for example groceries. Some mass storage systems are manual, relying on operators to move around fixed storage locations to retrieve goods and load them for packing and shipping. Automated mass storage systems employ, for example, shuttles, retrieval robots, automated mobile robots (AMRs), and / or assistant robots to automate the process of retrieving and moving goods from the mass storage system to an output, for example a pick line. Such automated mass storage systems typically include fixed or moveable storage locations (e.g. storage racks or the like) that hold storage containers with the goods. The storage containers themselves are typically retrieved and moved to the output.

[0003] Mass storage systems hold and process a large quantity and / or variety of goods, and are therefore challenging to operate when goods are required frequently with high throughputs while maintaining low retrieval latency.BRIEF SUMMARY OF THE DISCLOSURE

[0004] According to a first aspect of the present invention there is provided an automated buffer system for a storage and retrieval system. The automated buffer system comprises an input station arranged to receive units of goods from a mass storage system. The automated buffer system further comprises a buffer storage area arranged to receive units of goods from the input station. The buffer storage area comprises a plurality of tile units arranged in a grid having rows and columns, each tile unit being adapted to support a unit of goods and comprising a drive unit operable to move the units of goods to an adjacent tile unit in a row direction or in a column direction. The automated buffer system further comprises an output station for removal of goods from the buffer storage area.

[0005] Accordingly, the automated buffer system is located between the mass storage system and an output and acts as a buffer by storing goods in the buffer storage area. The arrangement of tile units provides high storage density and can be operated to store and / or sequence units of goods received from the mass storage system. In examples, the units of goods may be sequenced by sorting, collating and / or queueing of units of goods. The automated buffer system improves the efficiency of the mass storage system, and provides low retrieval latency for units of goods stored in the buffer storage area.

[0006] In examples, the buffer storage area comprises a plurality of layers, each layer comprising a plurality of tiles units arranged in a grid having rows and columns. In examples, each layer comprises an input station. In examples, each layer comprises an output station. In examples, the automated buffer system further comprises one or more lifts arranged to move units of goods between different layers of the buffer storage area and / or between the input station and a layer of the buffer storage area and / or between a layer of the buffer storage area and the output station. Accordingly, units of goods can be moved around the buffer storage area for storing and / or sequencing.

[0007] In examples, units of goods may be transitorily stored in the buffer storage area. For example, a unit of goods may be stored in the buffer storage area after being returned from the output station. Such units of goods may be temporarily stored before being returned to the mass storage system, or before being returned to the output station as needed.

[0008] In examples, the automated buffer system comprises a buffer control system configured to control the plurality of tile units. In examples, the buffer control system is operable to move the units of goods to the output station in a different order to which they are received at the input station. In examples, the buffer control system is configured to sequence the units of goods between the input station and the output station. In examples, the buffer control system is configured to track the positions of the units of goods within the buffer storage area and to control the drive units of the tile units to move the units of goods to the output station and / or to sequence the units of goods between the input station and the output station. In examples, the units of goods may be sequenced by sorting, collating and / or queueing of units of goods.

[0009] In examples, the buffer control system is configured to operate the automated buffer system to return units of goods from the output station into the buffer storage area. In examples, the buffer control system is configured to operate the automated buffer system to move units of goods from the buffer storage area into the mass storage system. Accordingly, in some examples, units of goods may be moved from the mass storage system or the buffer storage area to the output station for removal of goods, and then returned to the buffer storage area and optionally returned to the mass storage system. In such examples, the automated buffer system advantageously improves the movement of units of goods at the output station by storing and / or sequencing units of goods as they move towards the output station, and as the units of gods are returned from the output station. Providing the automated buffer system in this way can improve the efficiency of the mass storage system because the mass storage system does not need to fully sequence the units of goods moving into and out of the automated buffer system.

[0010] In examples, the buffer control system is configured to move a unit of goods from a tile unit of the buffer storage area to the output station by: moving units of goods in a column corresponding to the called unit of goods in the row direction to create an aisle in the column direction, and moving the called unit of goods along the aisle to the output station.

[0011] Accordingly, a dynamic aisle can be created for moving the called unit of goods. The dynamic aisle provides improved storage density as there are no fixed aisles within the grid of tile units.

[0012] In examples, the aisle has a minimum length of at least two tile units in the column direction, for example a minimum length of at least three tile units in the column direction.

[0013] In examples, during movement of the called unit of goods along the aisle the buffer control system is configured to move units of goods in the row direction to close the aisle behind the called unit of goods.

[0014] In examples, when the called unit of goods has passed by the row corresponding to a second called unit of goods, the buffer control system is configured to move units of goods in a column corresponding to the second called unit of goods in the row direction to create a second aisle in the column direction for the second called unit of goods, and to moving the second called unit of goods along the second aisle to the output station.

[0015] Accordingly, multiple dynamic aisles can be created for moving units of goods around the buffer storage area and to the output station. .

[0016] In examples, at a maximum storage density, one tile unit in each row is empty.

[0017] In examples, the buffer control system is configured to simultaneously or sequentially move a plurality of units of goods in a row of the buffer storage area in the row direction.

[0018] In examples, the output station comprises a pick station for removal of goods from the automated buffer system. In examples, the pick station may be a manual pick station when an operator can manually remove goods from the automated buffer system. In other examples, the pick station may comprise a robot for removal of goods from the automated buffer system. In some examples, each unit of goods comprises a storage container holding goods, and goods can be removed from the container. Alternatively, the container itself (the entire unit of goods) can be removed at the pick station. In various examples, the storage container may comprise a storage tote, a box, a crate, a pallet, a trolley, a dolly, a cage, or a bag.

[0019] In examples, the output station comprises a conveyor. In examples, the conveyor comprises a plurality of tile units. The conveyor may be a part of a pick station. The conveyor may be arranged to convey units of goods away from the buffer storage area, for example towards a vehicle loading station.

[0020] In examples, the input station comprises a tile unit arranged to receive units of goods from the mass storage system and operable to move a received unit of goods into the buffer storage area. In examples, the tile unit may receive units of goods manually loaded into the input station. In examples, the tile unit may receive units of goods loaded into the input station by a robot or by a lift, or by a part of the mass storage system (e.g., a retrieval robot, AMR, or shuttle).

[0021] In examples, the input station and the output station may be arranged on different sides of the automated buffer system, for example opposite or adjacent sides. In other examples, the input station and the output station may be arranged adjacent to one another on the same side of the automated buffer system. In other examples, the input station and the output station may be co-located. For example, the input station and the output station may both be formed by a conveyor or similar arranged at a side of the automated buffer system, where units of goods are received for moving into the buffer storage area, and where units of goods are moved from the buffer storage area for output. In such examples, units of goods received at the input station may reach the output station without entering the buffer storage area, or they may be moved into the buffer storage area for storage and / or sequencing before being moved to the output station.

[0022] According to a second aspect of the present invention there is also provided a storage and retrieval system comprising a mass storage system, and an automated buffer system. The automated buffer system comprises an input station arranged to receive units of goods from the mass storage system. The automated buffer system also comprises a buffer storage area comprising a plurality of tile units arranged in a grid having rows and columns, each tile unit being adapted to support a unit of goods and comprising a drive unit operable to move the unit of goods to an adjacent tile unit in a row direction or in a column direction. The automated buffer system also comprises an output station for removal of goods from the automated buffer system.

[0023] The automated buffer system may include any of the features described above with reference to the first aspect of the present invention.

[0024] In examples, the mass storage system comprises an automated mass storage system. In examples, the automated mass storage system comprises a fixed or moveable storage, for example fixed or moveable storage columns or storage racks. In examples, the automated mass storage system comprises a plurality of retrieval devices forconveying units of goods to the input station of the automated buffer system. In examples, the plurality of retrieval devices comprises at least one of: retrieval robots, autonomous mobile robots, shuttles, assistant robots.

[0025] In examples, the storage and retrieval system further comprises a transfer system for transferring units of goods from the mass storage system to the automated buffer system. In examples, the transfer system may comprise a robot, a conveyor, or a lift that moves units of goods from the mass storage system to the input station of the automated buffer system.

[0026] In some examples, a user may move goods and / or units of goods (e.g., goods in a container) from the mass storage system into the automated buffer system (particularly the input station). In some examples, the user may lift goods and / or units of goods from one or more containers of the mass storage system and place them in one or more a containers of the automated buffer system, particularly at the input station.

[0027] In examples, the storage and retrieval system further comprises a control system configured to track the positions of the units of goods within the mass storage system and within the automated buffer system. In examples, the automated buffer system comprises a buffer control system configured to move the units of goods to the output station in a different order to which they are received at the input station. In examples, the buffer control system is configured to sequence the units of goods between the input station and the output station of the automated buffer system. In examples, the units of goods may be sequenced by sorting, collating and / or queueing of units of goods.

[0028] In examples, the buffer control system is configured to store a first set of units of goods in the buffer storage area, and to move a second set of units of goods through the buffer storage area from the input station to the output station. In examples, the first set of units of goods are sequenced according to order processing information. In examples, the first set of units of goods may be sequenced by sorting, collating and / or queueing of units of goods. In examples, the first set of units of goods comprise frequently retrieved goods.

[0029] According to a third aspect of the present invention, there is provided a method of operating the automated buffer system described above. The method comprises: receiving, at the input station, units of goods from the mass storage system, storing, in the buffer storage area, at least some of the units of goods received from the mass storage system, and operating the tile units to move the units of goods to the output station.

[0030] In examples, the method comprises moving the units of goods to the output station in a different order to which they are received at the input station. In examples, the method comprises sequencing the units of goods between the input station and the output station. Sequencing may comprise one or more sequencing operations that may include sorting, collating and queueing of units of goods.

[0031] In examples, the method comprises storing a first set of units of goods in the buffer storage area, and moving a second set of units of goods through the buffer storage area from the input station to the output station. In examples, the first set of units of goods are sequenced according to order processing information. Sequencing may comprise one or more sequencing operations that may include sorting, collating and queueing of units of goods. In examples, the first set of units of goods comprise frequently retrieved goods. Accordingly, different units of goods may be handled differently. For example, units of frequently retrieved goods may be stored in the buffer storage area while other units of goods are moved to the output station.

[0032] In examples, the method comprises moving a called unit of goods from a tile unit in the buffer storage area to the output station by: moving units of goods in a column corresponding to the called unit of goods in the row direction to create an aisle in the column direction, and moving the called unit of goods along the aisle to the output station.

[0033] In examples, the method comprises simultaneously or sequentially moving a plurality of units of goods in a row in the row direction.

[0034] In examples, the aisle has a minimum length of at least two tile units in the column direction, for example a minimum length of at least three tile units in the column direction.

[0035] In examples, during movement of the called unit of goods along the aisle, the method comprises moving units of goods in the row direction to close the aisle behind the called unit of goods.

[0036] In examples, the method further comprises moving a second called unit of goods from a tile unit in the grid to the output station by: when the called unit of goods has passed by the row corresponding to the second called unit of goods, moving units of goods in a column corresponding to the second called unit of goods in the row direction to create a second aisle in the column direction for the second called unit of goods, and moving the second called unit of goods along the second aisle to the output station.

[0037] According to a fourth aspect of the present invention, there is provided a method of operating a storage and retrieval system, the storage and retrieval system comprising a mass storage system and an automated buffer system. The method comprises: retrieving units of goods in the mass storage system; transferring the units of goods from the mass storage system into the automated buffer system; storing and / or sequencing the units of goods in the automated buffer system; and moving the units of goods to an output station of the automated buffer system.

[0038] In examples, the units of goods may be sequenced by sorting, collating and / or queueing of units of goods. In examples, the units of goods may be manually retrieved in the mass storage system, or the mass storage system may be an automated mass storage system and the units of goods may be retrieved by retrieval robots, AM Rs, shuttles, or the like.

[0039] The mass storage system and the automated buffer system may be as described above with reference to the first to third aspects of the present invention.

[0040] In examples, each unit of goods comprises a storage container. In various examples, the storage container may comprise a storage tote, a box, a crate, a pallet, a trolley, a dolly, a cage, or a bag.

[0041] In examples, the automated buffer system comprises a plurality of skid plates. Each skid plate may be adapted to hold a unit of goods and wherein each tile unit is operable to move skid plates to an adjacent tile unit. Accordingly, units of goods may be stored in, and moveable on, the skid plates within the buffer storage area. In examples, each unit of goods may comprise a storage container that is supported on the skid plate.

[0042] In other examples, the tile units of the automated buffer system may receive units of goods directly on the tile units. In particular, one or more items of goods may be placed directly on the skid plate, in which case such items are a unit of goods.

[0043] With respect to the above description it is to be realised that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.BRIEF DESCRIPTION OF THE DRAWINGS

[0044] Embodiments of the invention are further described hereinafter with reference to the accompanying drawings, in which:FIG. 1 shows a storage and retrieval system having a mass storage system and an automated buffer system;FIG. 2 shows an example automated buffer system of the storage and retrieval system of FIG. 1 ;FIGS. 3A and 3B show a further example of an automated buffer system of the storage and retrieval system of FIG. 1 ;FIGS. 4A and 4B show a further example of an automated buffer system of the storage and retrieval system of FIG. 1 ;FIG. 5 shows a further example of an automated buffer system of the storage and retrieval system of FIG. 1 ;FIG. 6 shows a further example of a storage and retrieval system having an automated buffer system;FIG. 7 shows a part of the automated buffer system;FIG. 8 schematically illustrates operation of the automated buffer system;FIG. 9 schematically illustrates operation of the automated buffer system;FIGS. 10A and 10B schematically illustrate the formation of an aisle within the automated buffer system;FIGS. 11A to 11C schematically illustrate the formation of multiple aisles within the automated buffer system;FIGS. 12A and 12B illustrate a first example of a tile unit of the automated storage and retrieval system;FIGS. 13A and 13B illustrate a second example of a tile unit of the automated storage and retrieval system;FIG. 14 illustrates a rotation mechanism of the example tile units of FIGS. 12A to 13B;FIGS. 15A and 15B illustrate multiple tile units arranged in a grid in the automated buffer system;FIG. 16 illustrates a wheel guide formation of a storage container or skid plate of the automated buffer system;FIG. 17 illustrates a skid plate of the automated buffer system;FIG. 18 illustrates a storage container of the automated buffer system;FIG. 19 illustrates how adjacent tile units of the automated buffer system are connected together, including an electrical connection; andFIG. 20 illustrates an alternative arrangement for forming an electrical connection with the tile unit.DETAILED DESCRIPTION

[0045] FIG. 1 illustrates a storage and retrieval system 100, for example the type that would be installed in an order fulfilment centre or the like. In particular, the storage and retrieval system 100 may be used in third party logistics (3PL) warehouses, retail order fulfilment centres (including, e.g., groceries), and other applications where a large number and variety of goods are stored, for example in manufacturing supply chains.

[0046] The storage and retrieval system 100 includes two parts - a mass storage system 200 and an automated buffer system 1. As explained in detail below, goods are moved from the mass storage system 200 into the automated buffer system 1 and then output at an output station 7. From the output station 7 the goods may be removed, optionally packed, and transferred to a further conveyor or into a delivery vehicle.

[0047] In examples, the mass storage system 200 may comprise racking for storing units of goods. The mass storage system 200 may be manually operated, with operators, assisted by lifting devices and the like, moving units of goods into and out of the mass storage system 200. In such examples the operators may move units of goods from the mass storage system 200 to an input of the buffer system 1.

[0048] In other examples, the mass storage system 200 is an automated mass storage system. The automated mass storage system may be partially or fully automated. In various examples, the automated mass storage system 200 may comprise fixed or moveable storage. In various examples, the automated mass storage system 200 may comprise shuttles, retrieval robots, autonomous mobile robots (AMRs), and / or assistant bots.

[0049] In one example, the automated mass storage system 200 comprises a fixed storage grid formed of a plurality of columns in which units of goods are stacked. Retrieval robots may move across the tops of the columns, for example on rails, and retrieve the topunit of goods. In other examples, retrieval robots may move underneath the columns and retrieve the units of goods from the bottoms of the stacks.

[0050] In a further example, the automated mass storage system 200 may comprise a fixed storage grid with storage areas (e.g., racks) divided by aisles and ramps. Shuttles move along the aisles and ramps and move units of goods.

[0051] In a further example, the automated mass storage system 200 may comprise a fixed storage grid with storage areas (e.g., racks) divided by aisles and ramps. Autonomous mobile robots (AM Rs) move along the aisles and ramps and move units of goods.

[0052] In a further example, the automated mass storage system 200 may comprise moveable storage (e.g., storage racks) and AMRs that move the moveable storage. The moveable storage may comprise a storage rack holding multiple units of goods, and the AMRs may move the storage rack.

[0053] In a further example, the automated mass storage system 200 may be partially autonomous, having fixed storage areas separated by aisles and ramps, and assistant robots that work in cooperation with operators for retrieval of units of goods.

[0054] In a further example, the automated mass storage system 200 may comprise a grid of tile units that can move units of goods, such as the goods themselves, storage containers, pallets, dollies, or trolleys in X and Y directions. An example of such a mass storage system 200 is disclosed in applicant’s co-pending patent application published as WO2022195508A1 (Tharsus Limited).

[0055] Automated mass storage systems 200 such as those described above provide higher efficiency compared to manual systems. These automated systems are particularly effective for storing a large number and variety of different goods, which may or may not be perishable. The latest control systems associated with these systems, including artificial intelligence control systems, can provide efficiencies at large scale.

[0056] However, such mass storage systems 200, whether manual or automated, typically have relatively high retrieval latency because of the sheer size of the system and the inevitable time it takes to move units of goods around the mass storage system, for example to a pick station or output conveyor. Additionally, the size of the system and the availability of the retrieval robots, shuttles, AMRs, assistant robots and operators for moving the units of goods can limit the frequency of goods movements and increase the retrieval latency. Additionally, systems using retrieval robots, AMRs, and the like will typically rely on more than one robot to retrieve the various goods that make up a single order, creating challenges with sequencing. Often, retrieval robots or AMRs will experiencecongestion at certain points of the system and have to wait in a queues or be inefficiently routed.

[0057] The automated buffer system 1 disclosed herein addresses these issues. As described below, the automated buffer system 1 is a storage and retrieval system itself, which receives units of goods from the mass storage system 200 and provides them, as needed, to an output station 7. The automated buffer system 1 may store and / or sequence the units of goods received from the mass storage system 200. The automated buffer system 1 may handle different units of goods in different ways, for example by storing a first set of unit of goods and sequencing a second set of units of goods and / or moving the second set of units of goods to the output station 7. Accordingly, the automated buffer system can improve the efficiency of the mass storage system 200 because the mass storage system 200 needs to do less retrieval and less sequencing. The automated buffer system 1 may reduce retrieval latency of the storage and retrieval system 100, particularly for frequently retrieved goods, and may provide a more efficient output sequence of goods. Additionally, by storing and / or sequencing units of goods in the automated buffer system 1, the operation of the mass storage system 200 can be improved because frequently retrieved goods can be stored in the automated buffer system 1 and the mass storage system 200 does not need to sequence the units of goods itself. This allows the mass storage system 200 to operate to move the units of goods to the automated buffer system 1 in an efficient manner.

[0058] Goods are stored and moved around the storage and retrieval system 100 in units. In some examples, each unit of goods may comprise a plurality of items. The items may be the same or may be a mix of different items.

[0059] In examples, each unit of goods may comprise a storage container, such as a storage box, a tote, a pallet, a cage, a trolley, a dolly, or a bag. The storage containers may hold one or more items making up the unit of goods. In such examples, storage containers may be returned from the output station 7 to the automated buffer system 1 after removal of goods. For example, one or more items may be removed from a storage container at the output station 7, and the storage container can then be returned to the automated buffer system 1. As explained below, the returned storage containers may be stored in the automated buffer system 1 or returned to the mass storage system 200. Empty storage containers may be moved elsewhere for replenishment.

[0060] In other examples, each unit of goods may be moved around the mass storage system 200 and the automated buffer system 1 without a storage container. This may be appropriate for larger items such as furniture, kitchen equipment or homeware and the like, and for goods that have their own packaging, such as a box.

[0061] As described further hereinafter, in examples each unit of goods (whether in a storage container or not) may be received on a skid plate in the automated buffer system 1 and moved around the automated buffer system 1 on the skid plate. The skid plates can hold one or more goods that form a unit.

[0062] The automated buffer system 1 has a storage capacity. The storage capacity of the automated buffer system 1 is smaller than the mass storage system 200. For example, the buffer system 1 may have less than 20% of the storage capacity of the mass storage system 200, for example less than 15% of the storage capacity of the mass storage system 200, for example less than 10% of the storage capacity of the mass storage system 200, for example less than 5% of the storage capacity of the mass storage system 200, for example less than 1% of the storage capacity of the mass storage system, for example less than 0.5% of the storage capacity of the mass storage system. In some examples, the mass storage system 200 may comprise up to 20,000 storage locations, and the automated buffer system 1 may comprise less than 1 ,000 storage locations, for example less than 500 storage locations.

[0063] The storage density of the automated buffer system 1 may be greater than the storage density of the automated mass storage system 200.

[0064] The automated buffer system 1 may be used to store frequently retrieved units of goods, for example common or popular goods. Accordingly, the retrieval latency for such goods can be improved as they are stored at, and retrieved from, a location close to the output station 7 and the inefficiencies with the mass storage system 200 are avoided for those goods. Additionally, by storing and retrieving such goods from the automated buffer system 1 , the number of retrieval robots or the like in the mass storage system 200 can be reduced, which can reduce congestion and improve the efficiency of the mass storage system 200.

[0065] In some examples, units of goods may be transitorily stored in the automated buffer system 1. For example, a unit of goods may be stored in the automated buffer system 1 after being returned from the output station 7. Such units of goods may be temporarily stored before being returned to the mass storage system 200, or before being returned. In some examples, the automated buffer system 1 is arranged so that goods are transferred from the mass storage system 200 into the automated buffer system 1 at different locations, for example on adjacent or opposite sides of the automated buffer system 1. In other examples, the automated buffer system 1 is arranged so that goods are transferred from the mass storage system 200 into the automated buffer system 1 at the same location, for example on a conveyor on one side of the automated buffer system 1.

[0066] The automated buffer system 1 additionally provides sequencing of units of goods between the mass storage system 200 and the output station 7. Therefore, for example, units of goods for particular orders or for particular delivery vehicles can be held and processed in the automated buffer system 1 and provided to the output station 7 at the appropriate time and in the appropriate order, simplifying the process at the output station 7 and increasing throughput. This also improves the efficiency of the mass storage system 200 because the mass storage system 200 does not need to fully sequence delivery of units of goods. Similarly, some units of goods or orders may be prioritised over others and this can be addressed by sequencing within the automated buffer system 1. Sequencing operations may include sorting, collating and queueing of units of goods. For example, units of goods received at the automated buffer system 1 may be sorted according a criteria, for example order processing information or type of goods. The sorted units of goods may be collated into orders according to order processing information. Units of goods may be queued for output at the output station 7 in an order based on order processing information, such as a priority order or according to what delivery vehicles are available.

[0067] Accordingly, the automated buffer system 1 enhances the operation of the mass storage system 200. The combination of the mass storage system 200 and the automated buffer system 1 also improves throughput and retrieval latency compared to the mass storage system 200 alone, and can improve the efficiency of the processes performed at the output station 7 (e.g., picking, loading).

[0068] The storage and retrieval system 100 includes a control system that tracks the location of units of goods through the mass storage system 200 and automated buffer system 1. The control system may include, or may be linked with, an order processing system that receives orders and controls the storage and retrieval system 100 to move units of goods to the output station 7 based on order processing information. Accordingly, the control system is configured to process orders by moving units of goods to the output station 7, either from the mass storage system 200 via the automated buffer system 1 , or directly from the automated buffer system 1 if the relevant unit of goods is stored or otherwise present in the automated buffer system 1.

[0069] An example of an automated buffer system 1 is shown in overview in FIG. 2. As explained above, the automated buffer system 1 is installed together with a mass storage system (200, see FIG. 1) to provide an enhanced storage and retrieval system 100.

[0070] In the described examples the mass storage system 200 and the automated buffer system 1 are used to store and retrieve storage containers 4, such as storage totes. Goods are held in the storage containers 4. The goods may be, for example, groceries,clothing, retail goods and the like. However, in other examples the mass storage system 200 and the automated buffer system 1 may store and retrieve other forms of storage containers such as pallets, cages, trolleys, dollies and the like, or skid plates holding units of goods, as described further below.

[0071] As illustrated in FIG. 2, the automated buffer system 1 comprises a three dimensional matrix formed from a number of substantially horizontally aligned layers 2a-2f stacked above and below one another on a framework 30. The automated buffer system 1 also includes an input station 300 and an output station 7. In this example, the output station is a pick station where an operator can remove goods from the storage containers 4 or remove the storage containers 4 themselves. Further detail is provided in FIGS. 7 to 11 C, which illustrate a single layer 2 of the buffer system 1 shown in FIG. 2. In this example the input station 300 is provided at a rear of the automated buffer system 1 and the output station 7 is provided at a front of the automated buffer system 1. However, as will be apparent hereinafter, the input station 300 and the output station 7 may be arranged in different orientations and positions of the automated buffer system 1.In some examples, the output station 7 and the input station 300 may be collocated, for example on a conveyor 8 formed on side of the automated buffer system 1.

[0072] The framework 30 shown in FIG. 2 is configured to support a number of tile units 3 that are in use laid out in grids on the framework 30 to form the layers 2. The lowest layer 2f of tile units 3 may be located directly on the floor of the warehouse, or may be raised up from the floor of the warehouse.

[0073] In use, each tile unit 3 is capable of supporting a storage container 4. As described hereinafter the storage containers 4 may be received directly on the tile units 3, or a skid plate may be received on the tile units 3 and the storage containers 4 carried on the skid plates. In other examples, units of goods may be received directly on the tile units 3 or on skid plates.

[0074] The grid(s) of tile units 3 arranged in layers thereby provide a buffer storage area 206. In the illustrated examples, the tile units 3 are adapted to support storage containers 4, which are standardised, open-topped boxes for holding goods. The storage container 4 is a container holding the goods and, as described further below, is sized to fit on one of the tile units 3. In examples, the storage container 4 is a storage tote and each tile unit 3 is rectangular in plan view, and has a length of approximately 30 cm and a width of approximately 20 cm, or a length of approximately 80 cm and a width of approximately 60 cm, but various sizes are possible. In other examples, for example if the storage container 4 were a trolley, dolly or cage, the tile units 3 may be larger and correspond to the size of the storage container 4. The tile units 3 may be arranged so that the corners of adjacenttile units are located in the same position as one another, and not offset (i.e. , the inner corners of a set of four tile units arranged in a 2 x 2 pattern are all in the same location). Alternatively, there may be some gap between the edges of adjacent tile units 3, for example to accommodate a part of the framework 30.

[0075] The framework 30 is formed from beams, for example steel beams or similar, connected at their ends and along their length with suitable fasteners such as bolts, rivets, or similar. The sides and ends of the automated buffer system 1 are open but some areas may be closed off by screens.

[0076] As shown, in the example of FIG. 2 the buffer system 1 comprises six layers 2a-2f but it will be appreciated that one or more layers 2a-2f may be provided. In some examples, the buffer system 1 may comprise a single layer 2. In the example of FIG. 2, each layer 2a-2f is the same size as the others - that is, formed from the same number of tile units 3 in the same layout. In the example of FIG. 2, the buffer system 1 has six layers 2a-2d and the height of the framework 30 is around 2.5 metres, although it will be appreciated that different numbers of layers 2 and different heights of layers 2 would change the overall height of the buffer system 1. In this example the buffer system 1 has a width, in an X direction, of 10 tile units 3 and a width of approximately 6 to 8 metres. In this example the buffer system 1 has a length, in the Y direction, of 12 tile units 3 and a length of approximately 15 to 20 metres. However, it will be appreciated that in different installations the height, length and width may vary and can be adapted to fit the installation site (e.g., warehouse floor space and clearance) and / or the sizes of the storage containers 4. Accordingly, the number of layers 2 and the number of tile units 3 in the X and Y directions may vary accordingly. In addition, some tile units 3 may be omitted to accommodate other features of the installation site, such as columns or access points.

[0077] Each tile unit 3 in this embodiment is substantially the same size as every other, and appears square or rectangular when viewed in plan view. As shown in FIG. 2 and FIGS. 7 to 11 C, when a number of the tile units 3 are located side-by-side with one another in a layer 2 they form a grid, made up of the individual squares / rectangles of each tile unit 3. In this way, each layer 2a-2f of the system 1 comprises a grid of tile units 3. The tile units 3 are aligned in the Z (vertical) direction so that each layer 2a-2f has a substantially flat surface on which the storage containers 4 are received. As shown, the grid is formed of rows 5 of tile units 3 aligned in the X direction, and columns 6 of tile units 4 aligned in the Y direction. If multiple tiers 2 are provided the tiers 2a-2f are arranged on top of each other in a Z direction. In examples, the layers 2a-2f are aligned and overlap, for example partially overlap or completely overlap.

[0078] As mentioned above, storage containers 4 are supported on the tile units 3. As shown, the shape of the storage containers 4 approximately matches the shape of the tile units 3 and the storage containers 4 are sized slightly smaller than the tile units 3 so that storage containers 4 on adjacent tile units 3 are not in contact with each other. The storage containers 4 may be open-topped plastic containers (totes), and may have a standard size. For example, the storage containers 4 may be so-called Euro Containers having a standard size of 30 cm x 20 cm or 80 cm x 60 cm.

[0079] As described further below with reference to FIGS. 9 and 12A to 18, each tile unit 3 has a drive unit operable to move a storage container 3 in either the X direction (along a row 5) or in the Y direction (along a column 6). A buffer control system, which may be a part of the overall control system, is provided to operate the tile units 3 to move the storage containers 4 in the X direction or the Y direction. Accordingly, the tile units 3 can be operated to move storage containers 4 along rows 5 and / or columns 6 to move storage containers 3 around the grid of tile units 3. In particular, as shown in FIG. 9, the tile unit 3a is operable to move a storage container 4a to one of the tile units 3b or 3c in the X direction (along the row 5), or one of the tile units 3d or 3e in the Y direction (along the column 6).

[0080] In examples, a majority of the tile units 3 hold a storage container 4 to provide high storage density. Multiple tile units 3 can be simultaneously operated to simultaneously move several storage containers 4 along a row 5 or column 6. Alternatively, tile units 3 may be operated in a successive manner to successively move storage containers 4 along a row 5 or column 6, with a first moving into an empty space, followed by the others. To permit movement of the storage containers 4 along the rows 5, at least one tile unit 3 in each row 5 is empty as shown in FIG. 8. That is, there is at least one tile unit 4 in each row 5 that does not hold a storage container 4. In FIG. 8 empty tile units 3 are indicated by 3X. In the illustrated configuration each row 5 has one empty tile unit 3X. However, it will be appreciated that during operation, for example depending on removal and addition of storage containers 4, each row 5 may have more than one empty tile unit 3. Accordingly, tile units 3 can be operated to move storage containers 3 along the rows 5 to change the positions of the empty tile units 3X. In operation, to move a storage container 4 in the Y direction the tile units 3 are operated to move the other storage containers 4 in such a way to align the empty tile units 3 and create an aisle in the Y direction for passage of the storage container 4.

[0081] As shown in FIG. 2, the automated buffer system 1 comprises an output station, in this example a pick station 7. The pick station 7 is provided at the ends of the columns 6. The pick station 7 comprises a conveyor 8 at which an operator (or robot) can removegoods from storage containers 4 or remove storage containers 4 from the conveyor 8. The conveyor 8 may comprise a roller conveyor 9 and / or one or more tile units 3 arranged in a row 11, as illustrated. The conveyor 8 is preferably around waist height, so that an operator can stand by the pick station 7 and easily reach and move storage containers on the upper face of the pick station 7. In some examples, the pick station 7 is manual, with operators working to remove goods and / or storage containers 4 from the automated buffer system 1. In other examples, the pick station 7 may have one or more robots, for example pick-and-place robots or robots for lifting the storage containers 4. In other examples, the output station may comprise an output conveyor along which storage containers 4 and / or goods are conveyed, e.g., for loading into a delivery vehicle.

[0082] Where the automated buffer system 1 comprises more than one layer 2a-2f, as shown in FIG. 2, the pick station 7 may additionally comprise one or more lifts 10a, 10b for moving storage containers 4 in the Z direction, between layers 2a-2f. Storage containers 4 are moved along the first row 11 of tile units 3 to move from a layer 2 onto one of the lifts 10a, 10b, or after being deposited in a layer 2 by the lifts 10a, 10b. In other examples, one or more lifts 10a, 10b may be provided in other locations within the automated buffer system 1, and not necessarily at the output station and not necessarily at an edge of the layers 2. For example, one or more lifts 10a, 10b may be provided within the grid of tile unis 3, replacing one or more of the tile units 3.

[0083] In examples with only a single layer 2 of tile units 3, no lifts 10a, 10b are needed and the first row 11 of tile units 3 may act as an output station. In some examples the automated buffer system 1 has a plurality of layers 2 and no lifts. In such examples, each layer 2 may have an input station and an output station.

[0084] In the example of FIG. 2, a rear row 12 of tile units 3 is generally kept empty (i.e., free of stationary storage containers 4). The rear row 12 may thereby act as the input station 300 by allowing storage containers 4 to be deposited on the rear row 12 from the mass storage system 200 shown in FIG. 1 , or allowing goods to be transferred (e.g., by robot or user) into the storage containers 4 on the rear row 12. The tile units 3 of the rear row 12 can then be operated to move the storage containers 4 into the buffer storage area 206 provided by the other tile units 3. In some examples, the rear row 12 of one of the layers 2 provides the input station 300. In other examples, the rear row 12 of more than one of the layers 2 can provide the input station 300.

[0085] The storage containers 4 can be deposited into the automated buffer system at the input station 300 directly from the mass storage system 200 shown in FIG. 1. The storage and retrieval system 100 may comprise a transfer system for transferring the storage containers 4 from the mass storage system 200 into the automated buffer system 1. Invarious examples, the transfer station may be manual (operators move the storage containers 4), or the storage containers may be deposited directly onto the input station 300 by a retrieval robot, AMR, or shuttle of the mass storage system 200, or the transfer station may include a lift, crane, or conveyor that transfers the storage containers 4 into the input station 300.

[0086] In other examples, a user or operator may move units of goods from the containers of the mass storage system 200 into the storage containers 4 at the input station 300.

[0087] It will be appreciated that the input station 300 may alternatively be located elsewhere on the automated buffer system 1 , for example a different edge (at the end of a row 5 or column 6), or at a location in the top layer 2a away from the edges, for example in a central location, by lowering the storage containers 4 onto the top layer 2a of the automated buffer system 1.

[0088] In the example of FIG. 2, storage containers 4 are transferred from the mass storage system (200, see FIG. 1) into the automated buffer system 1 , and may be moved directly to the pick station 7. Or the storage containers 4 may be stored and / or sequenced on the tile units 3 of one of the layers 2. A first set of storage containers 4 may be sequenced and a second set of storage containers 4 may be stored. For example, storage containers 4 with frequently retrieved goods may be stored within the automated buffer system 1 and moved to the output station 7 as needed. This can reduce the retrieval latency of these goods. Additionally or alternatively, where an order has goods from several storages containers 4 may be sequenced within the automated buffer system 1 before being moved to the pick station 7. Additionally or alternatively, storage containers 4 for different orders may be sequenced in the automated buffer system 1. Such an arrangement thereby provides efficient retrieval with a low retrieval latency.

[0089] The automated buffer system 1 may include a buffer control system that controls the tile units 3. The buffer control system may monitor I track the positions of storage containers 4 within the automated buffer system 1. In some examples, each storage container 4 may comprise an identification device, such as a bar code or RFID tag, which is scanned or read as the storage container 4 enters and leaves the buffer storage are 206. Some or all of the tile units 3 may additionally comprise a scanner or reader for scanning or reading the identification devices of storage containers 4 within the buffer storage area 206. The buffer control system can therefore track and / or monitor the positions of individual storage containers 4 as they enter and leave the buffer storge area 206, and within the buffer storge area 206. The buffer control system can control the storage and sequencing of storage containers 4 within the buffer storage area 206, and control movement of the storage containers 4 to the output station 7.

[0090] In some examples, the automated buffer system 1 may be a multiple-input-multiple- output system, having more than one input station 300 and more than one output station 7. Multiple input stations 300 may be provided on the same or different layer 2, or on the same or different sides of the automated buffer station 1. Multiple output stations 7 may be provided on the same or different layer 2, or on the same or different sides of the automated buffer station 1. In some examples, the automated buffer system 1 may have multiple input stations 300 and a single output station 7, or a single input station 300 and multiple output stations 7.

[0091] In some examples, the automated buffer system 1 comprises more than one layer 2, for example six layers 2a-2f as shown in FIG. 2, and no lifts. In such examples, each layer 2 may comprise at least one input station 300 and at least one output station 7. For example, one row of tile units 3 of each layer 2 may provide an input station 300 and a different row may provide an output station 7. In this example storage containers cannot move between layers 2 of the automated buffer system 1 , but can be stored and / or sequenced on each layer 2 between the input station 300 and the output station 7.

[0092] FIGS. 3A to 6 illustrate different example mass storage and retrieval systems 100 with various arrangements of the automated buffer system 1 and the mass storage system 200. In each of these examples the mass storage systems 200 and the automated buffer systems 1 process units of goods that include storage containers 4. However, as described hereinafter the storage containers 4 may be received directly on the tile units 3, or a skid plate may be received on the tile units 3 and the storage containers 4 carried on the skid plates. In other examples, units of goods may be received directly on the tile units3 or on skid plates, but it will be appreciated that in other examples the units of goods may not include storage containers and / or may be provided on skid plates as described further hereinafter.

[0093] In the example of FIGS. 3A and 3B, the storage and retrieval system 100 comprises an automated mass storage system 200 and an automated buffer system 1. FIG. 3A shows a schematic view of the storage and retrieval system 100 and FIG. 3B shows the automated buffer system 1 in more detail.

[0094] As shown in FIG. 3A, the automated mass storage system 200 comprises a fixed storage grid 201 formed of a plurality of (vertical) columns 202 in which storage containers4 are stacked (only one column 202 is shown in FIG. 3A, but it will be appreciated that a plurality of columns 202 are provided in a high density arrangement). Retrieval robots 203 move across the tops of the columns 202, for example on rails. A retrieval robot 203 can retrieve a top storage container 4 from a column 202 or pick goods from the top storagecontainer 4 of a column 202. The retrieval robots 203 may retrieve a storage container 4 using a lifting mechanism (e.g., a winch), as shown.

[0095] As illustrated, the retrieval robots 203 move the retrieved storage containers 4 to a transfer system 250 where the storage containers 4 are transferred to the automated buffer system 1. In this example, the automated buffer system 1 is located alongside the automated mass storage system 200 and the storage containers 4 are moved down through the transfer system 250 into the automated buffer system 1. The transfer system 250 may include lifts, hoists or conveyors for this purpose, or the lifting mechanism of the retrieval robots 203 may lower the storage containers 4 through the transfer system 250.

[0096] As shown in FIG. 3B, storage container 4c is being lowered onto the automated buffer system 1. The storage container 4c is received on a tile unit 3 of the automated buffer system 1 , in particular tile unit 3f. Tile unit 3f is arranged in a grid of tile units 3 that forms an input station 300 of the automated buffer system 1. From the input station 300 the tile units 3 can be operated to move input storage containers 4c directly to the output station 7, which in this example is a pick station is formed of a row of tile units 3. As shown, an operator can remove the storage containers 4 and / or goods at the pick station 7. A packing area 204 may be provided to receive picked goods and / or storage containers 4. Alternatively, the tile units 3 can be operated to move the input storage containers 4c into a buffer storage area 206. In this example, the buffer storage area 206 is located below the floor 205 provided at the output station 7 and one or more lifts 10a, 10b are provided for moving storage containers 4 from the input station 300 into the buffer storage area 206. The buffer storage area 206 is as described with reference to FIGS. 2 and 7, having a plurality of layers 2a-2c, each formed of tile units 3 arranged in rows and columns on which storage containers 4 can be stored. The tile units 3 are each operable to move the storage containers 4 from a tile unit 3 to an adjacent tile unit 3 in the manner described above. Additionally, storage containers 4 can be moved from the buffer storage area 206 to the pick station 7 by operating tile units 3 and / or the lifts 10a. 10b to move a storage container 4 to the pick station 7.

[0097] Accordingly, storage containers 4 for a particular order may be received at the pick station 7 directly from the automated mass storage system 200 via the transfer station 250, or from the buffer storage area 206. Therefore, storage containers 4 are transferred from the automated mass storage system 200 into the automated buffer system 1 , and may be moved directly to the pick station 7 or they may be stored or sequenced in the buffer storage area 206. For example, storage containers 4 with frequently retrieved goods may be stored within the buffer storage area 206 and moved to the output station 7 when needed in order to reduce the retrieval latency of these goods. Additionally or alternatively,where an order has goods from several storage containers 4 they may be sequenced within the buffer storage area 206 before being moved to the output station 7. Additionally or alternatively, storage containers 4 for different orders may be sequenced in the buffer storage area 206 before being transferred to the output station 7. Such an arrangement thereby provides improved efficiency with low retrieval latency, and can improve the efficiency of the process at the output station 7 by providing the storage containers 4 in an appropriate order.

[0098] Storage containers 4 may be returned from the pick station 7 either to buffer storage area 206 or to the mass storage system 200, for example by the transfer system 250. Alternatively, empty storage containers 4 may be transferred elsewise to be replenished before being fed back into the mass storage system 200.

[0099] In other examples similar to that shown in FIGS. 3A and 3B, the retrieval robots 203 may move underneath the columns 202 and retrieve the bottom storage container 4 in each column 202. The retrieved storage container 4 (and / or goods) can be transported by the retrieval robot 203 to a transfer station that moves the storage containers 4 into the automated buffer system 1 , for example by lifting the storage containers 4 upwards and / or moving them sideways, depending on the relative positions of the automated mass storage system 200 and the automated buffer system 1.

[0100] In the example of FIGS. 4A and 4B, the storage and retrieval system 100 comprises an automated mass storage system 200 and an automated buffer system 1 that provides a buffer storage area 206. FIG. 4A shows the storage and retrieval system 100 from the direction of the pick station 7, and FIG. 4B shows the automated buffer system 1 from the direction of the automated mass storage system 200. The automated buffer system 1 is mostly the same as described with reference to FIG. 2 and detailed description is omitted.

[0101] As shown in FIGS. 4A and 4B, the automated mass storage system 200 comprises a plurality of tile units 207 arranged in a two-dimensional grid. Only a part of the grid is shown but it will be appreciated that the automated mass storage system 200 may extend across a large area. Each tile unit 207 of the automated mass storage system 200 can receive and hold a skid plate 210 and is operable, for example by drive wheels, to move the skid plate 210 to an adjacent tile unit 207 is a row or column direction. In the illustrated example, cages 209 are received on the skid plates 210 and the tile units 207 are operable to move the cages 209 around the automated mass storage system 200. The cages 209 carry a plurality of storage containers 4. The grid of tile units 207 that forms the automated mass storage system 200 of this example may be as described in applicant’s co-pending application published as WO2022 / 195508A1 (Tharsus Limited).

[0102] As shown most clearly in FIG. 4B, the automated mass storage system 200 extends up to the automated buffer system 1. In this example, the transfer station 250 includes lifts 208a, 208b that move transversely between a position in which they are above a tile unit 207 of the automated mass storage system 200 to a position in which they are above a tile unit 3 of the automated buffer system 1 , in particular a rear row of tile units3 that form an input station 300. The lifts 208a, 208b are operable to lift storage containers4 from the cages 209 and deposit them on the tile units 3 of the automated buffer system 1. The rear row of tile units 3 arranged to receive storage containers 4 from the lifts 208a, 208b thereby form an input station 300 of the automated buffer system 1.

[0103] When a storage container 4 is received in the automated buffer system 1 it is moveable about the buffer storage area 206 in the same way as described with reference to FIG. 2. In particular, the tile units 3 of the automated buffer system 1 can move the storage containers 4 to adjacent tile units 3, and lifts 10a, 10b can move the storage containers 4 between layers 2 and / or to / from the output station 7.

[0104] Accordingly, from the input station 300 the tile units 3 can be operated to move input storage containers 4 to the output station 7, which in this example is a pick station 7. As shown, an operator can remove the storage containers 4 and / or goods at the pick station 7. Alternatively, the tile units 3 can be operated to move the input storage containers 4 into the buffer storage area 206 provided by the automated buffer system 1. Additionally, storage containers 4 can be moved from the buffer storage area 206 to the pick station 7 by operating tile units 3 and / or the lifts 10a. 10b to move a storage container 4 to the pick station 7.

[0105] Accordingly, storage containers 4 can be transferred from the automated mass storage system 200 into the automated buffer system 1, and may be moved directly to the pick station 7 or they may be stored or sequenced in the buffer storage area 206. For example, storage containers 4 with frequently retrieved goods may be stored within the buffer storage area 206 and moved to the output station 7 when needed to reduce the retrieval latency of these goods. Additionally or alternatively, where an order has goods from several storage containers 4 they may be sequenced within the buffer storage area 206 before being moved to the output station 7. Additionally or alternatively, storage containers 4 for different orders may be sequenced in the buffer storage area 206 before being transferred to the output station 7. Such an arrangement thereby provides improved efficiency and low retrieval latency and can improve the efficiency of the process at the output station 7 by providing the storage containers 4 in an appropriate order.

[0106] In one example, the top layer 2a of the automated buffer system 1 may provide a sequencing area where storage containers 4 for particular orders are sequenced beforebeing transferred to the pick station 7. In this example, other storage containers 4 in the automated buffer system 1 , for example those holding frequently retrieved goods, may be stored in the other layers of the buffer storage area 206 and transferred to the pick station 7 or top layer 2a as needed. Such an arrangement can provide improved efficiency at the pick station 7 and low retrieval latency for frequently retrieved goods.

[0107] Storage containers 4 may be returned from the buffer storage area 206 to the mass storage system 200, for example by the transfer system 250. Alternatively, empty storage containers 4 may be transferred elsewise to be replenished before being fed back into the mass storage system 200.

[0108] In the example of FIG. 5, the storage and retrieval system 100 comprises a mass storage system 200 (only schematically indicated) and an automated buffer system 1 that provides a buffer storage area 206.

[0109] In this example, the mass storage system 200 may be a shop or a warehouse having a fixed storage arrangement. Operators, robots, robotic-assisted operators, or a combination of these, move around the fixed storage arrangement and pack goods into storage containers 4 on dollies 217, such as that shown in FIG. 5. The dollies 217 are then moved to the input station 300 of the automated buffer system 1. In other examples, the dollies 217 may be trolleys or cages.

[0110] As shown, in this example a transfer station 250 is provided for moving the storage containers 4 from the dolly 217 into a buffer storage area 206 at the input station 300. In this example the buffer storage area 206 is formed of a two dimensional grid of tile units 3 arranged in the same manner as described above with reference to FIG. 2, but in a single layer. The lift 250 lifts the storage containers 4 from the dolly 217 and deposits them on tile units 3 of the buffer storage area 206, from which they can be moved around the buffer storage area 206.

[0111] In the illustrated example the buffer storage area 206 comprises only a single layer 2 of tile units 3. However, it will be appreciated that further layers may be provided, with lifts as necessary.

[0112] The automated buffer system 1 also includes an output station 7. In this example, the output station 7 comprises one or more lifts 214a, 214b that move the storage containers 4 from the buffer storage area 206 and stacks them on dollies 216. In examples, a dolly 216 may be stacked with storage containers 4 for a single order, or for transfer to a single delivery vehicle. In other examples, the dollies 216 may be trolleys or cages.

[0113] As shown in FIG. 5, the storage and retrieval system 100 comprises an output buffer system 211 through which the dollies 216 are moved for output from the storage and retrieval system 100. The output buffer system 211 is formed of a plurality of tile units 213 that are the same as described above with reference to FIGS. 4A and 4B, and are as described in applicant’s co-pending application published as WO2022 / 195508A1 (Tharsus Limited). The tile units 213 are sized to hold and move the dollies 216.

[0114] In summary, the tile units 213 form a grid and the tile units 213 are operable to move skid plates 215 onto an adjacent tile unit 213. The dollies 216 can be positioned on the skid plates 215, so the tile units 213 can be controlled to move the dollies 216 around and through the output buffer system 211. The dollies 216 can be sequenced within the output buffer system 211. Advantageously, this may improve movement of the dollies 216 to the delivery vehicles as they arrive because the dollies 216 are already loaded and can be sequenced in the output buffer system 211.

[0115] The output buffer system 211 has an output station 7 from which an operator can move the dollies 216 for transfer to a delivery vehicle or the like.

[0116] The example of FIG. 5 may be particularly suited to a grocery mass storage system where the storage containers 4 are loaded with the various goods in the mass storage system 200 and the storage containers 4 are moved around on the dollies 217. Once ready, the dollies 217 can be unloaded into the automated buffer system 1 at the input station 300. The storage containers 4 can then be sequenced. Accordingly, the storage containers 4 do not need to be loaded in any order, which may improve the efficiency of loading the storage containers 4. The storage containers 4 are then output at output station 7 onto dollies 216. The dollies 216 can then be sequenced in the output buffer system 211, allowing the dollies 216 to be output in an efficient manner, for example depending on when a delivery vehicle is ready to be loaded.

[0117] In a further example similar to that of FIG. 5, the automated buffer system 1 comprises a buffer storage area that is the same as the output buffer system 211 described above, without the additional single layer buffer storage area. In such an example the dollies 217 from the mass storage system 200 may be transferred directly into the buffer storage area, stored and / or sequenced, and then output at output station 7. Such an example may be beneficial if, for example, the storage containers 4 are loaded onto the dollies 217 in the mass storage system 200 such that each storage container 4 contains goods for a particular order.

[0118] FIG. 6 schematically illustrates a further example storage and retrieval system 100. In this example, the mass storage system 200 comprises a fixed storage area 223, for example having a plurality of storage racks arranged in rows with aisles. In someexamples, the fixed storage area 223 may be a store. As indicated, storage containers are transferred from the fixed storage area 223 to the automated buffer system 1 via transfer system 250. For example, dollies holding storage containers can be moved from the fixed storage area 223 to the transfer system 250, similar to as shown in FIG. 5.

[0119] In examples, the storage containers may be manually loaded with goods within the mass storage system 200. Manual loading may be robot assisted. In other examples, loaded storage containers may be retrieved from the mass storage system 200 by a retrieval robot, a shuttle, or an AMR.

[0120] At the transfer system 250 the storage containers are moved into the automated buffer system 1 via input conveyor 221. The input conveyor 221 may be a belt conveyor, or may comprise a plurality of tile units, and is arranged to move storage conveyors to the automated buffer system 1 where they enter the buffer storage area 206.

[0121] The buffer storage area 206 is formed of a grid of tile units as described above. The buffer storage area 206 may have a single layer of tile units, or a plurality of layers of tile units. In the same manner as the other examples, within the buffer storage area 206 the storage containers can be stored and / or sequenced.

[0122] The storage containers are output from the buffer storage area 206 on output conveyor 222. The output conveyor 222 may be a belt conveyor, or may comprise a plurality of tile units, and is arranged to move storage conveyors from the automated buffer system 1 (in particular from the buffer storage area 206) to an output station 7. In this example the output station 7 includes a vehicle loading station 220, but in other examples they storage containers may be transported to a pick station or similar.

[0123] The input conveyor 221 and the output conveyor 222 may align with a tile unit of the buffer storage area 206 so that storage containers are transferred directly between the buffer storage area 206 and the input conveyor 221 1 output conveyor 222. In other examples, there may be a lift or similar that lifts storage containers from the input conveyor 221 onto the buffer storage area 206, and / or from the buffer storage area 206 onto the output conveyor 222.

[0124] Advantageously, the input conveyor 221 allows the buffer storage area 206 to be located away from the mass storage system 200, for example in a different location at the site. Similarly, the output conveyor 222 allows the buffer storage area 206 to be located away from the output station 7, such as the vehicle loading station 220 or pick station. Accordingly, the automated buffer storage system 1 can be more easily fitted to existing sites, and can be integrated with an existing mass storage system 200. In the example ofFIG. 6, the automated buffer system 1 may be installed between an existing mass storage system 200 and an existing vehicle loading station 220 as illustrated.

[0125] The example of FIG. 6 may be particularly suited to a grocery mass storage system where the storage containers are loaded with the various goods in the mass storage system 200 and the storage containers are moved around on dollies. Once ready, the dollies can be unloaded into the automated buffer system 1 at the transfer station 250. The storage containers can then be sequenced in the automated buffer system 1. Accordingly, the storage containers do not need to be loaded in any order, which may improve the efficiency of loading the storage containers. The storage containers are then output to the vehicle loading station 220 in the correct order, and at the appropriate time, for loading onto delivery vehicles.

[0126] In the various examples described above, during use of the automated buffer system 1 the buffer storage area 206 of the automated buffer systems 1 may operate at high capacity, with a majority of the tile units 3 being occupied by a storage container 4. This high storage density may preclude the formation of fixed aisles for moving storage containers 4 around the buffer storage area 206. In such examples, as described below, adaptive control systems can maintain a high frequency of movements of units of goods, to provide a high throughput and a low retrieval latency.

[0127] FIGS. 10A to 11C illustrate the formation of dynamic aisles that enable higher storage density in the automated buffer system 1 while maintaining low retrieval latency. In particular, FIGS. 10A to 11C illustrate the formation of dynamic aisles 13, 14 within the grid of tile units 3 for movement of storage containers 4 from the buffer storage area 206 to the pick station 7. In the illustrated examples the storage containers 4 are moved in the Y direction, towards and away from the pick station 7. FIGS. 10A and 10B illustrate the formation of a single aisle, and FIG. 11A to 11C illustrate the simultaneous formation of two or more aisles.

[0128] FIGS. 10A and 10B illustrate an operation to bring storage container 4A from the buffer storage area 206 to the pick station 7. As shown in FIG. 10A, initially there is one empty tile unit 3 in each row 5. In order to create an aisle for the storage container 4A, tile units 3 are operated to move the storage containers 4 in column 6e as indicated by the arrows. As explained above with reference to FIG. 9, multiple storage containers 4 in each row 5 can moved simultaneously, or successively, until the empty tile unit 3X is provided in column 6e. FIG. 10B shows the resulting aisle 13 of empty tile units 3X formed in column 6e, allowing the storage container 4A to be moved to the pick station 7 along the aisle.

[0129] FIGS. 11A to 11C illustrate an example of forming a second aisle 14 for storage container 4B, which is indicated in FIGS. 10B, 11A to 11C. In an initial state, shown in FIG.10B, the storage container 4B is called to the pick station 7 either before, during or after transit of the storage container 4A along the initial aisle 13. In this example, storage container 4A is first moved to the pick station 7, followed by storage container 4B. As shown in FIG. 11 A, once the storage container 4A has moved beyond the corresponding row of the storage container 4B, tile units 3 in column 6g are operated to move the storage containers 4 and create an aisle 14 in the column 6g corresponding to the storage container 4B. In other words, the aisle 13 can be closed behind the storage container 4A, allowing a second, offset aisle 14 to be created for passage of the storage container 4B towards the pick station 7, as shown in FIG. 11 B. FIG. 11C shows the completion of aisle 14 once the storage container 4A has reached the pick station 7. As shown in FIG. 11 C, the initial aisle 13 in column 6e has been closed in order to create space for the subsequent aisle 14.

[0130] It will be appreciated that multiple dynamic aisles 13, 14 can therefore be created to provide low retrieval latency retrieval of storage containers 4 from within the buffer storage area 206 to the pick station 7, and / or for transit of a storage container 4 from the input station 300 to the pick station 7 through the automated buffer system 1. In particular, as the aisles 13, 14 are dynamic they need only have a length (in the Y direction) of two or three tile units 3 within which the called storage container 4 moves. This allows multiple aisles to be created simultaneously, in different columns 6, so long as they are offset in the Y direction.

[0131] It will also be appreciated that the same concept may be used to create multiple aisles aligned in the Y direction (i.e. , no offset as described above) if there is more than one empty tile unit 3 per row 5. For example, large installations may be divided into operational sub-units, each sub-unit having at least one empty tile unit 3 per row 5. Additionally, as storage containers 4 are retrieved from the buffer storage area 206 they leave additional empty tile units 3 for at least a time until the storage container 4 is returned to the buffer storage area 206. Accordingly, during operation it may be possible to create multiple aisles that are aligned in the Y direction.

[0132] In some examples, if more than one tile unit 3 in a row 5 is empty, the storage container 4A, 4B may be moved into a different column 6 during transit to the pick station 7 (e.g., to avoid obstacles or to improve dynamic aisle creation). In such an example the aisle is formed in two different columns 6, or more than one storage container 4 is conveyed through an aisle.

[0133] In some examples, once a storage container 4 has reached the pick station 7 goods may be retrieved and / or deposited in the storage container 4 and the storage container 4 can be returned to the buffer storage area 206 in the same manner as it wasretrieved - by creating an aisle along one of the columns 6. Alternatively, if the storage container 4 is removed from the pick station 7 then additional storage containers 4 are received from the mass storage system as described above.

[0134] FIGS. 12A to 13B illustrate examples of the tile unit 3 of the automated buffer system 1. As described below, each tile unit 3 has a drive unit 16 operable to move a storage container 4 or skid plate that is received on top of the tile unit 3. The drive unit 16 has at least one directionally-adjustable drive, for example a drive wheel or drive belt, which engages the storage container 4 or skid plate and is driven to move the storage container 4 or skid plate. The control system of the automated buffer system 1 controls each tile unit 3 to operate the drive unit 16 such that storage containers 4 or skid plates can be moved in either the X direction (along a row of the grid) or in the Y direction (along a column of the grid) in the manner described above to move storage containers 4.

[0135] FIGS. 12A and 12B illustrate a first example tile unit 3 of the buffer systems 1 described with reference to FIGS. 1 to 11 C. As shown in FIG. 12A, the tile unit 3 has a housing 15. The housing 15 is generally quadrilateral, being rectangular as illustrated or square. The housing 15 has the general form of a shallow rectangular box with a planar, substantially closed upper surface. The housing 15 is a self-contained unit such that the storage and retrieval system 1 can be modular and easily adapted to different installation sites.

[0136] The top of the housing 15 is omitted from FIG. 12B for clarity. As shown in FIG. 12B, a drive unit 16 is housed within the housing 15. The drive unit 16 includes drive wheels 17, in this example four drive wheels 17a-17b. Each drive wheel 17a-17b has an associated drive motor unit 18a-18d for rotating the drive wheel 17a-17b. As shown in FIG. 12A, the drive wheels 17a-17d protrude through openings in the housing 15 and beyond a top surface 19 of the housing 15. Accordingly, when a storage container or skid plate is supported on the tile unit 3 the drive wheels 17a-17d are in contact with an underside of the storage container or skid plate. Rotation of the drive wheels 17a-17d by the drive motor units 18a-18d thereby moves the storage container or skid plate in the direction of rotation.

[0137] As shown in FIG. 12B, the drive unit 16 also includes a rotation mechanism 20 adapted to rotate the drive wheels 17a-17d through ninety degrees about an axis normal to the top surface 19 of the housing 15. The drive wheels 17a-17d are rotatably mounted to the housing 15 at pivots 40a-40d that permit the drive wheels 17a-17d to rotate to change orientation. The rotation mechanism 20 has an actuator 21 (a rotation motor) that is operable to move linkages 22 connected to each drive wheel 17a-17d to rotate the drive wheels 17a-17d. The actuator 21 is located approximately in the centre of the housing 15. In this embodiment, the actuation mechanism 21 is a ‘windscreen-wiper’-style motor, orsimilar. The actuator 21 may rotate in a single direction and cause the drive wheels 17a- 17d to rotate, or the actuator 21 may rotate in different directions and cause the drive wheels 17a-17d to rotate. The actuator 21 is connected to some, but not all of, the drive wheels 17a-17d. In this embodiment, the actuator 21 is connected to two of the drive wheels 17b, 17d by first linkages 22a, and those drive wheels 17b, 17d are connected to the other drive wheels 17a, 17c by second linkages 21b. In this example the actuator 21 comprises a linear actuator (lead screw) that is operable to move an end point of the first linkages 21a to rotate the drive wheels 17a-17d. Accordingly, the drive wheels 17a-17d can be rotated to different orientations, for moving a storage container or skid plate in the X direction or in the Y direction.

[0138] FIGS. 13A and 13B illustrate a second example tile unit 3 of the buffer systems 1 described with reference to FIGS. 1 to 11C. The tile unit 3 of FIG. 13A and FIG. 13B is similar to that of FIGS. 12A and 12B in that it has a housing 15 and a drive unit 16 located within the housing 15.

[0139] In this example, the drive unit 16 comprises four drive wheels 17a-17d as per the example of FIGS. 12A and 12B, and additionally comprises guide wheels 23a-23d. The guide wheels 23a-23d protrude beyond the top surface 19 of the housing 15 like the drive wheels 17a-17d, but are not driven (there is no motor that drives the guide wheels 23a- 23d). The guide wheels 23a-23d provide additional support for the storage container or skid plate.

[0140] The rotation mechanism 20 of the example of FIGS. 13A and 13B is similar to that of FIGS. 12A and 12B and is operable to rotate the drive wheels 17a-17d and the guide wheels 23a-23d about axes extending normal to the top surface 19 of the housing as previously described. The rotation mechanism 20, shown more clearly in FIG. 14, has an actuator 21 and linkages 22a to rotate the drive wheels 17a-17d, and additional linkages 22b provided to connect between the drive wheels 17a-17d and the guide wheels 23a-23d. In particular, the drive wheels 17a-17d are connected to the actuator 21 by linkages 22a, and the guide wheels 23a-23d are connected to the drive wheels 17a-17d via linkages 22b. Each drive wheel 17a-17d is therefore paired with a guide wheel 23a-23d. In this way, rotation of the drive wheels 17a-17d also rotates the guide wheels 23a-23d. In this example the actuator 21 is a motor arranged to rotate a plate to which the linkages 22a, 22b are pivotally connected.

[0141] In the example shown in FIG. 14, rotation mechanism 20 does not rotate all of the guide wheels 23a-23d in the same direction. As shown, the linkages 22b are arranged such that guide wheels 23a and 23c will rotate in the opposite direction to guide wheels23b and 23d. In this way, the net effect on a storage container or skid plate located on top of the tile unit 3 is as neutral as possible.

[0142] In the example of FIGS. 13A and 13B, the tile unit 3 has four drive wheels 17a- 17d, with the top part of each drive wheel 17a-17d protruding through apertures in the housing 15. The drive wheels 17a-17d are arranged so that in plan view / from above they are in a square formation, aligned so that the side of the square is rotated at substantially 45-degrees to the alignment of the side edges of the housing 15. The square is offset towards two edges of the housing 15, so two corners of the hollow square are at or close to the edges of the housing 15 and the other two are spaced from the edges of the housing 15. The guide wheels 23a-23d are arranged in the sides of the square, with one guide wheel 23a-23d disposed on each side of the square, between two drive wheels 17a-17d.

[0143] In an alternative example the rotation mechanism 20 illustrate in FIG. 14 may be used to rotate the drive wheels 17a-17d of the example of tile unit 3 of FIGS. 12A and 12B, but without the guide wheels 23a-23d and corresponding linkages 22b.

[0144] As shown in FIGS. 13A and 13B, additional rollers 24a-24d are also provided that protrude beyond the top surface 19 of the housing 15. The additional rollers 24a-24d are not driven and do not rotate, and help to convey a storage container or skid plate as it moves from the illustrated tile unit 3 to an adjacent tile unit.

[0145] As also shown in FIGS. 12A and 12B, each tile unit 3 comprises a sensor 25 provided on the top surface 19 of the housing 15. The sensor 25 is arranged to detect a presence I movement of a storage container or skid plate, and / or to read an identity of a storage container or skid plate on the tile unit 3. The sensor 25 is positioned on the tile unit 3, in particular on the top surface 19 of the housing 15, so as to ‘read’ upwards. In one example, the sensor 25 comprises a resonant inductive sensor to sense movement of a storage container or skid plate over and across the sensor 25. In other examples, the sensor 25 could be an optical sensor or similar. The sensor 25 will trigger when a storage container or skid plate moves over it, and off it. In other examples, the sensor 25 may comprise an RFID receiver or barcode scanner that reads a corresponding feature (RFID tag or barcode) on the storage container or skid plate to identify the storage container.

[0146] The control system of the buffer system 1 knows the location of each tile unit 3 within the grid through an addressing process when the grid is assembled. The control system may track the location of each storage container or skid plate, for example by recoding movements of storage containers or skid plate and / or by using sensor signals from the various sensors 25 of the tile units 3. Information received from the sensors 25 may additionally or alternatively be used to confirm that storage containers or skid plateshave moved from one tile unit 3 to another as instructed by the control system (i.e. , to verify operation of the drive units 16).

[0147] FIGS. 15A and 15B illustrate a small grid of tile units 3, or a portion of a larger grid of tile units 3. In this example the tile units 3 are those illustrated in FIGS. 13A and 13B, but other example tile units 3 could be used instead. As shown, the tile units 3 are aligned in the X direction (i.e., in rows) and in the Y direction (i.e., in columns). As shown, the framework 30 includes a seat 31 for each tile unit 3. Each seat 31 is adapted to receive and support a tile unit 3. In examples, the tile units 3 are insertable into the seats 31 from above, i.e., from the Z direction. In this way, tile units 3 can be assembled into the storage and retrieval system 1 by lowering them into the seats 31 of the framework 30, and can be lifted out of the seats 31 for removal from the storage and retrieval system 1. This may allow tile units 3 to be retrieved from the storage and retrieval system 1 without having to remove any other components.

[0148] As shown, in this example the tile units 3 are arranged with no or very little space between them, for example abutting each other along the sides of the housings 15. In other examples, the framework 30 may separate the tile units 3 from each other by a small distance.

[0149] As explained below with reference to FIGS. 16 to 18, in some examples the storage containers 4 are received directly on the tile units 3. A storage container 4 suitable for this is shown in FIG. 18 and described below. In other examples, a skid plate 32, such as that shown in FIG. 12B and FIG. 17, is received on a tile unit 3 and the storage container 4 is carried on top of the skid plate 32. The storage container 4 may be a storage tote, a box, a crate, a pallet, a trolley, a dolly, a cage, or a bag. In other examples, a unit of goods is directly received on a skid plate.

[0150] In the example of skid plates 32, the skid plates 32 are positioned on top of the tile units 3 and the skid plates 32 and tile units 3 are mutually configured so that the skid plates 32 move on top of the tile units 3 in use. Each skid plate 32 has a profile similar to or slightly smaller than that of the tile unit 3.

[0151] The skid plates 32 are loaded with a unit of goods. In examples, goods may be directly loaded onto the skid plates 32, or storage containers 4 (e.g., a boxes, totes, cages, trolleys, dollies, or bags) may be received on the skid plates 32. The storage containers 4 may have a plan profile roughly the same as or slightly smaller than that of the skid plate 5, and a height of 30cm (or 50cm in some embodiments). Each skid plate 32 is a flat plate formed from a robust material so that it will not easily bend or break in use.

[0152] In examples, the lower surface of the skid plate 32 or the lower surface of the storage container 4, whichever is in contact with the tile unit 3 in use, comprises a number of wheel guides 33 as shown in FIG. 16. The profile of wheel guides 33 shown in FIG. 16 may be provided on either the underside of the skid plates 32, or on the underside of the storage container 4 in the example without skid plates 32.

[0153] As illustrated in FIG. 16, the wheel guides 33 are arranged in the shape of crosses. The wheel guides 33 act to keep the skid plate 32 or storage container 4 aligned with the required axis of movement when it first moves off / away from a tile unit 3 on which it is located, and to compensate for any offset in the wheel or power differential from the motors that might cause the skid plate 32 or storage container 4 to become misaligned and to move in slightly the wrong direction or at the wrong angle when moved by the tile unit 3. The wheel guides 33 and drive wheels 17a-17d (see FIGS. 12A-13B) are sized and shaped so that the drive wheels 17a-17d can freely rotate within the centre of the cross formed by the wheel guides 33.

[0154] As outlined above, the tile units 3 are all the same shape and size, and are laid out in a continuous grid pattern, side-by-side with one another, so that the corners of directly adjacent tiles are proximate or coincident.

[0155] As shown in FIG. 19, the tile units 4 have a cut-out 38 at each corner, so that an aperture or socket 34 is formed at the mutually intersecting corners of any two or more (e.g., four) tile units 3 arranged adjacent to one another in the grid. As shown in FIG. 19, each cut-out 38 has an electronic socket connection 35 located within the cut-out 38, so that there are multiple electronic socket connections 35 formed within each socket 34 when a grid is formed.

[0156] In use, an interconnection and communication element or plug 36 locates into each socket 34. The plugs 36 comprise electronic socket connections 37 corresponding to the electronic socket connections 35 formed in the cut-outs 38 of the tile units 3, such that adjacent tile units can electronically connected for communication and power transmission between the tile units 3. This also facilitates connection to a central power source and / or controller that can be connected to just one (or more) tile units 3 of the grid, for example at an edge of the grid.

[0157] In alternative examples, the plugs 36 may be integrated into the framework that supports the tile units 3. The cut-outs 38 in the tile units 3 may be arranged on a bottom side of the tile units 3, with the electronic socket connections 35 directed downwards, and the electronic socket connections 37 of the plugs 36 may be directed upwards. In this way, the electronic socket connections 35 and electronic socket connections 37 are connected when a tile unit 3 is assembled into the framework. This arrangement also beneficiallyallows tile units 3 to be lifted from the grid without first having to remove the separate plugs 36 shown in FIG. 19. Power and communication connections can be routed through the framework to one or more of the integrated plugs 36, and can be distributed through the grid of tile units 3 via the tile units 36 themselves.

[0158] In the example of FIG. 20, the tile unit 3 is slid into the seat 31 formed in the framework 30. The tile unit 3 comprises an electrical socket connection 39 formed on a side of the tile unit 3, which is arranged to connect with a corresponding electrical socket connection 41 formed in the seat 31 or framework 30 when the tile unit 3 is slid substantially sideways into the seat 31 in the direction of arrow 42. The tile unit 3 may then be rotated in the direction of arrow 43 to be fully received in the seat 31. Accordingly, the tile unit 3 can be assembled into the seat 31 and an electrical connection formed via the electrical socket connections 39, 41. In this example, the tile unit 3 can be removed from the seat 31 (and grid) by lifting, rotating and sliding the tile unit 3 out of the seat 31, allowing the tile unit 3 to be removed without having to remove other components or fasteners.

[0159] In examples, each tile unit 3 contains one or more of various elements, such as for example a wireless transmitter, a power distribution node, a communication distribution system (e.g. location aware V1 CANBUS; UWB / BLE, an ethernet port); a power distribution system; a localised safety distribution system (RFID; UWB / BLE), and; an RFID reader. In one example, each tile unit 3 comprises a communications unit that is connected to other tile units 3 and a server to form a point-to-point network, with communications unit having a unique address within the network. Tile units 3 may communicate with the server to send sensor information and / or to receive instructions for operating the drive unit, or may directly communicate with other tile units 3 in the grid for the same reasons. Adjacent tile units 3 may be operated together to move a storage container or skid plate from one tile unit 3 to another.

[0160] It can be seen that each individual tile unit 3 in the grid therefore acts as a link in the overall network. Each tile unit 3 can establish its position relative to the other tile units 3. This helps to minimise infrastructure requirements, and also allows tiles to be swapped out and the grid reconfigured as required. Each tile unit 3 may be ‘plug and play’, and may not need to be configured individually into a unique grid layout. Tile units 3 can be ‘hot swapped’ without need to take the grid offline, or for each new tile unit 3 (and existing tile units 3 within the grid) to be configured for the new arrangement. The storage and retrieval system 1 can also continue to work around a missing or malfunctioning tile unit 3.

[0161] At least some and preferably all of the tile units 3 are configured so that they can communicate with a central control system (buffer control system). The control systemprovides instructions to the tile units 3, and receives status updates and similar information back from the tile units 3 in return. In examples, the tile units 3 are also configured so that they can communicate directly with other tile units 3 - at least the tile units 3 directly adjacent to themselves. This allows them to co-ordinate their actions with each other directly. In addition, the buffer control system may control operation of any lifts provided for moving units of goods into and out of the automated buffer system 1 and / or between layers of the automated buffer system 1.

[0162] Items on top of the grid - the storage containers 4 or skid plates 32 - are moved around the grid through the cooperation of multiple tile units 3 working in a coordinated manner to route items from one tile unit 3 to another, so that in overall operation items are moved from a source to a destination.

[0163] The control system may ‘know’ where each tile unit 3 is within the overall grid, and from this, which tile units 3 any particular individual tile unit 3 is physically adjacent to. The control system may ‘know’ what each tile unit 3 is doing / what action the tile unit 3 is undertaking at any particular time. The control system may use this information to send instructions to a tile unit 3, so that the tile unit 3 carries out the correct action at the correct time - e.g. moving an item across its surface in a particular direction.

[0164] As outlined above, the tile units 3 are arranged into a grid, with communications connections made through the plugs 36. In different examples, communication connections may be CAN bus or ethernet, and may form a point-to-point communications network. Suitable identification signals can be sent through each of these communications connections and may comprise X, Y and optionally Z address information. In this way, each tile unit may determine its location in the grid and the identity of adjacent tiles units in the grid and can communicate accordingly.

[0165] Throughout the description and claims of this specification, the words “comprise” and “contain” and variations of them mean “including but not limited to”, and they are not intended to (and do not) exclude other moieties, additives, components, integers or steps. Throughout the description and claims of this specification, the singular encompasses the plural unless the context otherwise requires. In particular, where the indefinite article is used, the specification is to be understood as contemplating plurality as well as singularity, unless the context requires otherwise.

[0166] Features, integers, characteristics, or groups described in conjunction with a particular aspect, embodiment or example of the invention are to be understood to be applicable to any other aspect, embodiment or example described herein unless incompatible therewith. All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and / or all of the steps of any method orprocess so disclosed, may be combined in any combination, except combinations where at least some of such features and / or steps are mutually exclusive. The invention is not restricted to the details of any foregoing embodiments. The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

Claims

CLAIMS1 . An automated buffer system for a storage and retrieval system, the automated buffer system comprising: an input station arranged to receive units of goods from a mass storage system; a buffer storage area arranged to receive units of goods from the input station, the buffer storage area comprising a plurality of tile units arranged in a grid having rows and columns, each tile unit being adapted to support a unit of goods and comprising a drive unit operable to move the units of goods to an adjacent tile unit in a row direction or in a column direction; and an output station for removal of goods from the buffer storage area.

2. The automated buffer system of claim 1 , wherein the buffer storage area comprises a plurality of layers, each layer comprising a plurality of tiles units arranged in a grid having rows and columns.

3. The automated buffer system of claim 2, wherein each layer comprises an input station.

4. Th automated buffer system of claim 2 or claim 3, wherein each layer comprises an output station.

5. The automated buffer system of any of claims 2 to 4, further comprising one or more lifts arranged to move units of goods between different layers of the buffer storage area and / or between the input station and a layer of the buffer storage area and / or between a layer of the buffer storage area and the output station.

6. The automated buffer system of any preceding claim, comprising a buffer control system configured to control the plurality of tile units.

7. The automated buffer system of claim 6, wherein the buffer control system is operable to move the units of goods to the output station in a different order to which they are received at the input station.

8. The automated buffer system of claim 6 or claim 7, wherein the buffer control system is configured to sequence the units of goods between the input station and the output station.

9. The automated buffer system of any of claims 6 to 8, wherein the buffer control system is configured to track the positions of the units of goods within the buffer storage area and to control the drive units of the tile units to move the units of goods to the output station and / or to sequence the units of goods between the input station and the output station.

10. The automated buffer system of claim 9, wherein the buffer control system is configured to move a unit of goods from a tile unit of the buffer storage area to the output station by: moving units of goods in a column corresponding to the called storage container in the row direction to create an aisle in the column direction, and moving the called unit of goods along the aisle to the output station.

11. The automated buffer system of any preceding claim, wherein the input station comprises a tile unit arranged to receive units of goods from the mass storage system and operable to move a received unit of goods into the buffer storage area.

12. The automated buffer system of any preceding claim, wherein each unit of goods comprises a storage container.

13. The automated buffer system of any preceding claim, wherein the automated buffer system comprises a plurality of skid plates, each skid plate being adapted to hold a unit of goods and wherein each tile unit is operable to move skid plates to an adjacent tile unit.

14. A storage and retrieval system comprising: a mass storage system, and an automated buffer system comprising:an input station arranged to receive units of goods from the mass storage system; a buffer storage area comprising a plurality of tile units arranged in a grid having rows and columns, each tile unit being adapted to support a unit of goods and comprising a drive unit operable to move the unit of goods to an adjacent tile unit in a row direction or in a column direction; and an output station for removal of goods from the automated buffer system.

15. The storage and retrieval system of claim 14, wherein the mass storage system comprises an automated mass storage system.

16. The storage and retrieval system of claim 15, wherein the automated mass storage system comprises a fixed or moveable storage, for example fixed or moveable storage columns or storage racks.

17. The storage and retrieval system of claim 15 or 16, wherein the automated mass storage system comprises a plurality of retrieval devices for conveying units of goods to the input station of the automated buffer system.

18. The storage and retrieval system of any of claims 14 to 17, further comprising a transfer system for transferring units of goods from the mass storage system to the automated buffer system.

19. The storage and retrieval system of any of claims 14 to 18, further comprising a control system configured to track the positions of the units of goods within the mass storage system and within the automated buffer system.

20. A method of operating the automated buffer system of any of claims 1 to 13, the method comprising: receiving, at the input station, units of goods from the mass storage system, storing, in the buffer storage area, at least some of the units of goods received from the mass storage system, andoperating the tile units to move the units of goods to the output station.

21. The method of claim 20, comprising moving the units of goods to the output station in a different order to which they are received at the input station.

22. The method of claim 20 or claim 21 , comprising sequencing the units of goods between the input station and the output station.

23. The method of any of claims 20 to 22, comprising storing a first set of units of goods in the buffer storage area, and moving a second set of units of goods through the buffer storage area from the input station to the output station.

24. A method of operating a storage and retrieval system, the storage and retrieval system comprising a mass storage system and an automated buffer system, the method comprising: retrieving units of goods in the mass storage system; transferring the units of goods from the mass storage system into the automated buffer system; storing and / or sequencing the units of goods in the automated buffer system; and moving the units of goods to an output station of the automated buffer system.

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